CONDOR Scissor Lift 3160 Operation's Parts & Vendor Manual - PDF DOWNLOAD

AERIAL WORK PLATFORM

MODEL 3160 (includes Models 2032,3146, and 3154)

OPERATOR'S, MAINTENANCE, ILLUSTRATED PARTS, AND VENDOR MANUAL

SHIPPING ADDRESS CALAVAR CORPORATION 8300 IMPERIAL DRIVE VVACO, TEXAS 76712 (817) 666-4545

MAILING ADDRESS CALAVAR CORPORATION P.O. Box 21447 VVACO, TEXAS 76702-1447 (817) 666-4545 MANUAL922n SEPTEMBER 1993

AERIAL WORK PLATFORM

MODEL 3160 (includes Models 2032, 3146, and 3154)

OPERATOR'S MANUAL

MAILING ADDRESS

SHIPPING ADDRESS

CALAVAR CORPORATION P.O. Box 21447 VVACO, TExAs 76702-1447 (817) 666-4545

CALAVAR CORPORATION 8300 IMPERIAL DRIVE VVAco,TExAs76712 (817) 666-4545

MANUAL 922n-001 SEPTEMBER 1993

INTRODUCTION

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

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

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

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

It is also YOUR RESPONSIBILITY to understand and obey all federal, state, and local regulations regarding the operation and use of aerial work platforms. A copy of the ANSI/SIA Manual of Responsibilities is attached for your use: ANSI/SIA A92.5-1992 is provided for BoomSupported Elevating Work Platforms, and ANSI/SIA A92.6-1990 is provided for Self-Propelled Elevating Work Platforms.

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

DO NOT ALTER OR MODIFY THIS CONDOR® WITHOUT PRIOR WRITTEN APPROVAL FROM THE MANAGEMENT OF CALA VAR CORPORA TION

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

NOTE:

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

MANUAL 92277-0111 SEPTEMBER 1993

TABLE OF CONTENTS

INTRODUCTION .......••••...........•..........•••.....•....•..••......•..........•...........•............•........... i TABLE OF CONTENTS ...............................•............................................................... ii

I. PREPARATION, INSPECTION, AND MAINTENANCE •.•...........•......•........................... 1 A. B. C. D. E.

OVERALL CONDITION.................................................................. •............• LOWER CONTROL STATION .........•.•...•.•••........••...•..........••....•...................• PLATFORM & UPPER CONTROL STATION ....................•...•.•..................••.•..

HYDRAULIC SYSTEM •..•...........•..•.•.........................•.................................

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

1 1 1 2 2

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

LOADING AND UNLOADING ...........•...............•....•......•...............................

RAMP METHOD ..............•.••.••.•.....•....•••..................•................•.•..............

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

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

4 4 4 5

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

ii MANUAL 922n-001 SEPTEMBER 1993

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

PREPARATION. INSPECTION. AND MAINTENANCE

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

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

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

A. OVERALL MACHINE CONDITION. TIRES AND WHEELS: CHECK FOR CRACKS, TEARS, CUTS, OR MISSING OR LOOSE LUG NUTS (A RUST LINE RUNNING DOWN THE RIM FROM THE LUG NUT INDICATES A LOOSE LUG Nun. MISSING, BROKEN, OR DAMAGED PARTS: CHECK CYLINDER MOUNTING PINS, PIVOT PINS, PIN RETAINERS, BOLTS, AND NUTS. STRUCTURAL: CHECK FOR DAMAGED OR CRACKED WELDS ON STRUCTURAL COMPONENTS-ARMS, PLATFORM, CHASSIS. STEERING: CHECK TIE ROD ENDS AND STEERING CYLINDER FOR PROPER AND SECURE MOUNTING. DECALS:ALLDECALSANDWARNINGSIGNS ARE IN PLACE AND ARE CLEARLY LEGIBLE.

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

1 MANUAL 92277·001 SEPTEMBER 1993

D. HYDRAULIC SYSTEM

B.

CHECK THE HYDRAULIC TANK FLUID LEVEL WITHTHEARMS LOWERED. MAINTAIN FULL FLUID LEVEL-DEPENDING ON THE UNIT, THIS WILL BE TO THE MARK ON THE SIGHT GLASS, TO THE MARK ON THE DIPSTICK, OR TO WITHIN ONE INCH FROM THETOPOF THE TANK. ADD SHELL TELLUS T32 HYDRAULIC OIL TO THE SYSTEM. ENSURE THE BREATHER CAP IS CLEAN AND INPLACE ON THE TANK.

MODEL 2032

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

LOWER CONTROLS

AT THE LOWER CONTROL STATION THERE ISASELECTOR SWITCH, A TOGGLE SWITCH, AND CONTROL LEVER. TO OPERATE THE LOWER CONTROLS, TURN THE SELECTOR SWITCH TO THE LOWER POSITION. TO RAISE THE PLATFORM, PUSH THE TOGGLE SWITCH TO THE UP POSITION. THEN MOVE THE CONTROL LEVER IN THE UP POSITION. TO LOWER THE PLATFORM, PUSH THE TOGGLE SWITCH TO THE DOWN POSITION. THEN MOVE THE CONTROL LEVER IN THE DOWN DIRECTION.

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

MODEL 3160

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

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

II. MACHINE OPERATION A. RATED WORK LOAD THESE PLATFORMS WILLSUPPORT A COMBINED WEIGHT EQUAL TO THE UNIT'S RATED WORK LOAD-INCLUDING PERSONNEL, TOOLS, AND EQUIPMENT-THROUGHOUT THE WORKING ENVELOPE OFTHE MACHINE.

ATTHE LOWER CONTROL STATION, THERE IS A "PUMP" SWITCH, A "PUSH TO LOWER" SWITCH, AND CONTROL LEVER.

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

MANUAL 92277-001 SEPTEMBER 1993

2

TO OPERATE THE UNIT FROM EITHER CONTROL STATION, TURN THE KEY SELECTOR SWITCH ON. TO RAISE THE PLATFORM, DEPRESS THE "PUMP" SWITCH, THEN MOVE THE CONTROL LEVER IN THE UP DIRECTION. TO LOWER THE PLATFORM, DEPRESS THE "PUSH TO LOWER" SWITCH, THEN MOVE THE CONTROL LEVER IN THE DOWN DIRECTION. C. PLATFORM CONTROLS NOTE: AT LOWER CONTROL STATION, THE OPERATOR SELECTOR SWITCH MUST BE SWITCHED TO THE PLATFORM TO ENERGIZE THE UPPER CONTROLS. EMERGENCY POWER BUTTON PULL TO TURN ON AND PUSH TO TURN OFF. NOTE: THIS IS ALSO AN EMERGENCY STOP SWITCH. PUSH TO CEASE ALL FUNCTIONS. THE CONTROLS ARE ENERGIZED ONLY WHEN THE FOOTSWITCH IS DEPRESSED. THE PLATFORM CONTROL BOX CONTAINS THE FOLLOWING CONTROLS: DRIVE/STEER CONTROL THIS FOUR-WAY CONTROL LEVER OPERATES THE DRIVE AND STEER FUNCTIONS. DRIVE "FORWARD" MOTION IS DETERMINED WITH THE STEERING WHEELS LEADING THE WAY, AND "REVERSE" MOTION IS DETERMINED WITH THE DRIVE WHEELS LEADING THEWAY. MOVING THE DRIVE/STEER CONTROL LEVER TO THE FORWARD OR REVERSE DIRECTION WILL CAUSE THE UNIT TO DRIVE IN THOSE RESPECTIVE DIRECTIONS. MOVING THE SAME CONTROL LEVER TO THE RIGHT OR LEFT WILL CAUSE THE UNIT TO STEER RIGHT OR LEFT RESPECTIVELY. THE FOOTSWITCH MUST BE DEPRESSED WHILE OPERATING THESE FUNCTIONS. THE CONDOR® SCISSOR LIFTS HAVETHREE (3) DRIVE SPEEDS: LOW, HIGH, AND CREEP. LOW SPEED IS ACCOM-

PLISHED WITH THE SCISSOR ARMS COMPLETELY LOWERED. THIS ALLOWS THE GREATEST POSSIBLE TORQUE FOR DRIVING UP MAXIMUM INCLINES. HIGH SPEED IS AVAILABLE WITH THE PLATFORM RAISED JUST A FEW INCHES SO THE ARMS JUST CLEAR THE TRANSMISSION VALVE ACTUATOR. THIS ALLOWS THE FASTEST DRIVE SPEED, BUT HAS REDUCED TORQUE. CREEP SPEED IS ACCOMPLISHED BY RAISING THE SCISSOR ARMS FURTHER, APPROXIMATELY 12 INCHES, TO CLEAR THE CREEP VALVE ACTUATOR. THIS ALLOWS THE MINIMUM DRIVE SPEED AND GREATLY REDUCED TORQUE WHILE DRIVING AT INCREASED PLATFORM HEIGHTS. LIFT UP/DOWN CONTROL LEVER TO RAISE THE UNIT, MOVE THE CONTROL LEVER TO THE "UP" POSITION. TO LOWER THE UNIT, MOVE THE CONTROL LEVER TO THE "DOWN" POSITION. THE FOOTSWITCH MUST BE DEPRESSED FOR BOTH "UP" AND "DOWN" OPERATIONS; HOWEVER, THE HYDRAULIC PUMP WILL NOT BE OPERATINGDURINGTHEHDOWN" FUNCTION. GRAVITY LOWERING IS ACCOMPLISHED. III. OPTIONAL EQUIPMENT THE FOLLOWING OPTIONSAREAVAILABLE ON THE CONDOR® AERIAL WORK PLATFORM: -DECK EXTENSION -TRAVEL WARNING HORN _5° MULTI-AXIS SLOPE SENSOR -110V LINE TO PLATFORM -SELF-CLOSING GATE -HOUR METER -3154 OPTION

3 MANUAL 92277-001 SEPTEMBER 1993

IV. EMERGENCY LOWERING THE CONDOR® IS EQUIPPED WITH EMERGENCY LOWERING VALVE(S) LOCATED AT THE HOLDING VALVE ON THE LIFT CYLINDER(S). TO OPERATE THE EMERGENCY LOWERING VALVE(S), DEPRESS THE RED-KNURLED KNOB AND TURN COUNTERCLOCKWISE UNTIL IT POPS OUT SLIGHTLY (1/8" - 1/4"). THE LIFT/LOWER CONTROL LEVER AT THE LOWER CONTOL STATION CAN NOW BE MOVED TO THE "LOWER" POSITION AND THE PLATFORM WILL LOWER. (NO ELECTRICAL ACTIVATION IS NECESSARY) V. MOVING FROM JOBSITE TO JOBSITE

THE RAMP SHOULD BE SET AT AN ANGLE NO STEEPER THAN THE MACHINE'S RATED GRADE-ABILITY. MODELS 2032 AND 3146: 11° OR 21%, OR A RISE OF 25 INCHES IN 10 FEET. MODELS3154AND3160: 15°0R26%, OR A RISE OF 32 INCHES IN 10 FEET. BEFORE DRIVING THE UNIT ON THE RAMP, LOWER THE PLATFORM COMPLETELY, TEST THE DRIVE/STEER CONTROLS AND THE BRAKE SYSTEM, AND BEWARE OF FREEWHEELING CONDITIONS. DRIVE UP OR DOWN THE RAMP SLOWLY, ALLOWING FOR STEERING CORRECTIONS TO BE MADE. KEEP UNIT IN ALIGNMENT WITH THE CARRIER AND RAMP DURING LOADING AND UNLOADING PROCEDURES.

A. LOADING AND UNLOADING ALTHOUGH THE CONDOR® IS SOMEWHAT SMALL COMPARED WITH LARGER CONSTRUCTION EQUIPMENT,ITREQUIRESTHE SAME CARE AND ATTENTION IN LOADING, TRANSPORTING, AND UNLOADING AS DOES LARGER EQUIPMENT. AT NO TIME SHOULD ITS SIZE BE UNDERESTIMATED. BEFORE LOADING OR UNLOADING, INSPECT THE UNIT FOR ANY PHYSICAL DAMAGE OR DEFECTS. THE MEANS BY WHICH YOU LOAD OR UNLOAD THE UNIT SHOULD BE OF SUFFICIENT STRENGTH TO WITHSTAND THE WEIGHT OF THE CONDOR®.

MODEL WEIGHT(#) WEIGHT (KG) 962 2032 2,120 2,105 3146 4,640 2,622 5,780 3154 2,250 4,960 3160

C. FORKLIFT LOADING AND UNLOADING METHOD ENSURE THAT THE FORKLIFT HAS SUFFICIENT CAPACITY TO HANDLE THE WEIGHT OF THE CONDOR®.

(SEE PAGE 4) MODELS 2032, 3146, AND 3154 SHOULD ONLY BE LIFTED FROM THE SIDE, POSITIONING THE FORKS UNDERNEATH THE CHASSIS. FORKS SHOULD BE LONG ENOUGH TO GO ACROSS THE WIDTH OF THE FRAME AND SHOULD BE POSITIONED AS CLOSE TO THE INSIDE OF THE TIRES AS POSSIBLE. NOTE: DO NOT ATTEMPT TO LIFT THESE MODELS FROM EITHER END. MODEL 3160 SHOULD ONLY BE LIFTED FROM THE FRONT OR REAR, USING THE FORKLIFT BOOTS PROVIDED.

B. RAMP METHOD

THE CONDOR® SHOULD ONLY BE RAISED TO A HEIGHT SUFFICIENT TO CLEAR ANY OBSTRUCTIONS.

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

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

4 MANUAl 92277-001 SEPTEMBER 1993

D. TRANSPORTING THE CONDOR®CAN BE EASILY AND SAFELY TRANSPORTED FROM THE JOBSITE IF THE FOLLOWING RULES AND PROCEDURES ARE FOLLOWED: BLOCK ALL WHEELS TO PREVENT FORWARD AND REVERSE MOTION. TIE DOWNTHECONDOR®WITH CHAINS OR CABLES, RUNNING THEM THROUGH THE TIE-DOWN BRACKETS ONLY. DO NOTCHAIN OR STRAP OVER THE GUARD RAILS. SEVERE DAMAGE TO THE SCISSOR ARMS MAY RESULT FROM SECURING THE UNIT OVERTHETOPOFTHEPLATFORM,DUETO EXCESS PRESSURE. ALWAYS TURN THE POWER OFF AT THE GROUND CONTROL STATION. VI. FREEWHEEL OPERATION CAUTION: WHEN USING THE FREEWHEEL VALVE, THECONDOR®MUSTBEONLEVEL GROUND. TURN VALVE KNOB CLOCKWISE UNTIL CLOSED AND DRIVE THE CONDOR® APPROXIMATELY 3 FEET. THIS WILL DISABLE THE BRAKE, ALLOWING THE CONDOR® TO BE MOVED. THE VALVE KNOB MUST BE TURNED FULLY COUNTERCLOCKWISE (OPEN) FOR NORMAL OPERATION. NEVER EXCEED 5MPH WHEN MOVING THE CONDOR® IN THE FREEWHEEL MODE.

5 MANUAL 922n-001 SEPTEMBER 1993

A div. of TIME Manufacturing Company

SELF-PROPELLED ELEVATING WORK PLATFORM

MODEL 3160 MAINTENANCE MANUAL

MAILING ADDRESS

SHIPPING ADDRESS

CONDOR®

CONDOR®

A DIV. OF TIME MFG. CO.

A DIV. OF TIME MFG. CO.

8300 IMPERIAL DRIVE VVAco,TEXAS76712 (817) 666-4545

P.O. Box 21447 VVAco,TEXAS76702-1447 (817) 666-4545

MANUAL 92277-002 JUNE 1996

I

INTRODUCTION The primary purpose ofthis manual is to provide the user with a thorough understanding ofthe proper operating procedures necessary to comply with the intended use ofthe CONDOR®, and to provide the information necessary to maintain and service the CONDOR®.

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

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

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

It is also YOUR RESPONSIBILITY to understand and obey all federal, state, and local regulations regarding the operation and use of aerial work platforms. A copy of the ANSIISIA Manual of Responsibilities is attached for your use: ANSIISIA A92.5-1992 is provided for Boom-Supported Elevating Work Platforms, and ANSIISIA A92.6-1990 is provided for Self-Propelled Elevating Work Platforms.

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

DO NOT ALTER OR MODIFY THIS CONDOR® WITHOUT PRIOR WRITTEN APPROVAL FROM THE MANAGEMENT OF CALA VAR CORPORATION

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

NOTE:

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

A div. of TIME Manufacturing Company

CONDOR® SERVICE INFORMATION

1. If you need assistance or have any service or maintenance questions, Condor service and parts personnel are always available by phone or fax. The telephone numbers are: (817) 666-4545 Telephone (817) 666-5125 Voice Mail (800) 443-5803 FAX

2. There are numerous written Maintenance Procedures available for this CONDOR®.

These procedures are available through the Condor Service Department to anyone who requests them.

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

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

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

8300IMPERIALDRIVE,P.O. Box21447, WACO, TEXAS 76702-1447 817-666-4545, 817-666-4544 FAX 0

iii

Condor® Self-Propelled Booms and Scissors WARRANTY Calavar Corporation (" Calavar") warrants to the purchaser that each new aerial work platform made by Calavar is free from defects in material and workmanship arising under normal use and service-in the case of major weldments, (chassis, turret, and booms), for a period of five (5) years after the original shipment of the aerial work platform from Calavar's plant; and in the case of all other parts, for a period of one (1) year after the aerial work platform is placed in service or two (2) years after the original shipment of the aerial work platform from Calavar' s plant, whichever comes 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 event shall Calavar or its suppliers be liable to the purchaser or any other person for transportation charges or for any incidental, collateral, special, or consequential damages, including without limitation damages for loss of profits, loss of customers, loss of goodwill or work stoppage, claims by any party other than the purchaser, or any other similar damage or loss even if Calavar, its suppliers, or its representatives have been advised of the possibility of such damages.

Parts claimed to be defective and for which repair or replacement is desired shall be returned transportation prepaid to Calavar'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 Calavar shall, at Calavar's option, void this Warranty. Calavar shall have no liability or responsibility for damages resulting from accident or the malfunction of equipment and components not supplied by Calavar.

No agent, employee, distributor, dealer, or other representative of Calavar is authorized to modify this Warranty in any way. Accordingly, additional statements or presentations by any such representative, whether oral or written, do not constitute warranties by Calavar and should not be relied upon as limited warranties of Calavar, and no attempt, effort, or promise to repair equipment by 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 the 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 purpose. Any applicable implied warranty shall be limited in duration to the warranty period.

8300 Imperial Drive, P.O. 80x 21447, Waco, Texas 76702-1447 0 817-666-4545,817-666-4544 FAX Form NO.513·3M-392

Effective Date 911/90 Printed in U.S.A.

Effective January 1, 1993

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

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

A.

WARRANTY PERIOD 1.

The Self-Propelled Boom and Scissor Warranty is one (1) year from placing the CONDOR® in service or two (2) years following shipment from Calavar, whichever comes first. In the case of major weldments (chassis, turret, and booms), the Warranty Period is five (5) years following shipment from Calavar.

2.

The Truck-Mounted CONDOR® Warranty Period is one (1) year from shipment of the CONDOR® from Calavar's plant.

3.

F or parts so ld through the Parts Department, the Warranty Period is six (6) months from utilizing the component or placing it in service, or twelve (12) months following shipment from Calavar, whichever comes first, unless the part is furnished to correct a defective part on the original shipment still under Warranty.

4.

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

5.

During the Warranty Period, in addition to covering the parts replaced under Warranty, Calavar will pay a Dealer Warranty Labor Rate which is based on a percentage of your standard shop labor rate.

NOTE: The term "IN SERVICE" means that the Warranty starts at the time the CONDOR® is first used for any purpose. An example: The dealer may have purchased a CONDOR® to have in stock, but may not use it. After three months, the CONDOR® is sold or the dealer decides to putthe CONDOR® into its rental fleet. In this situation, the Warranty Period begins the day the dealer puts the CONDOR® into the fleet or when the CONDOR® is delivered to the end user.

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

B.

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

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

2.

It will be the responsibility ofthe original recipient ofthe CONDOR® from Calavar, whether it will be the dealer orthe end user, to complete this form and return itto Calavar's facility within 45 days from the date of receipt to set up the Warranty Account.

3.

Failure to complete the P.D.1. sheet and return it to Calavarwithin the time frame given will result in voiding the Warranty on the CONDOR® .

NOTE: The form must be filled out completely, giving the name of the dealer, address, model number, serial number, person inspecting the CONDOR® 's, signature, and date of inspection. (The date of inspection does not constitute the "In Service" date.)

C.

ITEMS NOT COVERED UNDER WARRANTY Some components are used on the CONDOR® which are not warranted by Calavar. However, these are warranted by the component manufacturer. Some of these are:

1.

Engine: Manufacturers used include Wisconsin, Ford, Deutz, Isuzu, Kubota, Onan, Cummins, John Deere, and others. To apply for warranty on the engine, contact should be made with the engine manufacturer's dealer in your area. Calavar can advise you who the dealer is if unknown to you.

2.

Tires and Batteries: These are normal wear items and are considered normal maintenance items. However, ifthey are found to be defective, contact can be made with the manufacturer's local dealer.

3.

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

4.

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

5.

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

6.

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

7.

Troubleshooting: Troubleshooting is not covered or reimbursable. However, Calavar Warranty will cover reasonable labor charges for the removal and replacement of defective components.

D.

PROCESSING OF WARRANTY CLAIM During the Warranty Period, should a component failure be encountered within the guidelines of the Calavar Warranty Policy, the following procedure is to be followed: 1.

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

Issuing an order to our Parts Department through normal channels, which entails your being invoiced.

b.

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

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

2.

c.

Although not recommended, you may purchase the part locally. When this is done, a copy of the purchase order or receipt MUST accompany the claim.

Calavar has the option to ship a replacement part at no charge if the local cost would be greater, in lieu of issuing credit for locally purchased parts.

d.

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

Complete the Warranty Claim as noted in the "Warranty Claim Procedure" section.

Provide as much information as possible to enable Calavar to thoroughly evaluate the claim and process it in the shortest amount of time possible.

NOTE: WARRANTY CLAIMS NOT RECEIVED BY CALAVAR WITHIN 45 DAYS OF FAILURE WILL BE DENIED 3.

E.

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

RETURN AUTHORIZATION 1.

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

2.

It will be necessary for you to call the Calavar Service Department and ask to be issued a Return Authorization (R/A) number. You will be asked for a Dealer Claim Number.

As noted in Section 2, Item A, ofthe Warranty Claim Procedure, this is a number assigned by the dealer for the purpose of tracking the claim, as there may be more than one claim for the same CONDOR®. The R/A number issued must be logged in the appropriate section ofthe claim form, and the gold copy (R/A) ofthe form must be returned with the parts being returned.

NOTE: DO NOT SHIP ANY RETURN PARTS WITHOUT A RETURN AUTHORIZATION (RIA) NUMBER Doing so may result in parts getting lost in the system and may delay processing the claim, or may cause denial due to the time element ofthe claim.

3.

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

4.

All parts claimed under Warranty will be required to be shipped back to Calavar FREIGHT PREPAID. No freight collect shipments will be accepted.

CONDOR® Model 3160

MAINTENANCE MANUAL TABLE OF CONTENTS

INTRODUCTION ..................................................................................................................... i CONDOR® SERVICE INFORMATION .............................................................................. ii SELF-PROPELLED WARRANTY ........................................................................................ iii

Table of Contents ...................................................................................................................... 1 Specifications ............................................................................................................................ 3 Recommended Tool List ........................................................................................................... 4 Serial Number Location ............................................................................................................ 5 Hydraulic System Description .................................................................................................. 7 Electrical System Description ................................................................................................. 17 Battery Service ........................................................................................................................ 27 Preventive Maintenance .......................................................................................................... 31 Hydraulic Oil Specifications .................................................................................................. 41 Bolt Torque Chart ................................................................................................................... 43

REVISEDJULY1996 MANUAL 92277-002 JUNE 1996

•

•

NOTES

MANUAL 92277-002 JUNE 19%

•

SPECIFICATIONS SPECIFICATIONS

3160

Maximum Working Height Platform Height Stowed Platform Height Overall Length Overall Width Overall Height Platform Size Platform Capacity Gross Weight Power System Battery Capacity Number of Batteries Battery Voltage Battery Charger WheelBase Tires

31 ft.

25 ft.

51" 120" 60" 93" 116" x 56.5" 15001bs.

4,960Ibs. 36 volt DC 250 amp hour 6 6 volt 35 amp 7'-6" 600x9 (Solid Rubber) 8'-6" 0-2.4 mph 25%/14° 35/24 sec

Inside Turning Radius Drive Speed Gradeability LiftlLower Time OPTIONS

* * * * * *

Battery Condition Indicator Strobe Light Non-Marking Tires Hour Meter Travel Alarm Charging Cut-Out Relay

* * * * *

MotionIMovement Alarm Descend Alarm 5° Slope Alarm Low Volt Warning/Interrupt Battery Protection System 110 volt Line to Platform

The CONDOR® Model 3160 is designed and built to conform to Calavar's understanding and interpretation of all applicable OSHA rules and regulations as well as ANSI standards: ANSI Standard A92.6 - 1990 ................... Self Propelled Elevating Work Platform

CAUTION It is imperative that all owners and operators of the CONDOR® read, understand and conform to these regulations. Ultimate compliance to prevailing OSHA regulations is the RESPONSIBILITY of the employer utilizing the equipment.

MANUAL 92277-002 JUNE 1996

•

RECOMMENDED TOOL LIST The following is a list oftools that you will find helpful when performing service, maintenance or troubleshooting the CONDOR® equipment.

1 each 1 each 1 each 1 each 1 each 1 each 1 each 1 each 1 each 1 each 1 each 1 each 1 each 1 each 1 each 1 each 1 each 1 each 1 pair 1 pair 1 pair 1 pair 2 pair

Volt/Ohm Test Meter Hydraulic FlowMeter, 0-10 GPM Hydraulic Flow Meter, 0-50 GPM Hydraulic Quad Meter Pressure Gauge Battery Hydrometer Battery Load Tester 1/2" Drive Torque Wrench, 0-250 ftIlbs Pry Bar Strap Type Filter Wrench Grease Gun Hammer, 24 oz.

Vice Grip Pliers Combination Wrench Set, 1/4" to 1-1/2" 3/8" Drive Socket Set, 114" to 3/4" 112" Drive Socket Set, 3/8" to 1-112" Hex Key (allen wrench) Set, up to 1/2" Screwdriver Set, Phillips Tip & Slot Tip Punch Set; Drift, Lineup and Straight Wire Stripping Pliers Wire Crimping Pliers Wire Cutting Pliers Needle Nose Pliers Jumper Wires with Alligator Clips

NOTE: This list is notintended to be all inclusive ofthetools required to perform every maintenance function that may be required on this specific CONDOR® model. However, these tools will greatly assist in troubleshooting problems and conducting routine maintenance on the equipment.

MANUAL 92277-002 JUNE 1996

SERIAL NUMBER LOCATION

2

The CONDOR® Model 3160 Serial Number is stamped in two locations on the machine.

1.

The first place to find the serial number is on the data plate affixed to the chassis rail, near the lower control valve.

2.

The second place to find the serial number is at the rear of the right side armstack pivot, near the footsteps.

MANUAL 92277-002 JUNE 1996

•

o

NOTES

MANUAL 92277-002 JUNE 1996

•

HYDRAULIC SYSTEM DESCRIPTION

The following is a detailed description of the hydraulic system used on the CONDOR® model 3160 scissor, and how it is designed to operate. To assist in understanding the system, this description should be used in conjunction with the hydraulic schematics found at the end of this section.

GENERAL The hydraulic system on the CONDOR® model 3160 consists of a single gear pump and two control valves, one located at each control station, and is ofthe open-center valve type, meaning that the hydraulic fluid circulates back to the tank when the pump is running and no functions are being operated.

Additionally, because this is an open-center system, the valve nearest the pump will have priority over the other valves. At the upper controls, the steering and drive have priority. For example, if steering or drive were commanded while lifting the platform, the platform would slow down or even stop lifting.

The system is designed to operate at a maximum of2400 psi, with all lift and drive functions operational from the platform controls and only lift functions available from the ground controls.

HYDRAULIC TANK The hydraulic tank (See FIG. 1) is a rectangular weldment having a fluid capacity of 5 US gallons, and is located next to the batteries in the belly pan, nearest the fixed axle end ofthe unit. A filler cap, and a level sight glass are provided for checking and maintaining the fluid level. Filtration of the hydraulic fluid is provided through a 10 micron spin-on return filter, located at the end of the tank nearest the lower control valve. A ball valve, or shut-off valve, is located in the suction line leading to the pump, and when closed, will prevent the hydraulic tank from draining during repairs to the hydraulic system. The cylinder vent fitting indicated in FIG. 1 is provided to connect the rod end of the lift cylinders to the hydraulic tank. This effectively vents the cylinders and allows any fluid that may leak past the cylinder packing, to have a path back to the hydraulic tank.

Cylinder Vent Fitting

Filler Cap

Level Sight Glass

Ball Valve

FIG. 1

NOTE: Only check the tank fluid level when the unit is in its stowed position to ensure the level will be at its highest. The hydraulic fluid used is Shell Tellus T-32 and only this fluid, or its equivalent should be used.

DO NOT MIX HYDRAULIC FLUIDS.

MANUAL 92277-002 JUNE 1996

•

PUMP/MOTOR The pump and motor assembly is located in the right side of the belly pan, between the tank and the battery charger (See FIG. 2). A 36 volt DC motor drives a gear pump, which draws fluid through the ball valve, from the hydraulic tank, and discharges this oil at a fixed, constant flow rate of 4.26 gallons per minute (GPM) throughout the hydraulic system and back to the tank.

Battery Charger (reference)

Hydraulic Tank

FIG. 2

LOWER CONTROL VALVE Located in the left rear comer of the belly pan, nearest the fixed axle is the lower control valve, which allows operation of the lift function only (See FIG. 3). This valve is of the closed-center working port, open-center pressure port, manually-operated directional control type. The valve also contains a system relief cartridge which is adjusted to 2400 psi. Function speed (raising/lowering) is controlled by the amount of handle movement.

Chassis Cover

Pump Switch and Control Selector Switch

o

o

e

ll~PE~ O~ ,,~

Valve Handle

SEl..ECTORSWlTCH

Lower Control Valve Pump Solenoid System Relief Cartridge

Terminal Strip

J.l:C----

Free-wheel Valve with thumbwheel

Shuttle Valve

FIG. 3

UPPER CONTROL VALVE The upper control valve is located at the forward right hand side of the platform inside an enclosure, and it allows operation oflift, steer, and drive (See FIG. 4 on following page). The lift and steer sections, like the lower control valve, have closed-center working ports, which means that each function port is "blocked" when the spool is in its center position. The drive section uses a motor spool, which provides the drive function ports with a path back to tank. This effectively reduces dynamic shock to the drive motors. A guard protects the lift lever from falling objects or accidental activation. The steer/ drive control handle, or joystick, protrudes directly from the top side of the control valve.

Inside the box assembly is a microswitch for activation ofthe pump solenoid and holding valves.

The microswitch is located near the lift valve handle on early model machines (as illustrated in FIG. 4), and for late model machines the microswitch is mounted to the valve itself, to the lower end of the lift spool.

MANUAL 92277-002

JUNE 1996

~

____________________________________~41) Emergency Stop Button Lift Handle

I~==::~=/::::J ____

Drive/Steer Handle

Speed Selector Switch (late models)

Control Lever Guard

Emergency Stop Button

~

Microswitch mounted inside box assembly (early models) Lift Handle

o

Lower end of Lift Spool (location of microswitch on late models)

/ Control Lever Guard

FIG. 4

STEERING SYSTEM When the footswitch is depressed, the pump motor turns on, thus pumping fluid through the lower control valve to the upper control valve and then returning tothe hydraulic tank. While the pump is running, the drive/steer control handle can be moved to the left or right from its vertical position to direct fluid to the steering cylinder base end for left, or fluid to the rod end for right steering. Once the control handle is released to its vertical position, the steering cylinder becomes "locked" by the closed-center working ports of the upper control valve. Steering cannot be accomplished at the lower control valve.

LIFT SYSTEM To raise the platform from the lower controls, press the lift toggle switch upward to tum the pump on then move the valve handle upward. To lower the platform, press the toggle switch downward to energize the holding valve on the lift cylinders (note: the pump will not run while the holding valves are energized), then move the valve handle downward to begin lowering the platform.

The lift system functions the same from the upper controls. Here, the toggle switch is replaced by a footswitch which must be depressed before any functions can be operated. For lowering, the footswitch is depressed, then the lift handle is pushed downward, and as the handle is moved, a microswitch will be activated by the handle lever. Activation of this microswitch will tum the pump off and energize the holding valves. At this point, the handle can be moved further downward to begin lowering the platform. At either control valve, the speed of movement is dependent on the amount of handle travel from its center position.

MANUAL 92277-002 JUNE 1996

•

LIFT CYLINDERS The 3160 armstack consists of a grouping of tubing weldments assembled in such a manner that, when the arms are separated from one another, the stack raises upward. The process of separating the arms from a collapsed, or stowed, position is accomplished through the use of two lift cylinders that work together simultaneously. The primary means of maintaining the platform in any position other than stowed is employed by the use of a solenoid operated manual-control valve, or holding valve, Rod End of Lift - I located at the base port of each lift cy linder (See Cylinder ~ FIG. 5). This valve allows fluid to flow unrestricted to the cylinder, and blocks the flow of fluid from the cylinder. Lowering of the platVent Port - Routed back to Tank ~ form requires fluid to escape the lift cylinders, therefore both holding valves must be opened by applying 24 volts to the solenoids by pushing Lift Cylinder the upper control valve lever downward while depressing the footswitch, or by pressing the toggle switch at the lower controls to the downHydraulic Hose ward position, then pressing the valve control lever downward to lower the platform. In either Holding Valve at Base Port situation (upper or lower controls), the holding valves become energized but the platform will not start to lower until the valve handle is moved from its center position to allow the fluid to flow past the spool and return to tank from the cylinders.

The platform can be lowered if the solenoid or electrical system becomes inoperative.

To manually lower the platform, depress and Manual Release Knob at tip of Cartridge tum the small red knob counterclockwise 1800 (on both holding valves), then push the lower control valve handle downward to begin lowering the platform. To reset the holding valve for normal operation, push the red knob "in" and tum clockwise. This method of activation "manually" opens the holding valve cartridge rather than electrically, however, it must also be "manually" reset. .106" Orifice Located in this Fitting As shown in Figure 5, each cylinder has a vent port at the rod end which is routed back to the hydraulic tank. This port allows any fluid that may leak past the cylinder packing to be FIG. 5 returned to the hydraulic tank and also "vents" the cylinder to prevent any pressure or vacuum from building up within the cylinder.

MANUAL 92277-002 JUNE 1996

DRIVE SYSTEM The CONDOR® model 3160 scissor drive system utilizes two hydraulic drive motors located at the fixed axle of the chassis. Both drive motors have a 29.1 cubic inch per revolution (CIPR), but both motors are not identical and are not interchangeable. The right side motor has a keyed, tapered shaft for direct wheel hub mounting, and the left side motor has a splined shaft which mates to a brake assembly which has the same size keyed, tapered shaft for direct wheel hub mounting identical to the right side wheel/motor. A more detailed description ofthe brake system and how it operates can be found following this drive system description.

The drive function is only available from the upper controls, and the drive function lever also activates steering. Movement ofthe lever in the left or right side ofits centerline operates steering, while movement in the forward or reverse side of its left to right centerline operates drive. Both steer and drive can be manipulated simultaneously by moving the lever in an angled fashion from its forward/reverse and left/right centerlines.

There are three travel speeds available when operating the drive function; high, low, and creep speed. However, from serial number 3900 and up, the methods which these speeds are produced or achieved by are different from earlier models. The drive speeds and how they operated will be discussed in more detail following the brake system description.

BRAKE SYSTEM The 3160 brake system consists of a Left Rear Axle Tube single, spring-applied/hydraulicaUy-released, Brake Assembly dry friction-disc brake, which is located at the Drive Motor left rear wheel of the drive axle (See FIG. 6).

Ports Refer to paragraph one under "Drive System" Output Shaft for a description of the mounting configuration.

Figure 7 illustrates a partial cutaway Brake Port view of the brake assembly and itemizes the following components: (1) brake springs which FIG. 6 apply holding pressure, (2) friction discs which lock the output shaft when compressed by springs, (3) keyed, tapered output shaft for mounting of (1) (6) the wheel hub, (4) drive motor mounting/input / (2) end, (5) brake piston which transfers spring pressure to the friction discs, and (6) brake pressure port.

The brake assembly releases when approximately 200 psi or more is applied at the (4) pressure port (6). This fluid pressure overcomes the static pressure being applied on the piston by the twelve brake springs (1), and therefore pushes the piston (5) away from the friction discs (2) and thus compressing the springs and allowing the output shaft (3) to rotate. Pressure for FIG. 7 operating the brake assembly comes from a shuttle valve in the drive circuit which allows fluid to be directed to the brake assembly regardless of the direction of travel activated. Free-wheeling of the unit can be accomplished by turning the thumbwheel on the free-wheeling valve (located next to the lower control valve - See FIG. 3) fully clockwise, then MANUAL 92277-002 JUNE 1996

CD

BRAKE SYSTEM (cont'd) energizing travel for about 3 feet. This will allow drive pressure to build up to above 200 psi and unlock the brakes. Since the free-wheeling valve (which is simply an adjustable check/choke valve) is closed, it will not allow fluid to pass back through from the brake and therefore the brake is maintained in its released state and the unit can be moved. WARNING! -- In this condition the unit may begin to roll if it is resting on an incline. To return the brake system to normal operation open the free-wheeling valve by turning the thumbwheel counterclockwise.

The free-wheeling valve, in addition to free-wheel operation, can control the rate at which the brakes apply which can be beneficial by helping to provide smoother braking action. The brake applies as the hydraulic pressure is reduced to below that of the brake spring pressure. Ifthe hydraulic pressure is restricted in such a manner that the hydraulic pressure reduces at a slower rate, then the rate at which the brake applies will also be slower. The free-wheeling valve in its fully open (counterclockwise) position will allow the hydraulic fluid to escape the brake housing at a faster rate when the drive function is released. In this situation the brake may apply quickly while the unit is still rolling under momentum and result in a jerky stop. On the other hand, if the free-wheeling valve were adjusted to nearly closed (almost full clockwise), the unit would have time to stop or almost stop on its own as the brake applies.

CAUTION! -- Do not adjust the free-wheeling valve in such a manner that the brake does not apply at a rate which will effectively stop the unit on an incline.

DRIVE SPEEDS The 3160 utilized two methods for achieving the three available drive speeds which are: high, low, and creep. High speed is a condition where fluid flows through the two drive motors in series, thus providing a faster speed from the available flow rate. Low speed allows fluid to pass through the drive motors in parallel, providing more drive torque but reduced speed since the available flow is split in half.

Creep speed is utilized for travelling at platform heights above 7 feet were movement of the unit while on flat, level ground can be achieved without repeatedly lowering the platform. Drive torque and speed are both dramatically reduced when in this condition by directing some ofthe fluid from the drive circuit back to tank and effectively reducing pressure and flow.

Current production models (serial # 3900 and up) use an electromechanical system whereas each speed is controlled by some electrical means. Older production models (serial #'s up to 3899) use strictly a mechanical system meaning that there are no electrical circuits used for controlling the drive speed of the unit. In both systems the primary means of speed control is hydraulic, however, it's the secondary activation method where the differences lie.

Electromechanical system models utiSeries/Parallel Valves with Coils lize a 3-position rotary switch at the upper controls for controlling the transmission valve (See FIG. 8) which is located on the chassis at the fixed end of the armstack, and the creep valve which is located near the lower control valve.

Flow Divider/Combiner This configuration allows selection of any ofthe three speeds in any platform position below 7 feet. At heights of7 feet or above, a limit switch mounted to the chassis becomes activated by the Series/Parallel Valve lower arm ofthe armstack and thus energizes the creep valve. This activation is automatically controlled by the position of the platform and FIG. 8 will override the speed selected by the rotary switch at the upper controls.

MANUAL 92277-002 JUNE 1996

DRIVE SPEEDS (cont'd) Mechanical system models rely on strictly platform position for controlling drive speeds. There are no electrical circuits in the drive speed system on the previous 3160 model scissors (serial #'s up to 3899). A transmission valve (See FIG. 9) is mounted to the chassis near the fixed end of the armstack and contains a 2position 5-way cartridge which has a plunger protruding from the top of the cartridge. This plunger is depressed by the armstack when the platform is stowed, and is fully released when the platform is raised approximately 6 inches from its stowed position. These two positions of the platform yield two drive speeds - low and high, with the armstack fully stowed (plunger depressed) being low speed, and platform raised slightly (plunger released) being high speed.

A creep valve is also activated by armstack position (See FIG. 10). The armstack depresses a spool in the same manner as that of the transmission valve. However, due to the positioning ofthe valve in relation to the armstack pivot, the valve plunger moves at a much slower rate. This means that when the platform is fully stowed, the valve's spool is depressed and the valve is closed. As the platform is raised the creep valve spool gradually moves until at a certain point (platform at approximately 7 feet) the ports inside the valve become open to one another since the spool has eventually uncovered the ports. When the ports are uncovered, fluid is allowed to pass between the forward and reverse drive circuits which will diminish drive speed and torque. Inside one of the creep valve hydraulic fittings is an orifice to control the amount of fluid bypass when operating in the creep speed mode. When the creep valve spool is fully released, or opened, the drive circuit will operate in creep speed.

Malfunctioning of the mechanical system could possibly be due to a benttransmission valve plunger, spools sticking or binding, or insufficient depression of a plunger or spool due to armstack geometry and valve mounting locations. Contamination of the hydraulic system can cause problems with any hydraulic circuit's operation and should not be overlooked when troubleshooting hydraulic systems.

MANUAL 92277-002 JUNE 1996

Armstack Movement Operates Plunger

Plunger

2-Position 5-Way Cartridge Flow Divider/Combiner

Transmission Valve

FIG. 9

Armstack Movement Operates Spool

Manually Operated Spool

Creep Valve

FIG. 10

UPPER CONTROL VALVE 315-00034-00 BRAKE, ESKRIDGE

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126-10005-00

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SEE NOTE 1

FLOW CONOROL

______________

~V~AL~V~EQ5~2~66~'

__________________

k+~~*-~~~~~-~~ I

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BRAKE, ESKRIDGE

126-10005-00

MDLJ146 & MDU154

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STROKE: 21.75

106 )i

~g;~:0015(O;O~t~ M

OIA

j94

2500 RPM

~

106

PUMP 017BR1 A ADAPTER 735298

54286-394

~--~.

STROKE: 20.56

NOTES:

WACO,

PRESSURE SWITCH USED ONLY WITH TRAVEL ALARM OPTION. 7101

c-:::-+-5cc6~45~~07,;/JC'o/",9JtR:..:.G::.j.

5468

3810

06/29/93

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TEXAS

SCHEMATIC, 31 XX HYDRAULIC TOLERANCES

ON:

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54284

c

TRAVEL ALARM OPTION

MOTOR 321 - 00005 - 00 BRAKE

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S703

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UPPER CONTROL~AL~.~15-00034-00

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MOTOR 321-00002-00

HYDRAULIC TANK 02D-R0060-00

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UFT CYL 2 PL 55116 BORE:4.0 ROO:2.0 smOKE: 20.56

I

HOLDING VALVE 2 PL 527.l3

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II WACO, TEXAS

NOTES; 1. THIS SCHEMATIC SUPER CEDES 54284.

2. THIS SCHEMATIC REFLECTS IMPROVED "CREEP" PERFORMANCE 3. ADJUST CREEP SPEED TO 80-100 SEC/88 FEET, ON FIRM, LEVEL GROUND (REF .. 75/6 MPH).

4. LINE SIZES SHOWN ARE MIN I.D. FOR HYD HOSE.

A.HITTLE 04/05/95 4/25/95

B

RAK CHECKEO APPR. "'PPROVED

RAK 04/07/9 SCI\LE NONE

c

55057 1 OF 1

NOTES

MANUAL 92277-002 JUNE 1996

•

ELECTRICAL SYSTEM DESCRIPTION

The following is a detailed description of the electrical system used on the CONDOR® model 3160 scissor, and how it is designed to operate. To assist in understanding the system, this description should be used in conjunction with the electrical schematics found at the end of this section.

GENERAL The electrical system of the CONDOR® model 3160 is a 36 volt DC (direct current) negative ground system, which is made up of six, 6 volt Deep Cycle batteries connected in series to each other.

The pump motor, optional low volt interrupt (LVI), and the optional battery condition indicator are the only circuits operating on the full 36 volt battery source while all other electrical circuits use only 24 volts and are isolated from the batteries by a 20 amp fuse or circuit breaker. The 24 volt supply is achieved by using the same negative ground and by making the positive lead connection at the positive terminal of the fourth battery's positive terminal. This separate "grouping" of batteries, although they are still in the 36 volt "total" system, yields the necessary 24 volts to power other machine functions which have a 24 volt maximum capacity.

BATTERIES To ease in battery maintenance, there is a pull-out battery tray weldment on each side ofthe belly pan, in front ofthe hydraulic tank, nearest the steer axle. Each tray contains three 250 amp hour batteries, which are connected in series combining their voltage to make up the 36 volt DC system. The batteries are ofthe wet-cell type, and when filled with electrolyte, each battery weighs 781bs. Iffilling is needed during routine maintenance, distilled water can be used to bring the level up to the indicator in each cell.

DO NOT OVERFILL ANY CELL. More information on batteries in general can be found in the Battery Service Section beginning on page 23.

BATTERY CHARGER The battery charger has a 40 amp @ 36 volt DC nominal output, and operates off of aIlS volt AC (alternating current), 160 Hz, 8 amp input. The charger is located on the right side of the belly pan, between the hydraulic pump/motor and the fixed axle (See FIG. 11).

Electric Motor Battery Charger (reference)

\l"",

[~2J "-,_, i

0

Ref, Hydraulic Tank

,,/

FIG. 11 MACHINE FUNCTIONS The 3160 pump motor is rated at 6 HP @ 2500 RPM with a 160 amp current draw and utilizes the 36 volt system described in the General Description. The motor is turned on by means of a 24 volt solenoid, mountednextto the lower control valve, whereas the solenoid contacts handle the 36 volt motor circuit and the solenoid coil is activated by a 24 volt signal. The solenoid receives a signal whenever the footswitch is depressed or the lower control pump switch is pushed upward.

MANUAL 92277-002 JUNE 1996

MACHINE FUNCTIONS (cont'd) When the solenoid is energized the contacts close completing the 36 volt pump motor circuit. In any situation, the red Emergency Stop Buttons must be pulled out to allow operation of the UPPER! LOWER selector switch which must be set for the intended control station. Since lift, drive, and steer are hydraulic functions, the pump motor must be running to obtain the hydraulic pressure to perform these functions.

Lowering ofthe lift is accomplished by energizing the holding valves on the lift cylinders. When operating from the lower controls this can be accomplished by pressing the pump switch downward to energize the holding valves, then move the lift valve handle downward to begin lowering the platform.

When operating from the upper controls, lowering is achieved by depressing the footswitch to energize the electrical circuits, then simply moving the lift valve handle (at the upper controls) downward to begin lowering. The upper lift handle controls a microswitch. This switch completes a circuit, from its normally closed contacts, from the footswitch to the pump solenoid in all situations except lowering. When the footswitch is depressed the pump motor turns on, then as the lift control handle is moved downward, the pump will tum off as the contacts are opened. Likewise, the normally open contacts close as the handle is moved downward, which then completes a circuit from the footswitch (common terminal of microswitch) to the holding valves. When lowering the platform from either control station, once the holding valves are energized, the fluid is still being held in the lift cylinders by the control valve spools and can be released by downward movement of either control valve handle. When the holding valves are energized, the pump motor does not run because the unit utilizes a gravity lowering system whereas the fluid is allowed to escape from the cylinders at a controlled rate. This rate is proportional to the amount of handle travel.

Drive and steer functions can only be operated from the upper controls. When the footswitch is depressed and the pump turns on, movement of the vertical joystick (on top of the upper control valve) will operate drive, steer, or both simultaneously depending on the direction of handle movement. Handle movement in the forward or reverse direction of the unit itself produces drive in that direction, while movement to the left or right ofthe handle centerline produces steering in that direction. NOTE: The steering wheels will remain in their position as the handle is released and will not return to center or straight-line travel. The wheels must be returned to the straight forward position by operation of the joystick in the opposite direction until the wheels are in the proper or intended position.

CHARGING CUT -OUT RELAY (OPTION) A charging cut-out relay (R3) can be utilized to prohibit machine operation during charging. This is accomplished by a 115 volt AC relay which is energized when the battery charger is plugged in. The R3 relay uses two sets of contacts, R3-A and R3-B. Contacts R3-A are normally closed and they open when relay R3 is energized (batteries charging). The R3-A contacts are wired into the 24 volt DC tap circuit and the opening of these contacts disables all machine functions from either control station.

Simultaneously, the R3-B contacts close (since they are normally open) and energize a green charging light through the 24 volt DC tap circuit.

BEACON/STROBE (OPTION) Power is supplied to the beacon/strobe light from either position of the "UPPERILOWER SELECTOR SWITCH", and functions as long as the lower Emergency Stop Button is pulled out.

Although the current draw is relatively small, the batteries could become discharged ifthe beacon/strobe were left on for a substantial period of time.

MANUAL 92277-002 JUNE 1996

LOW VOLT INTERRUPT (OPTION) The Low Volt Interrupt Module (L VI) is used to shut down all functions at the upper controls should the battery voltage drop to 31.5 volts while under a load for 21 seconds. This will protect the electrical system from damage due to high amp draw from a low battery voltage condition. The interrupt system can be overridden by a momentary push button switch at the upper controls to allow the operator to lower the unit and connect the battery charger to a suitable power source for charging. The override should only be used when absolutely necessary and will only allow three, repeated by-pass cycles of 2 minutes 30 seconds each. Once the unit is re-charging, the battery voltage must reach 38.25 volts to reset the LVI module and allow normal operation ofthe CONDOR®. When the unit is in the "interrupt" mode, an amber light will be illuminated at the upper controls, next to the override button. The interrupt system is only operational when the upper controls are selected, and the operation ofthe lift can still be performed from the lower controls, although the usage time should be kept to a minimum during an interrupt condition.

TRAVEL ALARM (OPTION) The travel alarm signals forward or reverse movement ofthe CONDOR®. This is accomplished by a pressure switch located in the brake line and senses brake pressure (brake released), thus closing the switch and energizing the alarm.

HOUR METER (OPTION) The hour meter is used to monitor the "run time" of the unit, which is reflected by the actual running of the pump motor itself. The hour meter is powered by the circuit which controls the pump solenoid when operated from either the upper, or lower controls, therefore the meter only runs when the pump motor runs. The meter does not run during lowering of the platform.

MOTION ALARM (OPTION) The motion alarm signals both raising and lowering of the platform. This is accomplished through the use oftwo diodes, one for the pump solenoid circuit (similar to the hour meter circuit) and another diode for the holding valve circuit.

DESCEND ALARM (OPTION) The descend alarm signals descent of the platform only, and does not require the use of any diodes. The alarm is powered by the holding valve circuit and will sound as long as the holding valves are energized, even though the platform may not actually be lowering (valve spool barely shifted resulting in microswitch activation but no fluid flow past the spool).

110 VOLT LINE TO PLATFORM (OPTION) The CONDO R® 3160 can be equipped with a 110 vo lt AC receptacle at the upper contro Is, next to the lift valve lever, and an extension cord pigtail in the belly pan, which would allow small electric tools or lights to be operated from within the platform. The male pigtail should be connected to a suitable AC power source such as that which the battery charger is connected to. While the platform can be raised or lowered when using the 110 volt outlet, it is not recommended that the machine be driven while the supply cord is connected to the pigtail to prevent any damage to, or accidental disconnecting of the cord.

MANVAL 92277-002 JUNE 1996

•

5° SLOPE SENSOR/ALARM (OPTION) The optional slope sensor system consists of a multi -axis level sensor, a slope alarm, and a limit switch (for early 3160 models). The purpose ofthe system is to notify the operator when an out-of-Ievel condition exists, by sounding an alarm. The functions are not inhibited when in this condition to allow the operator to reverse the direction of travel to bring the unit back to a level condition. The sensor is mounted to the base ofthe belly pan and is adjusted to "level" when the chassis is on a level surface. The alarm is mounted at the upper controls. The sensor is supplied 24 volts when the upper/lower selector switch is placed in the upper position. When the CONDOR® is driven to an out-of-Ievel condition of 5° or more, the sensor turns on, thus grounding the alarm which has 24 volts supplied to it. Essentially, the sensor completes the ground circuit for the alarm when positioned 5° or more out-of-Ievel. The early 3160 models which also incorporate a limit switch will not be active until the platform is raised approximately 6 feet. The 24 volt circuit to the alarm is connected to the normally closed contacts of the limit switch and therefore breaks the circuit when the platform is stowed or raised up to approximately 6 feet. Once the limit switch closes, the supply circuit to the alarm is complete and the system is ready to notify an out-of-Ievel condition. Regardless of model, both systems will energize the sensor when in the upper control mode, but the later models alarm may sound regardless of platform position when an out-of-Ievel condition exists.

BATTERY CONDITION INDICATOR (OPTION) The optional battery condition indicator, located at the upper controls, measures the voltage of the 36 volt system and provides a "state of charge" reading for the operator. This indicator is connected directly to the batteries through a 3 amp circuit breaker, and is not switchable so it will remain on at all times, however its amp draw is relatively low and not a concern for battery drain.

MANUAL 92277-002 JUNE 1996

BEACON/STROBE OPTION

GROUND

NEG

36 VDC BATTERY

HYD PUMP

'"w~

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PLATFORM RAISING

L.::.LO::.:W.:.:E",R---<>-__ RED

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EMERGENCY

f----4

~

OPTIONAL BATTERY

GAGE

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JL~-~-~Y

R2

CONDITION INDICATOR

SEE NOTE 4 6

I

SEE NOTE 5

~------------------~RE~D~ S"

BLK

SEE NOTE 4 o

SLOPE ALARM OPTION

LOW VOLT SENSOR

R-.

\..V

LOW VOLT OVERRIDE

SLOPE SENSOR OPTION

SEE NOTE 4 } - - - - - - + LOW VOLT WARNING

R2

SEE NOTE 6

L-_ _ _~"'- ,'---------------1 HORN f - - - - . TRAVEL ALARM OPTION

= GROUND

NOTES: 1. THIS SCHEMATIC IS STANDARD FOR MDL3146, MDL3154, AND MDL3160 SCISSOR LIFTS. REFER TO DIAGRAM 54356.

2. SWITCH ACTIVATED BY VALVE LEVER IN PLATFORM. 3. SECOND HOLDING VALVE, ON MDL3160 ONLY. 4.

THRU (j) REPRESENT TERMINALS OF OPTIONAL LOW VOLTAGE WARNING/INTERRUPT SENSOR/SWITCH. 5. LIFT LIMIT SWITCH IS SHOWN W1TH PLATFORM ALL THE WAY DOWN. 6. PRESSURE SWITCH SENSES BRAKE RELEASE PRESSURE.

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SWITCH ACTIVATED BY VALVE LEVER. LIFT LIMIT SWITCH SHOWN WITH PLATFORM ALL THE WAY DOWN. THIS DIAGRAM IS STANDARD FOR MODELS 3146, 3154 & 3160

REFER TO SCHEMA TIC 54355 4. ONE VALVE COIL SHOWN FOR MDL3146 & MDL3154; MDL3160 HAS TWO HOLDING VALVES. 5. PRESSURE SWITCH SENSES BRAKE RELEASE PRESSURE.

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NOTES: 1. THIS SCHEMATIC SUPERCEDES 54996.

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THRU (j) REPRESENT TERMINALS OF OPTIONAL LOW VOLTAGE WARNING/INTERRUPT SENSOR/SIIHCH. 5. PRESSURE SWITCH SENSES BRAKE RELEASE PRESSURE.

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2

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B=RED/BLK

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7=WHT BLK 5=ORN

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10=ORN BLK HOLDING VALVE ON CYLS SEE NOTE 1

NOTES: PRIlPI'IETAIIYINFQIOIoIAl1ON

1. MOL .3146 HAS ONLY ONE HOLDING VALVE. MDU160 HAS TWO. 2. PRESSURE SWITCH SENSES BRAKE RELEASE PRESSURE. .3.

THRU (j) REPRESENT TERMINALS ON OPTIONAL LOW VOLT SENSOR/SWITCH.

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~_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _'''_~'"_'~_''OO_E_ _ _ _ _'~_'_ _~ED

•

NOTES

MANUAL <XI.277-002 JUNE 1996

BATTERY SERVICE

•

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

Suggested battery tools and their use are described below.

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

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

BATTERY CARRIER A battery carrier should not place any undue strain on the battery terminals or the container. An excellent carrier for plastic cased batteries is a clamp ("ice tong") type carrier with rubber pads which grip the SIDE WALLS ofthe container just below the lip of the cover. It is used on the side walls rather than the end walls, since the side walls have additional strength from the inner cell partitions. Gripping the flexible end walls of plastic containers could cause electrolyte to spew from some of the cells.

DANGER ,

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

MANUAL 92277-002 JUNE 1996

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

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

When there is corrosion on the terminal posts or hold-down, the tray or hold-down parts are rusty, or the battery is very dirty, it is recommended that time be taken to clean the parts. A wire brush can be used to remove dirt, corrosion or rust from parts. Clean dirt from the battery top with a cloth wetted with ammonia or baking soda in water.

Next, wipe with a cloth with clearwater. After rust is removed from a part with a wire brush, rinse with clear water, dry and paint with an acid-resistant paint.

If corrosion is found on the terminal posts, remove the cable terminals from the battery (ground cable first), using the proper end wrench. A wire cleaning brush can be used to clean the posts and the mating surfaces ofthe cable clamps. Connect the cables to the terminal posts (ground cable last). Coat the terminal connections with a spray corrosion inhibitor or high temperature grease.

The second item in routine servicing of conventional batteries is to check the electrolyte level in all cells. If necessary, add clear, odorless, mineral free water to bring the liquid level to the level indicator in all cells. If the battery does not have a level indicator, bring the level to 112" (13mm) above the tops ofthe separators. Do not overfill any cell. When a cell is overfilled, the excess electrolyte may be forced from the cell by the gas formed in the battery. This will cause excessive corrosion of adj acent metal parts, reduced performance and shorter life.

MANUAL 92277-002 JUNE 1996

BATTERY TESTING

•

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

STEP 1 - VISUAL INSPECTION F or protection, wear a face shield. First, visually inspect the battery. Check for container, cover or terminal damage that might cause leakage ofelectrolyte or internal damage. If serious damage is found, replace the battery. Check the electrolyte level in each cell. Ifbelow the tops ofthe plates in any cells, fill all cells with water to just above the tops of the separators and charge for 15 minutes at 15-25 amps to mix the water with the electrolyte. If electrolyte levels are above the tops ofthe plates, continue to Step 2.

STEP 2 - HYDROMETER TEST Using the hydrometer, measure and record the specific gravity (sp. gr.), corrected to 80 degrees F (26.7 C) ofthe electrolyte in each cell. Ifthe range (highest-lowest) is 50 points (0.050 sp. gr.) or greater orthe lowest is less than 1.225 sp.gr., charge the battery atthe recommended rate or until all cells are 1.225 sp.gr. or greater and the range is less than 50 points. If no amount of charging will achieve these conditions, replace the battery. Ifthese conditions are achieved, apply a 150 amp load for 15 seconds to remove the surface charge on the battery and continue to Step 3.

The average state ofcharge ofthe cells in a battery can be determined by measuring the stabilized voltage ofthe battery. The voltage is stabilized ifthe battery has been on open circuit overnight or for a period of several hours. A voltage reading of 12.4 (6.2 on a 6 volt battery) is equivalent to a specific gravity of 1.225. The disadvantage of measuring the open circuit voltage is that a lower voltage cell can be masked by the remaining cells. Ifthe cell connectors are accessible for voltage measurements, a range of 0 .05 volts between the highest and lowest cells corresponds to a 50 point variation in specific gravity.

A cell voltage of2.07 is equivalent to a specific gravity of 1.225.

MANUAL 92277·002 JUNE 1996

•

NOTES

MANUAL 92277-002 JUNE 1996

PREVENTIVE MAINTENANCE In conjunction with the pre-operation inspection, a good preventive maintenance program will ensure a properly operating CONDOR®. This section is directed toward those items of maintenance which the operator should be aware of, and which may be accomplished prior to the operation of the equipment. Refer to the "Preventive Maintenance Daily Inspection" and the "Preventive Maintenance 50 Hour Inspection" for detailed inspection procedures. Included in this section are checklists, for the Daily and 50 Hour Inspections, to assist in maintaining the CONDOR®. Please note that on the 50 Hour Inspection, some items may be stated as 500 Hours, where applicable.

LUBRICATION NOTE:

Recommended lubrication intervals are based on normal use in normal environmental conditions. The operator is cautioned to adjust the lubricating interval accordingly to meet each individual condition and usage. The recommended lubricants are generally the best choice. Should these lubricants be unavailable in your area, consult your local supplier for an equivalent.

Under NO circumstances should lubricant containing "Lithium" be used.

1.

Wheel Bearings Lubricant:

Wheel bearing grease.

Time Interval:

Every 500 hours of operation or yearly, whichever comes first --or upon disassembly.

Procedure:

Raise chassis and support. Remove fixed axle wheels. Remove outer dust cap, spindle nut, and washer. Remove outer cone bearing, hub, dust seal and inner cone bearing. Clean cone bearings and races, and inspect both for physical damage (pitting, etc). Inspect spindle for bending, cracked welds, or other physical damage.

IMPORTANT: If damage is evident, remove the CONDOR® from service until the spindle assembly is replaced, and contact the Condor Service Department to report the damage.

Repack cone bearings using fresh wheel bearing grease, install new dust seal, then reassemble components in reverse order of disassembly. Tighten spindle nut until hub will not tum, tum spindle nut counterclockwise one castellation, or until cotter pin will pass through spindle and spindle nut. Secure cotter pin, ensure that hub will rotate. Reinstall wheel assembly; torque wheel nuts to 120 ft lbs.

MANUAL 92277-002 JUNE 1996

•

2.

Hydraulic System Fluid Level:

Check level daily. Maintain fluid level at full mark on sight glass with platform in stowed position.

Return Filter:

Replace factory-installed filter element after first 50 hours of operation. Thereafter, replace filter every 500 hours of operation.

Tank BreatherlInlet Screen:

If equipped, clean every 50 hours of operation. Remove from tank and clean with solvent; air blow-dry.

Hydraulic Tank:

Drain oil from tank and replace annually. Add oil to required level using only Shell Tellus T-32 or equivalent.

Suction Strainer:

Drain oil from tank and replace strainer annually. If operating in dusty or harsh conditions, inspect filter more frequently and replace if necessary.

DO NOT MIX HYDRAULIC OIL 3.

Battery Servicing

FOR PROTECTION WHEN SERVICING BATTERIES, AL WAYS WEAR A FACE SHIELD. Visual Inspection:

Inspect for defective cables, loose connections, corrosion, cracked or swelling cases or covers, loose hold downs, and loose or deformed terminal posts.

Cleaning:

When needed, a wire brush can be used to remove rust, corrosion, or dirt from terminal ends or posts. The battery top can be cleaned with a cloth wetted with ammonia, or baking soda with water, then wiped with a cloth and clear water.

Electrolyte Level:

Check electrolyte level daily. Ifnecessary, add electrolyte or clear, odorless, mineral free water to bring the level to 112" above the top ofthe separators, or to the level indicator (if equipped), in each cell.

MANUAL 92277-002 JUNE 1996

PREVENTIVE MAINTENANCE INSPECTION

•

This field inspection list provides for a systematic inspection of the CONDOR®. The items listed to be inspected or checked daily will ensure proper unit performance prior to operation. By following the daily inspection procedure on a regular basis, any potential malfunction will be identified before it can become a major problem. The 50 Hour Inspection will detect any defective, damaged, or improperly secured part. The 50 hour Inspection also includes items requiring attention at 500 hours or yearly which, are indicated where applicable.

The time interval of 50 hours applies to normal operation under normal conditions. Should the unit be subjected to extensive use or abnormal environmental conditions, the inspections should be made more frequently. Condor recommends that a maintenance log be maintained, and that abnormal conditions of any kind be recorded. To help assist in starting a maintenance log, there are inspection checklists included after each inspection list. These are intended to be used with the field inspection lists to help gain familiarity with the repetitive tasks.

DAILY INSPECTION A.

B.

VISUAL INSPECTION Overall Condition:

Inspect platform, armstack, and carriage to make certain that no physical damage is evident. Look for missing components and hardware, loose components, etc.

Tire Condition:

Inspect tires for wear, cuts, and abrasions.

Battery Cable Connections:

For protection, wear a faceshield. Inspect for swelling of battery sides, tightness and corrosion of terminals. If corrosion is present, remove cables from the battery (ground cable first).

Clean terminals and posts with a wire brush and reconnect to battery (ground cable last). Coat the terminal connections with a spray corrosion inhibitor, or high temperature grease.

Hydraulic Fluid Leaks:

Inspect to ensure that there is no evidence of leaking hoses or fittings.

Decals and Placards:

Verify that all decals and placards are in place and are legible.

It is recommended that any decals or placards which are tom, damaged, missing, or painted over, be replaced.

FLUID LEVEL CHECK Hydraulic Tank Level:

Iflow, add hydraulic oil as required to maintain level at full mark on sight glass, with platform in stowed position.

Battery Electrolyte Level:

For protection, wear a faceshield. Check electrolyte level and add electrolyte or clear, odorless, mineral free water as required to bring the level to 112" above the tops of the separators in each cell.

MANUAL 92277-002 JUNE 1996

--

C.

OPERATIONAL TEST Instrument Check Hour Meter: (Option)

Ensure that meter is recording properly.

Battery Condition Indicator: (Option)

Ensure that indicator is monitoring the batteries state-ofcharge properly.

Ground Control Operation Check Emergency Stop Button:

Ensure that machine will not operate with button pushed in.

Check that button maintains its in or out position.

Control Selector Switch:

Ensure that switch controls the selection of "UPPER or LOWER" properly. Make certain that machine will not operate with switch in its center position.

Lift Control Function:

Check that switch, and valve lever both return to their normal position when released, and that lift/lower function is working properly.

Platform Control Operation Check Emergency Stop Button:

Ensure that machine will not operate from upper controls with upper emergency stop button pushed in. Check that button maintains its in or out position.

Lift Control Function:

Check that lever returns to its normal position when released, and that the lift/lowering of the platform functions properly.

Make certain that lift/lower function does not operate unless footswitch is depressed.

Drive/Steer Functions:

Depress footswitch and operate drive and steer functions.

Drive Speed Selection:

Ensure that each speed selection (either by electrical switch at platform [late models], or by platform position [early models]) is functioning properly.

Slope Sensor:

Tilt sensor more than 5° (located in belly pan), and check for audible alarm at platform controls. Controls must be in "UPPER" mode.

MANUAL 92277-002 JUNE 1996

•

PREVENTIVE MAINTENANCE DAILY INSPECTION MON

ITEM

~V

I

HOURS

VISUAL INSPECTION

TUES

WED

THURS

FRI

SAT

SUN

VVVVVV

Overall Condition Tire Condition Battery Cable Connections Hydraulic Fluid Leaks Battery Electrolyte Level Verify Legibility of Decals & Placards

OPERATIONAL TEST Hour Meter (Option) Battery Condition Indicator (Option)

GROUND CONTROLS Emergency Stop Button Control Selector Switch Lift Control Function

PLATFORM CONTROLS Emergency Stop Button Lift Control Function Drive/Steer Functions Drive Speed Selection Slope Sensor

MANUAL 92277-002 JUNE 1996

PREVENTIVE MAINTENANCE INSPECTION 50 HOUR INSPECTION A.

CHASSIS Visual Inspection:

Inspect for cracks in welds, dents or bends in material.

Steering Cylinder:

Check cylinder, pins, and cotter pins holding cylinder in place for proper installation.

Steering Tie Rod:

Check clevis bolts and jam nuts for proper installation. Check for bends in tie rod. Check tie rod clevis' for any abnormal or exceSSIve wear.

Steering Knuckles:

Inspect thrust bearings and pivot bushings for excessive wear.

Inspect welds for cracks in knuckle weldments and chassis yokes.

Ensure there is no binding throughout range of travel.

Wheels:

Check for loose or missing lug nuts, loose hub assemblies (fixed axle), and damaged or cracked rims.

Drive Motors:

Check motor hydraulic lines for leakage. Check wheel hub retaining nut and cotter pin for proper installation.

Brake Assembly:

Check hydraulic lines for leakage and mounting bolts for tightness. Check for proper brake release/apply operation.

Hydraulic Hoses and Fittings:

Inspect for leaks, cuts, and abrasions. Check fittings for tightness.

Tires:

Inspect for excessive or abnormal wear, cuts and abrasions.

Belly Pan:

Check belly pan for damage, and welds to chassis for cracks.

Check for security of components.

Battery Charger:

Inspect for damage. Verify proper charging operation.

Wiring and Electrical Connections:

Electric Motor and Pump:

Inspect for damage, fraying or cracked insulation, tightness of terminal ends, and proper routing.

Inspect motor and pump mounting hardware for tightness, cable connections for tightness, corrosion, fraying, or damage.

MANUAL 92277-002 JUNE 1996

B.

ARMSTACK Visual Inspection: Lift Cylinder Hoses and Fittings:

Inspect for leaks, cuts, and abrasions. Check for tightness and proper routing.

Electrical Cable:

Inspect for fraying or cracked insulation. Check for proper slack throughout range of movement.

Lift Cylinders:

Inspect for damage to chrome on lift cylinder rod, damage to cylinder body, and all welds for cracks. Inspect holding valve fittings for tightness, and valve coil and wiring for security.

Lift Cylinder Pins and Retaining Bolts: Limit Switch:

Lower Electrical Connections:

Armstack Bearing Pads (chassis):

C.

Inspect for cracks in welds, dents or bends in material.

•

Inspect cylinder pins and retaining bolts for security.

Inspect for damage to switch housing, orto arm lever. Inspect for security of internal wiring, proper strain relief sealing, and security of switch mounting.

Inspect wiring connections at chassis end of armstack electrical cable for corrosion and tightness. If rust or corrosion are present, clean with a wire brush and coat terminal connections with a spray corrosion inhibitor or high temperature grease.

Inspect for binding, cracking, pitting, or abnormal wear. Clean any dirt or debris from pad slide area. If binding or chatter is present during movement, lubricate sliding surfaces with antiseize compound.

PLATFORM Visual Inspection:

Inspect for cracks in welds, dents or bends in material.

Platform Pivot Shafts and Retaining Bolts:

Inspect security of retaining bolts and pin.

Platform Bearing Pads:

Inspect for binding, cracking, pitting, or abnormal wear. Clean any dirt or debris from pad slide area. If binding or chatter is present during movement, lubricate sliding surfaces with antiseize compound.

Platform Entrance Chain:

Inspect for damage.

MANUAL 92277-002 JUNE 1996

C.

PLATFORM (cont'd) Footswitch:

Inspect for damage. Ensure that pump turns on when depressed (must be in "upper" mode).

Electrical Cable Connections: Inspect for damage, fraying or cracked insulation, and proper routing.

Manual Storage Tube:

D.

Inspect for damage and security. Ensure that cover or end caps provide a watertight seal and that operator's manual is inside.

GROUND CONTROLS Visual Inspection

E.

External:

Inspect for damage to any guards/covers. Ensure that all applicable decals are in place and are legible.

Internal:

Inspect for tightness of mounting of all related components.

Inspect for any visible damage.

PLATFORM CONTROLS Visual Inspection External:

Inspect for damage to enclosure or controls. Ensure that all applicable decals are in place and are legible, and that lift lever guard is in place and secure.

Internal:

Inspect for tightness of wire ends at all locations. Ensure that valve and electrical components are securely mounted.

MANUAL 92277-002 JUNE 1996

•

PREVENTIVE MAINTENANCE 50 HOUR INSPECTION MON

ITEM

I

rz / HOURS

CHASSIS

TUES

WED

THURS

FRI

SAT

/ / / / / /

Visual Inspection Steering Cylinder Steering Tie Rod ,

Steering Knuckles Wheels Drive Motors Brake Assembly Hydraulic Hoses and Fittings Tires Belly Pan Battery Charger Wiring and Electrical Connections Electric Motor and Pump

ARMSTACK Visual Inspection Lift Cylinder Hoses and Fitting Electrical Cable Lift Cylinders Lift Cylinder Pins and Retaining Bolts Limit Switch Lower Electrical Connections Armstack Bearing Pads (chassis)

PLATFORM Visual Inspection

MANUAL 92277-002 JUNE 1996

SUN

PREVENTIVE MAINTENANCE 50 HOUR INSPECTION (cont'd) MON

ITEM

TUBS

WED

THURS

FRJ

SAT

SUN

Z / / / / 1/!//

I

HOURS

PLATFORM (cont'd) Platform Pivot ShaftslRetaining Bolts Platform Bearing Pads Platform Entrance Chain Footswitch Electrical Cable Connections Manual Storage Tube

GROUND CONTROLS Visual Inspection--External Visual· Inspection--Internal

PLATFORM CONTROLS Visual Inspection--External Visual Inspection--Internal

MANUAL 92277-002 JUNE 1996

HYDRAULIC OIL SPECIFICATIONS FOR CONDOR® AERIAL WORK PLATFORMS

Tellus - T32 Hydraulic Oil

Viscosity SUS@ 100°F SUS@2100F

155 47

Viscosity Index Typical

154

Flash Point of

325°

Pour Point of

-54°

COLD TEMPERATURE OPERATION

For continuous operation in subzero temperatures, an oil change is required. We recommend the following oils.

A)

Conoco DN-600 Antiwear Hydraulic Oil Manufacturer: Continental Oil Co., Houston, Texas

B)

Sun Low Temperature No.3 Hydraulic Oil Manufacturer: Sunoco, Inc., Toronto, Ontario, M5S 2S4, Canada

C)

Oil Conforming to MIL-H-5606C Specifications.

Examples: Chevron Aviation Hydraulic Fluid-C Shell L.O. Hydraulic #23

MANUAL 92277-002

JUNE 19%

•

NOTES

MANUAL 92277-002 JUNE 1996

APPENDIX A

A div. of TIME Manufacturing Company

BOLT TORQUE CHART NOMINAL THREADS

BASIC STRESS

TENSILE STRENGTH (T) MIN

MAJOR AREA SQ. IN INCH

PROOF LOAD (P) SAE GRADE (1957) GRADES liRADE8

DIA

T

p

T

SAE GRADE 5 LAMP LOAD LBS.

P

ASSEMBLY TORQUE R-.ZOODRY -.ISOLUB

SAEGRADE8 CLAMP LOAD LBS.

ASSEMBLY TORQUE R-.ZOODRY -.ISOLUB

4-40

.IIZO

.00604

IZOKS]

8SKS]

ISOKS]

IZOKS]

380

8LB-IN

6LB-IN

S40

IZLB-IN

9LB-IN

4-4/S o-J1.

0-4U

.l1Z0

.00661

IZOKS]

8SKS]

ISOKS]

IZOKS]

4Z0

9LB-IN

7LB-IN

600

13LB-IN

10LB-IN

.1380

.00909

IZOKS]

8SKS]

ISOKS]

IZOKS]

S80

16LB-IN

IZLB-IN

8Z0

Z3LB-IN

17LB-IN

.1380

.0101S

IZOKS]

8SKS]

ISOKS]

IZOKS]

640

18LB-IN

I3LB-IN

920

ZSLB-IN

19LB-IN

8-32

.1640

.01400

IZOKS]

8SKS]

ISOKS]

IZOKS]

900

30LB-IN

ZZLB-IN

IZ60

4ILB-IN

3ILB-IN

IS-Jo IU-1.4 IU-J1.

.1640

.01474

IZOKS]

8SKS]

ISOKS]

IZOKS]

940

3ILB-IN

Z3LB-IN

13Z0

43LB-IN

3ZLB-IN

.1900

.017S0

IZOKS]

8SKS]

ISOKS]

IZOKS]

IIZO

43LB-IN

3ZLB-IN

IS80

60LB-IN

4SLB-IN

.1900

.OZOO

IZOKS]

8SKS]

ISOKS]

IZOKS]

IZ8S

49LB-IN

36LB-IN

1800

68LB-IN

SILB-IN

l/4~1.U

ZSOO

.03180

IZOKS]

8SKS]

ISOKS]

IZOKS]

ZOZO

8LB-FT

7SLB-IN

Z860

IZLB-FT

9LB-FT IOLB-FT

l/4~1./s

ZSOO

.03640

IZOKS]

8SKS]

ISOKS]

IZOKS]

Z3Z0

10LB-FT

86LB-IN

3Z80

14LB-FT

~/10-1/s

.3IZS

.OSZ40

IZOKS]

8SKS]

ISOKS]

IZOKS]

3340

17LB-FT

13LB-FT

4720

ZSLB-FT

18LB-FT

~/ 10-1.4

.3IZS

.OS800

IZOKS]

8SKS]

ISOKS]

IZOKS]

3700

19LB-FT

14LB-FT

SZZO

ZSLB-FT

ZOLB-FT

J//S-l0 J//s-1.4 //1/-14

.37S0

.077S0

IZOKS]

8SKS]

ISOKS]

IZOKS]

4940

30LB-FT

Z3LB-FT

7000

4SLB-FT

3SLB-FT

.37S0

.08780

IZOKS]

8SKS]

ISOKS]

IZOKS]

S600

3SLB-FT

ZSLB-FT

7900

SOLB-FT

3SLB-FT

.437S

.10630

1Z0KS]

8SKS]

ISOKS]

IZOKS]

6800

SOLB-FT

3SLB-FT

9SS0

70LB-FT

SSLB-FT

.437S

.11670

IZOKS]

8SKS]

ISOKS]

IZOKS]

7SS0

SSLB-FT

40LB-FT

10700

80LB-FT

60LB-FT

.SOOO

.14190

IZOKS]

8SKS]

ISOKS]

lZOKS]

90S0

7SLB-FT

SSLB-FT

IZ7S0

110LB-FT

80LB-FT

.sooo

.IS990

IZOKS]

8SKS]

ISOKS]

1Z0KS]

10700

90LB-FT

6SLB-FT

14400

IZOLB-FT

90LB-FT

.S6ZS

.18Z00

IZOKS]

8SKS]

ISOKS]

IZOKS]

11600

lIOLB-FT

80LB-FT

16400

ISOLB-FT

IIOLB-FT

.S6ZS

.Z0300

IZOKS]

8SKS]

ISOKS]

IZOKS]

IZ9S0

IZOLB-FT

90LB-FT

18ZS0

170LB-FT

I30LB-FT

::>11\-11

.6ZS0

.ZZ600

IZOKS]

8SKS]

ISOKS]

IZOKS]

14400

ISOLB-FT

1l0LB-FT

Z03S0

ZZOLB-FT

170LB-FT

5/1S-11S

.6ZS0

.ZS600

IZOKS]

8SKS]

ISOKS]

IZOKS]

169S0

180LB-FT

I30LB-FT

Z3000

Z40LB-FT

180LB-FT

3/4-IU 3/4-10

.7SOO

.33400

IZOKS]

8SKS]

ISOKS]

IZOKS]

Z1300

Z60LB-FT

ZooLB-FT

30100

380LB-FT

Z80LB-FT

.7S00

7116-20 1/2-13 1/2-20 9116-12 9/16-18

.37300

IZOKS]

8SKS]

ISOKS]

IZOKS]

Z3800

300LB-FT

ZZOLB-FT

33600

4Z0LB-FT

3Z0LB-FT

7/8-9 7/8-14

.87S0

.46Z00

IZOKS]

8SKS]

ISOKS]

IZOKS]

Z9S00

SZOLB-FT

390LB-FT

41600

600LB-FT

460LB-FT

.87S0

.S0900

IZOKS]

8SKS]

ISOKS]

IZOKS]

3Z400

S70LB-FT

430LB-FT

4S800

660LB-FT

SOOLB-FT

I-IS

1.000

.60600

IZOKS]

8SKS]

ISOKS]

IZOKS]

38600

770LB-FT

S80LB-FT

S4S00

900LB-FT

680LB-FT

1-12 1 118-7

1.000

.66300

IZOKS]

8SKS]

ISOKS]

IZOKS]

4Z300

8S0LB-FT

630LB-FT

S9700

1000LB-FT

740LB-FT

1.1ZS0

.76300

10SKS]

74KS]

ISOKS]

IZOKS]

4Z300

8ooLB-FT

600LB-FT

68700

IZ80LB-FT

960LB-FT

I InS-I1.

1.1ZS0

.8S600

IOSKS]

74KS]

ISOKS]

IZOKS]

47S00

880LB-FT

660LB-FT

77000

1440LB-FT

1080LB-FT

1 114-7 1114-12

I.ZS00

.96900

10SKS]

74KS]

ISOKS]

IZOKS]

S3800

lIZOLB-FT

840LB-FT

87200

18Z0LB-FT

1360LB-FT

I.ZS00

1.0730

10SKS]

74KS]

ISOKS]

IZOKS]

S9600

IZ48LB-FT

9Z0LB-FT

96600

ZOOOLB-FT

OOLB-FT

I J//S-O

1.37S0

1.1SS0

IOSKS]

74KS]

ISOKS]

IZOKS]

64100

1468LB-FT

lIOOLB-FT

104000

Z380LB-FT

80LB-FT

13/8-12

1.37S0

1.31S0

IOSKS]

74KS]

ISOKS]

IZOKS]

73000

I 680LB-FT

IZ60LB-FT

118400

Z7Z0LB-FT

Z040LB-FT

I 111.-0

1.5000

1.4OS0

10SKS]

74KS]

ISOKS]

IZOKS]

78000

I 940LB-FT

1460LB-FT

IZ6S00

3160LB-FT

Z360LB-FT

1112-12

1.5000

1.5800

10SKS]

74KS]

ISOKS]

IZOKS]

87700

ZZOOLB-FT

I 640LB-FT

14ZZ00

3S60LB-FT

Z660LB-FT

NOTES: 1. THIS CHART SHOWS RECOMMENDED BOLT TORQUES. 2. TORQUE = R X D X T R = .150 FOR LUB CONDITIONS R = .200 FOR DRY CONDITIONS TO ASSURE CONSISTENCY IN TORQUE, LUBRICATE FASTENERS WITH ENGINE OIL (MAY BE USED OIL) D = NOMINAL DIAMETER IN INCHES T = DESIRED CLAMP LOAD IN POUNDS = 75% PROOFLOAD X STRESS AREA

MANUAL 9ZZ77-00Z JUNE 1996

~

APPENDIXB

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

A div. of TIME Manufacturing Company

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

-THE TORQUE VALUES FOR EACH DIAMETER ARE ACCEPTABLE FOR ANY THREAD PITCH IN THAT DIAMETER.

PROPERTY CLASS 8.8

PROPERTY CLASS 9.8

PROPERTY CLASS 10.9

PROPERTY CLASS 12.9

DRY

DRY

LUBRICAJED

DRY

LUBRICAJED

DRY

THREADS THREADS

THREADS

THREADS

THREADS

THREADS

THREADS

THREADS

M4

27.5*

17*

30*

18*

38.5*

24*

53*

32.5*

M5

56.5*

33.5*

61*

37*

78*

47*

107*

65*

M6

95*

57.5*

103*

61*

132*

79*

180*

109*

M8

19

12

21

13

27

16

37

22

MIO

39

23

42

25

53

32

73

44

M12

67

40

73

44

92

55

127

76

M14

107

64

116

69

146

89

203

122

M16

167

100

181

108

230

138

316

190

M20

325

195

352

211

449

269

617

370

M24

562

337

609

386

775

465

1066

640

M30

1117

670

1210

726

1540

924

2188

1271

DIAMETER

LUBRICAJED

MANUAL 92277-002 JUNE 1996

LUBRICAJED

AERIAL WORK PLATFORM

MODEL 3160 (includes Models 2032,3146, and 3154)

ILLUSTRATED PARTS MANUAL

SHIPPING ADDRESS

MAILING ADDRESS

CALAVAR CORPORATION

CALAVAR CORPORATION

8300 IMPERIAL DRIVE VVAco,TExAs76712 (817) 666-4545

P.O. Box 21447 VVACO, TEXAS 76702-1447 (817) 666-4545

MANUAL 92277-003 SEPTEMBER 1993

INTRODUCTION

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

THE OPERATOR'S MANUAL MUST BE RETAINED ON THE CONDOR® A TALL TIMES.

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

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

It is also YOUR RESPONSIBILITY to understand and obey all federal, state, and local regulations regarding the operation and use of aerial work platforms. A copy of the ANSI/SIA Manual of Responsibilities is attached for your use: ANSI/SIA A92.5-1992 is provided for BoomSupported Elevating Work Platforms, and ANSI/SIA A92.6-1990 is provided for Self-Propelled Elevating Work Platforms.

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

DO NOT ALTER OR MODIFY THIS CONDOR® WITHOUT PRIOR WRITTEN APPROVAL FROM THE MANAGEMENT OF CALA VAR CORPORA TION

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

NOTE:

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

CONDOR® SERVICE INFORMATION

1. If you need assistance or have any service or maintenance questions, Calavar service and parts personnel are always available by phone or fax. The telephone numbers are: (817) 666-4545 Telephone (817) 666-5125 Voice Mail (800) 443-5803 FAX

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

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

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

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

CALAVAR CORPORAnON

8300 IMPmuAL DRIVE, P.o. Box 21447, WACO, TEXAS 76702-1447.817-666-4545,817-666-4544 FAX

(

Self - Propelled Booms and Scissors

WARRANTY Calavar Corporation ("Calavar") warrants to the purchaser that each new aerial work platform made by Calavar is free from defects in material and workmanship arising under normal use and service, in the case of major weldments (chassis, turret and booms), for a period of 5 years after the original shipment of the aerial work platform from Calavar's plant; and in the case of all other parts, for a period of 1 year after the aerial work platform is first placed in service or two years after the original shipment of the aerial work platform from Calavar's plant, whichever 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 event shall Calavar or its suppliers be liable to the purchaser or any other person for transportation charges or for any incidental, collateral, special or consequential damages, including without limitation damages for loss of profits, loss of customers, loss of goodwill or work stoppage, claims by any party other than the purchaser, or any other similar damages or loss even if Calavar, its suppliers or its representatives have been advised of the possibility of such damages.

Parts claimed to be defective and for which repair or replacement is desired shall be returned transportation prepaid to Calavar'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 Calavar shall, at Calavars option, void this Warranty. Calavar shall have no liability or responsibility for damages resulting from accident or the malfunction of equipment and components not supplied by Calavar.

No agent, employee, distributor, dealer or other representative of Calavar is authorized to modify this Warranty in any way. Accordingly, additional statements or presentations by any such representative, whether oral or written, do not constitute warranties by Calavar and should not be relied upon as limited warranties of Calavar, and no attempt, effort or promise to repair equipment by 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 purpose. Any applicable implied warranty shall be limited in duration to the warranty period.

8300 Imperial Drive, P.O. Box 21447, Waco, Texas 76702-1447 • 817-666-4545, 817-666-4544 FAX Form No. 513-1 M-495

Printed in U.S.A.

How to Order Parts

1.

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

2.

If known, please specify the Calavar part number(s) for the part(s) you require, and always provide a complete description of all parts.

3.

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

4.

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

II

5.

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

6.

Calavar classifies its orders in the following ways: Emergency

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

Stock

Order to be shipped within (1) week.

7.

Calavar has a $25.00 Net Minimum Billing charge per order.

8.

All price quotations will be valid for 90 days.

9.

Parts shown as shipped on the Calavar packing list and subsequent invoice but not received by the dealer/customer MUST be reported within 10 days after the date of shipment. If the parts are still required, a NEW parts order must be submitted. Shortages and discrepancies will be reviewed on an individual basis by the Parts staff and adjustments will be made accordingly.

10.

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

CALAVAR PARTS DEPARTMENT FAX ORDER FORM

(

IPURCHASER

ACCOUNT # C U S T

I N F

FAX NO. 800-443-5803 SALES ORDER # NAME

NAME

ADDRESS 0 R M 0 CITY A M T E I R PHONE 0 ) ( N CUST. PURCHASE ORDER NO.

STATE

S H I P

ZIP

FAX

(

)

I ORDER DATE

I

I

I

T

ADDRESS

0 CITY

STATE

PHONE

FAX

(

(

)

REQUEST DATE

ZIP

)

SPECIAL MARKS & NUMBERS

SHIPPING INSTRUCTIONS

PART NUMBER

QTY.

DESCRIPTION

(

"(

FOR ORDER STATUS PLEASE CHECK APPROPRIATE BOX BELOW EMERGENCY STOCK

NOTES

TABLE OF CONTENTS

3160

FIGURa 10 21 22 30

31 50 51 52 70

71 72 73

74 75 76 77

TI'rLB

Final Installation Electrical Diagram Hydraulic Schematic Platform Installation Platform Control Box Assembly Lift Installation Lift Cylinder Assembly Arm Stand Assembly Chassis Installation Drive and Brake Installation Brake Assembly Hydraulic Tank Assembly steering Installation Battery Installation Pump Asseably Ground Control Assembly

FIGURE 10 FINAL INSTALLATION

!

1 REF

,:

~

3

'~45

:

~~

~

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6

FIGURE 10 FINAL INSTALlATION I

T E

..

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

CALAVAR PART . NUMBER

34354 92272 67793 BOW31444 BOW36725 BOW31201 FIGURE 21 FIGURE 22 001-04000-1A 030-A4000-00 001-04000-2A 001-A4000-3B ~13 58276 10014 67470-001 1-15 287-96491-00

DESCRIPTION

QUANllTY

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

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

SOLENOID

~------r-----~

+ MOTOR

I +

I

o

KEY SWIl CH

PUSH BUTTON

+ -

MASTER DISCONNECT SWITCH

r--

') +

Jl=1

==>-+W::.!H!il..!...!TE~

'-

EMERGENCY STOP

+

+

r---e

L----e

BATTERIES ,--",B=LA..;.;:C=K--c==l

FOOT S~Jl TC H

BATTERY CHARGER

BRAKE LINE

1

C

A fB RIGHT DRIVE MOTOR

LEFT DRIVE MOTOR & BRAKE L-B AI

UPPER CONTROL VALVE 0-

w

W

0

P

-i

0

11

-i

0

""0

-i -i

0

3:

0 -i

0

-i -i

0

.... .... ""Oi

3:

0 ..... c-i ~Q1Q1 CO CO Z

L_

J

GREEN

J

PURPLE YELL 011

r®:~

~

IN HYDRAULIC TANK

r

...."" ~

LOW SPEED VALVE

OUT f - -

;v

3

PRESSURE

0 ;v ])

11--

RED..JC!NQ YAL~

W

;v 0

2

5

m

c

Z Gl

m

c z

J RED

0 ROD END

LOWER CONTROL VALVE

r H

"

r .... "....

'--

MOTOR

l=rt ROD END

CAP END

p~~p

J

IN

-< r

:z:

0 <II

m

OUT

H

Z

LIFT

•

0

rn

CAP END

:lJ

I

&rtT

STEER CYLINDER

our

TO U. C. v ..

-l

()

0

I

ORANGE

BROliN

FIGURE 30 PLATFORM INSTALLATION

, 3:,-- - I

7

2'

101

r-:~r=--=~=-~~b.iiiiii.-llL_fJ1l--~

1 14

13,

19

II

18

/I

~21

~I. 17

---r ® .,,,/

/

15

16

12

FIGURE 30 PLATFORM INSTALlATION I

T

.

E

CALAVAR PART NUMBER

1 010-A4028-00 2 010-S4034-00 3 010-S4031-00 4 010-S4030-00 5 010-S4029-00 6 FIGURE 31 7 570-A4003-00 8 570-A4004-00 9.392-00031-00 10 11 52963 12 37515 13 50277 14 58419 15 164-00013-00 16: 019-A4028"'OQ 171533";00001-00 18!

19 i BOW30006 20: BOW31401 211BOWl4272 22 i BOW34113 23 245-00008-00

DESCRIPTION

QUANnTY

12345 Weldaent, Platform Frame 'Welament, Right Side Rear Guardrail We lament , Left Side Rear Guardrail Welament, Side Guardrail Welament, Front Guardrail Assembly, Platform Control (See Fig. 31) Guard, Deck Hose Guard, 4" Deck Hose SWitch, Foot Clipper Assembly , Platform Floor Decal, Capacity 1,500 LBS Decal, 3160 Becal, CORDOR Tape, Orange and Red 31LF chain ·Welciment, Platform Frame Link, Chain Welciment, Rear Movable Guardrail Belt, Hex Washer, Flat .ut, Lock R.ivet, Pop Pin, Lanyard Hitch

1 1 1 2 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 1 1 AIR AIR

FIGURE 31 PlATFORM CONlROL BOX ASSEMBLY

rr----17 9 _ _~~~~

10 8--~

-t---H----18

19

$1\\

~

bI---5

2

12

7

6

4

FIGURE 31 PlATFORM CONTROL BOX ASSEMBLY I

T E

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,

..

".",,'

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

CALAVAR PART NUMBER

DESCRIPTION

12345

020-R2047-00! Assembly Control Box 010-R1013-00· • Weldment, Control Box Handle 529-R1083-00 • Cover, Control Box .620-R1078-00 • Panel, Control Box Side . 128-00009-00 • Bolt, Hex ·475-00070-00 • Washer, Flat BOW34272 • h t , Hex Lock 31b-00219-00 Deeal, Control Cover 275-00002-00 Knob, Emergency stop Plastic 392-00009-00 Switch, Emergency On-Off 0.20-A4025-00 Assembly, Platform Control Valve 315-00034-0.0 • Valve, Platform Control 253-96632-00 • Fitting 253-96662-0.0 • Fitting 253-96670-00 • Fitting 310-00159-00 Decal, caution Volt Lines I

310-00214-00 310-00151-00

QUANlllY

Decal, Operation Sheet Deeal, Lift Control Deeal, Read rnstructions

1 1 1 1 12 4

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

FIGURE 32 UPPER CONTROL BOX INSTALLATION

18

11

4 PL

15

17

o

14

92277-003

0

IITEM Ref.

1 2 3 4

5 6 7 8 9 10 11 12 13 14 15 16 17 18

FIGURE 32 UPPER CONTROL BOX INSTALLATION PART NUMBER DESCRIPTION 55151 54060 54061 010-R1013-00 54498 020-M1035-00 51913 51914 67872 BOW34273 BOW30037 BOW33848 52672 BOW31127 54192 54193-001 52028 54187 55109

QTY

Upper Control Box Installation .................................................. 1 Cover, Control Box ..................................................................... 1 Panel, Side Control Box ............................................................. 1 Handle, Control Box ................................................................... 1 Spacer, Upper Control Valve ...................................................... 3 Valve Assembly, Upper ControL ............................................... 1 Switch, Emergency Shut Off ...................................................... 1 Contact Block, NC ...................................................................... 6 Switch-Short Arm ....................................................................... 1 Nut, Stop, 5/16-18UNC .............................................................. 3 Bolt, Hex .31 "-18UNC x 3.00" ................................................... 3 Screw, Self-Tap .25" x 1.00" ...................................................... 8 Base + INO Contact ZB2-BZI01 ............................................... 1 Screw Grade 5, #6-32 ................................................................. 2 Plug, Hole 1.25" Dia................................................................... 1 Plug, Hole 1.125" Dia................................................................. 1 Operator, 2 Pos. Rot. ZB2-BD2 .................................................. 1 Decal, Lift Control ....................................................................... 1 Decal, 3146/60 Upper Control Top ............................................ 1

92277-003

FIGURE 50 LIFT INSTALLATION

5 -_ _ _'\

9

1

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

FIGURE 50 LIFT INSTALlATION I

T

.

E

1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16

CALAVAR PART NUMBER

124-00028-00 124-00032-00 128-00013,-00 8OW34278 010-S4020-00 010-S4025-00 010-S4026;"00 020-H5015-00 010-S4022-00 010-S4024-00 010-S4027-00 010-S4018-00 124-00030-0,0 167-00002-00 8OW40541 524-00006-00

DESCRIPTION

QUANnTV

12345

BuShing

cam, 2" Flower Bolt, Hex

Nut, stop We I dment, Upper outer Arm Weldment, Upper Inner Arm Weldment, Middle Inner Arm Assembly, Lift Cylinder (See Fig. 51) Weldment, Middle outer Arm Weldment, Lower outer Arm We I dment, Lower Inner Arm We I dment, Arm Stand (See Fig. 52) Bushing Collar, Shaft Screw, Set Cable, Arm

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

~

FIGURE 51 LIFT CYLINDER ASSEMBLY 2

3

L------3

7

8

I

..

-CALAVAR PART NUMBER

1 2

621-G91l1-00 128-00026-00

3 4 5 6 7 8 9

331-00098-00 162-96438-00

I

253-96618-00 154-00007-00

257-00·001-00 253-~6C;09-00

DESCRIPTION

QUANl1TY

12345

Pin, Lift cylin4er

Bolt, Hex »ut, Esna Assembly, Lift Cylinder • Kit, Seal Pittinq Clamp, Hose ru.8, Velcty Pit.tilVJ, Adapt.er

4 4 4 1

1 1 1 1 1

FIGURE 52 ARM STAND ASSEMBLY

1

5

I

T E

.

1 2

3 4 5 6

CALAVAR PART NUMBER 531-G9125-00 BGW16055 BOW34274 010-54018-00 BOW34113 245-00008-00

DESCRIPTION

QUANnTY

1 2345 B:racket, Alt1I stand pivot 801't, Hex

.'u.t, Lock weldment, Arm stand Rivet, Pop pin, Lanyard Hitch

!.

2

8 8 1 1 1

FIGURE 70 CHASSIS INSTALIATION

8

I

I

..

CALAVAR PART NUMBER

1 010-04000-JA 2 315-00035-00 3 FIGUD 71 4 47 6-0·Q02i"';oo 5 315-00037-00 6. 020-A4049-00 7 FIGURE 74 8 FIGURE 75 9 355-00006-00 10 355-00016-66 11 322-00015-00 12 026-S4042-(}0 13 396-00003-00 14 289-00007-(}0 15 321-00002-00 16 FIGURE 77

DESCRIPTION

QUANl1lY

WeldlBent, 3160 Chassis Valve, Creep In&talla'tion, Drive and Brake (~,-ee~!'CJl._71) Assembly, TiJie Valve, Transaission Assembly, Hydra.ulic Tank (See Fig. 73) Installa.tion", steering (See Fig. 74) Installation, Battery (See Fig. 75)

1 1 1 4

12345

Assembly, Battery Charger Assembly, Pump (See Fig. 76) Assembly, Electric Motor Assembly, Motor Hub • Stud, Wheel • Drive, Hub • Assembly, Motor Assembly, Ground Control (See Fig. 77)

1 1 1 1 1 1 1 1 5 1 1 1

FIGURE 71 DRIVE AND BRAKE INSTALLATION

6

5

4

® I T

CALAVAR PART

..

NUMBER

1 2 3 4 5 6

396-00003-00 289-0Cil007-00 126-10007-00 253-96506-00 321-10005-00 253-96610-00

E

DESCRIPTION

QUANllTY

12345 stud, Wheel

5

Drive, Brake, Elbow, Motor, Elbow,

1 1 1 1 2

Il\H)

Eskridqe (See Fiq. 72) 90

Brake Wheel 90

FIGURE 72 BRAKE ASSEMBLY 9

5

22

FIGURE 72 BRAKE ASSEMBLY I

T E

.

CALAVAR PART NUMBER

tmJ01034 DRJ01035 D&J01036 DBJ01037 Dal01038 DlU01039 DRJ01040 DRJ01041 mu01042 DlU01043 DRJ01044 DRJ01045 DRJ.01047 DRJ01048 EmJ01049 l ' DRJ01050 -17 0&101051 18 19 20 21 22 23 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

DESCRIPTION

QUANllTY

12345 .,ut, Slotted Jam

Screw, Socket Head cap PlUCJ, Hollow Hex case, Brake Bearinq, output Key Shaft Spacer Plate, Separate Plate, Bronze Friction Piaton Sprinq, Blue COver, Brake .Bearinq, Input ·lling , , Snap Ring, Snap Kit,' Seal • Rinq, Piston Backup • G-Rinq, Piston • O-Rinq, Piston • ainq, Piston Backup • O-Rinq, Case Seal • Gasket Mountinq

1 4 1 1 1 1 1 1 9 8

1 12 1 1 1 1 1 1 1 1 1 1 1

FIGURE 73 HYDRAULIC TANK ASSEMBLY

11

4 10.-~

16

9----<

r----22,

3

FIGURE 73 HYDRAULIC TANK ASSEMBLY I

T E

.

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

CALAVAR PART NUMBER

DESCRIPTION

QUANlllY

12345

(U;O-S.401l"'eO Weld.Jaellt, Hydraulic Tank 254-96611-00 Elbow, street 450-00051-00 Valve, Ball Shut Off 253-96612-00 Pitting, Adapter 260-00001-00 Gauge, oil Level 310-00160-00 Decal, Hydraulic Fluid 254-00051-00 Plug, Black Steel 253-96618-00 alhow, 90 259-00001-00 Gasket, Tank 529-S1076-00Cever, Hydraulic Tank 152-00008-00 cap, Breather BOW36002 Bolt, Hex BOW36725 Washer, SPL Lock 253-96596-00 Fitting 253-96597-00 It.educer 253-96616 ... 00 Bl·bow, 90 33430 !'ilter, Return 61408 • Blement, Filter 254-00042-00 Elbow, Steel 254-00009-00 Ripple, Close Pipe 254-00008-00 Hipple, Close Pipe 254-00041-00 Blbow, Steel 2'54-00084-00 Pl.uq, Pipe

1 1 1 1 1 1 1 1 1 1 1 8 8 1 1 1 1 1 1 1 1 1 1

FIGURE 74 STEERING INSTALlATION 1

2'

8

9

16.

15---1

®

FIGURE 74 STEERING INSTALlATION I

T E

.

CALAVAR PART NUMBER

1 289-00002-00 2 396-00003-.0 3 BOW30160-3 4 BOW30160-2 5 BOW34278 6 119-00012-00 7 BOW32278 8 663-54151-00 9 010-54009-00 10 010-S4010-00 11 350-00017-00 12 13 14 BOW40541 15 16 124-00028-00 17 475-00062-00 18 124-00033-00 19 020-ROO'55-GO 20 253-96659-00 21 1'2-96440-00 22

DESCRIPTION

QUANnlY

1 2345 Hub Dri'V'e -Stud, Wheel Bolt, Hex Bolt, Hex Rut, Elastic stop End, Male Rod Hut, Jam lloci, Tie Weldment, Spindle Left Weldment, Spindle Right Set, King Pin • Shim • Bearing, Sealed • Screw, Set • Pln Bushing Bblm Bushing Assembly, Steering Cylinder • Elbow, 90 • €ylinder, Steering • • lCit, Seal

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

-,

FIGURE 75 BATTERY INSTALlATION

I

T E

.

CALAVAR PART NUMBER

1 010-S4013-'00 2 121-00004-00· 3 010-S4016-00 4 1:.12-00014-00 5 1:.12-00015-00 6 122-00017-00 7 122-00020-00 8 (U.0-S4017-00 S0070 10 010-S4015-00

,

DESCRIPTION

QUANnrv

1 2345 Weldment, Right Side Cover kittery, 6 Volt Weldment, Battery Box Mount caDle, Battery 7.2 5LG eable, Battery 22LG eable, Battery 59LG QUle, Battery 28LG weldment, Battery Hold Down Decal, Battery Service tfeldment, Battery Tray

1.

6 1 6

2 2 2 2 2 1

FIGURE 76 PUMP ASSEMBLY

I T

.

E

CALAVAR PART NUMBER

1 018-00110-00 -2 018-00053-00 3 4

5 6 7 8 9

10 11 12 13 , 14 15

16 17 .

018-00114-00 018-00113-00 018-00112-00 018-00111.-00

DESCRIPTION

QUANllTY.

12345 'Cover, Back Kit, Seal • O-Rinq • Plate, Thrust • Plate, Wear • Shield, Heat • Gasket • V-Seal • Seal, Shift Gear, Driven Gea,r, Drive Section, center pin, Dowel COver, Front Washer, SPL Lock Screw, Cap SCrew, Hex

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

FIGURE 77 GROUND CONTROL ASSEMBLY

13 9I

1

1

16---r--flta

5

21 23 20 1----24 221

25

~/ 2

17

®

7

FIGURE 77 GROUND CONlROL ASSEMBLY I

T

.

E 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

CALAVAR PART NUMBER 020-A4020-00 253-96662-00 253-96667-00 315-0.0036-00 253-96626-00 253-96605-00 253-96631-00 310-00153-00 394-00009-00 010-54014-00 310-00161-00 392-00021-00 310-00157-00 312-00008-00 G20-A4030-00 0-2335 315-00047"'()() 315-00048-00 253-96516-00 2·53-96605-()() 315-00052-00 020-A4015-00 253-95538-00 450-00072-00 253-96614-00

DESCRIPTION

QUANllTY

12345 AsseUly, Lower Control • FittiRCJ • J'itting • Valve, Lower Control/Lift • Elbow, 90 • Elbow, 90 • 'fee Dacal, Warning Arm Stand Se1enoid, 36 Volt Weldment, Left Side Cover Decal, Free Wheeling Valve Switch, Push Button Deeal, Master Disconnect switch SWitch, Master Disconnect Assembly, P /R Valve • Blbow, 90 • 'Valve, Cartridge • Valve, Body • Connector, STR • Fitting • Valve, Shuttle • Assembly, Freewheel Valve • • Elbow, 90 • • Valve,. Freewheel • • Elbow, 90

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