CONDOR Scissor Lift V14 1833-XL Operator's Manual - PDF DOWNLOAD

TIME CONDOR Corporation

SELF-PROPELLED ELEVATING WORK PLATFORM

MODEL V14/1833-XL OPERATOR'S SECTION

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1.1■11.111EI

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SHIPPING ADDRESS

MAILING ADDRESS

TIME CONDOR Corporation

TIME CONDOR Corporation

8300 IMPERIAL DRIVE WACO, TEXAS 76712 (254)420-5200

P.O. Box 21447 WACO, TEXAS 76702-1447 (254)420-5200 MANUAL 92377-001 March 1998

INTRODUCTION

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

THIS MANUAL MUST BE RETAINED ON THE CONDOR® AT ALL TIMES.

Do not attempt to operate this 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® contain vital information. Read all decals before operating this CONDOR 0

It is YOUR RESPONSIBILITY to follow procedures while operating this 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 of the personnel when making decisions regarding the intended use of this CONDOR®.

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 A92.6-1990 Manual of Responsibilities is attached for your use.

Condor Div. 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. Manuals are continually updated to reflect these changes.

DO NOT ALTER OR MODIFY THIS CONDOR® WITHOUT PRIOR WRITTEN APPROVAL FROM THE MANAGEMENT OF CONDOR Div.

SERVICE & MAINTENANCE Many of the parts used in the manufacture of this CONDOR® have specific properties, and the manufacturer recommends that replacement parts be purchased through Condor Div. 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 Condor Operation, Parts & Maintenance Manual for information on service and maintenance of this CONDOR®.

MANUAL 92377-001 March 1998

11

TIME CONDOR Corporation 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: (254) 420-5200 Telephone (254) 420-5299 Voice Mail (800) 443-5803 FAX 2. There are numerous written Maintenance Procedures available for this CONDORS. 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(D 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.

8300 IMPERIAL DRIVE, P.O. Box 21447, WACO, TEXAS 76702-1447- 817-420-5200, 817-666-4544 FAX

MANUAL 92377-001 March 1998

ill

TABLE OF CONTENTS

INTRODUCTION SERVICE INFORMATION TABLE OF CONTENTS

ii iii

I. PREPARATION, INSPECTION, AND MAINTENANCE

A. B. C. D. E. F.

Overall Machine Condition Lower Control Station Emergency Lowering Platform and Upper Control Station Hydraulic System Batteries

Rated Work Load Lower Controls Upper Controls Emergency Lowering Lift-up Entry Gate Deck Extension Removable Upper Control Box

HI. MOVING FROM JOB-SITE TO JOB-SITE

A. B. C. D. E.

1 1 1 2 2 2 2

II. MACHINE OPERATION

A. B. C. D. E. F. G.

1

Loading and Unloading Ramp Method Forklift Loading and Unloading Method Transporting Freewheel Operation

2 2 3 3 3 5 5 5 5 5 5 6

IV. STORAGE

6

APPENDIX: DECALS ILLUSTRATION

8

ANSI/SIA A92.6 - 1990 MANUAL OF RESPONSIBILITIES

MANUAL 92377-001 March 1998

IMPORTANT: A COPY OF THE ANSUSIA A92.6 - 1990 MANUAL OF RESPONSIBILITIES IS ATTACHED TO THIS OPERATOR'S MANUAL. IT CONTAINS IMPORTANT OPERATING INFORMATION FOR THIS CONDOR®. READ IT BEFORE OPERATING THIS CONDOR®.

I. PREPARATION, INSPECTION, AND MAINTENANCE

STEERING: Check steering link to knuckle connections and steering cylinder for proper and secure mounting.

The condition of this CONDOR® is very important, as it directly affects the operator as well as others. The operator must perform a thorough walk-around inspection each day prior to operating the CONDOR®. 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 and any discrepancies should be corrected before operating this CONDOR®.

BRAKES: Check for abnormal wear between deadbolts and hubs, and for loose or missing bolts, nuts, and pins.

DECALS:

KNOW THIS CONDOR® AND ITS CAPABILI'T'IES. REPORT ANY UNUSUAL OPERATION, SUCH AS ERRATIC SWAY OR MOTION OF THE ARMS OR PLATFORM.

Check that all decals and warning signs are in place and are clearly legible.

Some major areas to check daily are: CAUTION Defective components, structural damage, missing parts, and equipment malfunction jeopardize the operator and other personnel and may cause excessive damage to the unit. A poorly maintained CONDOR® could become the greatest operational hazard you may encounter.

A. OVERALL IVIACHINE CONDITION MISSING, BROKEN, OR DAMAGED PARTS: Check cylinder mounting pins, pivot pins, pin retainers, bearing pads, bolts, and nuts.

STRUCTURAL: Check for damaged or cracked welds on structural components-arms, platform, chassis.

B. LOWER CONTROLS Check that all functions operate properly, that switches return freely to neutral position. Do not operate the CONDOR® with sticking controls

TIRES AND WHEELS: Check for cracks, tears, cuts, or missing or loose lug nuts (a rust line running down the rim from the lug nut indicates a loose lug nut).

C. EMERGENCY LOWERING Check emergency lowering function by pulling red T-handle.

MANUAL 92377-001 March 1998

D. PLATFORM AND UPPER CONTROL STATION Keep battery tops clean and dry.

■••■■■•••...■

Check that lift-up entry gate is functional and that chain is secure.

Keep vent caps tightly in place.

Re-check the structural condition of the platform—pins, railings, and floor.

Check that battery cable connections are tight and clean and free of corrosion.

Check for missing bolts & nuts - Replace before operating.

Make sure the battery charger and the indicator lights and meter are not damaged.

Check that extension deck is locked in place.

II. CONDOR® OPERATION Check function of red button. It disconnects power to the controls and, when pushed, stops all powered functions.

Check that drive control lever returns freely to neutral.

E. HYDRAULIC SYSTEM Check the hydraulic tank fluid level with the platform all the way down. Fluid must be visible in sight glass. Add Shell Tellus T-32 Hydraulic Fluid if required. Ensure that the breather cap is clean and in place on the tank.

CAUTION CONDOR® MUST BE OPERATED ON FIRM, LEVEL GROUND ONLY. A. RATED WORK LOAD The platform will support a combined weight equal to the unit's rated work load—including personnel, tools, and equipment—throughout the working envelope of the CONDOR®.

Rated work load, on extension deck only, is not to exceed 250 lbs. (113 kg) including one occupant.

Total rated work load is not to exceed 600 lbs. for the V1433, 500 lbs. for the V1833.

B. LOWER CONTROLS

Check for hydraulic leaks at all fittings and valves.

Check all hydraulic hoses and tubes for damage and kinks.

F. BATTERIES CAUTION Keep flame, sparks and metal away from the batteries.

Check Electrolyte level daily in each cell.

If necessary, add clear, odorless, mineral free water to bring the level to 1/2" above the top of the separators, or to the Level Indicator (if equipped), in each cell. Only add water after charging cycle is complete.

CAUTION ARM STAND MUST BE USED WHEN MAINTENANCE PERFORMED ON CONDOR® REQUIRES SCISSOR ARM'S TO BE RAISED. 1. To engage arm stand, raise platform, then rotate stand until it hangs vertically.

Lower the platform until the arm stand rests on the cross tube on the frame. Maintenance can now begin.

MANUAL 92377-001 March 1998

Turn "controls" switch to "lower" position, to operate from ground.

"XL" MODELS: To drive forward or reverse, squeeze lever switch on handle, and push or pull handle in the intended direction of travel. Release lever switch to stop movement. Letting go of handle also will stop movement.

In an emergency, push red button. To operate, button must be pulled out. (Also, if applicable, battery disconnect switch must be "on" to operate.)

NON "XL" MODELS: To drive foward or reverse, depress foot switch, and engage "Forward/Reverse" toggle switch iin the intended direction of travel.

Push "raise" or "lower" switches to move platform.

Brakes are automatically released whenever the drive handle is moved. Let go of the handle to automatically set the brakes.

2. To store arm stand, raise platform so that arm stand can be rotated until it rests on the stop provided on the scissor arms.

Turn switch to "upper" position, to operate from platform.

C. UPPER CONTROLS

Turn "controls" switch, on lower control panel, to "upper" position to operate from platform.

To steer left or right, squeeze lever switch on handle, and depress rocker switches on top of handle in the intended direction of travel. Steering is not automatically self-centering. Be sure the steering wheels point in the direction you want before letting go of the steer switch.

D. EMERGENCY LOWERING

NOTE:

Chain should be snapped in place across entry.

Gate should be lowered and closed when operating CONDOR® from upper controls.

In an emergency, push red button. To operate from platform, both red buttons, on lower and upper controls, must be pulled out.

To raise and lower platform, push and hold the green "power" button, and push the "raise" or "lower" button. Release buttons to stop movement.

For emergency lowering, grasp the Tee-handle located below the rear bumper.

Gently pull to lower the platform. Release handle to stop lowering.

E. LIFT-UP ENTRY GATE

To load 4' wide sheets, lift entry gate up until lockpins snap in place. After loading, pull at both lockpins, to let gate fall into place. Keep gate down, except for loading and unloading.

Select desired drive speed with the "high/low/ creep" switch. (A limit switch automatically cuts drive speed to "creep" as the platform is raised.)

MANUAL 92377-001 March 1998

LOWER CONTROLS

RED EMERGENCY STOP BUTTON RAISE/LOWER BUTTONS OPERATING INSTRUCTIONS

CONTROL STATION SELECTOR SWITCH CONTROL CIRCUIT BREAKER

UPPER CONTROLS RIGHT/LEFT STEER ROCKER SWITCH

LEVER SWITCH

DRIVE CONTROL HANDLE

RED EMERGENCY STOP BUTTON RAISE/LOWER BUTTONS

HIGH/LOW/CREEP DRIVE SPEED SELECTOR SWITCH

POWER BUTTON

MANUAL 92377-001 March 1998

F. DECK EXTENSION

B. RAMP METHOD

Lift lockpin, at right side of deck, and push extension deck forward (or out). When fully extended, lockpin will automatically lock. To retract, lift lockpin and pull extension deck all the way back until lockpin automatically locks extension deck in place.

Ensure that the ramp is sufficiently strong to support the weight of the CONDOR®.

CAUTION Do not lower extension deck onto people or any objects!

The ramp should be set, not steeper than this CONDOR®'s rated gradeability, which for Model V1433/XL, V1833/XL is 14° or 25%, or a rise of 30 inches in a run of 10 feet.

Before driving the CONDOR® on a ramp, lower the platform completely, test the drive/steer controls and the brake system.

G. 'REMOVABLE' UPPER CONTROL BOX

CAUTION Select "low" drive speed, not "high" and not "creep".

Unsnap overcenter latch at bottom of upper control box and pull plug out of receptacle. Bend cable so that plug faces down. Snap cover onto receptacle at bottom of box. Lift box and store it in a secure place to prevent unauthorized use of the CONDOR 0

III. MOVING FROM JOB-SITE TO JOB-SITE

The front of the CONDOR® should be uphill, meaning: Drive forward uphill and reverse down.

Keep CONDOR® in alignment with the ramp during loading and unloading procedures.

C. FORKLIFT LOADING AND UNLOADING METHOD

A. LOADING AND UNLOADING Although this CONDOR® is somewhat small compared with larger construction equipment, it requires the same care and attention in loading, transporting, and unloading. At no time should its size,or weight be under estimated. Before loading or unloading, inspect the CONDOR® for any physical damage or defects.

The means by which you load or unload the CONDOR® should be of sufficient strength to withstand its weight.

MODEL WEIGHT(#) WEIGHT(KG) V1433/XL 2,200 lbs. 998 kg V1833/XL 2,400 lbs. 1089 kg

Ensure that the forklift has sufficient capacity to handle the weight of this CONDOR®.

This CONDOR® can be lifted from the rear, using the forklift pockets provided.

NOTE THAT THE CENTER OF GRAVITY IS 50 INCHES FROM THE END OF THE CONDOR®.

The CONDOR® should only be raised to a height sufficient to clear any obstructions.

Keep forklift travel to a minimum, carry CONDOR® as close as possible to the ground, and set it down gently.

MANUAL 92377-001 March 1998

D. TRANSPORTING ••

This CONDOMD can be easily transported between job-sites if the following rules and procedures are followed: Block all wheels to prevent forward and reverse motion.

Tie down the CONDOR® with chains or cables, running them through the tie-down holes only. Do not tie down over the guardrails or entry steps.

Always turn the power off at the lower control station.

E. FREEWHEEL OPERATION

CAUTION This CONDOR® must be on firm, level ground when releasing the parking brakes.

To put the CONDOR® into freewheel mode, use the brake release handles on the rear axle.

One handle is on the front side of the axle and the other is on the rear side of the axle. Turn each release handle Wand at the same time, slightly rotate it. The brakes are now released.

(Released brakes will automatically reset the next time forward or reverse drive is used, then will engage when drive is stopped.)

Never exceed 5 mph when moving the CONDOR® in the freewheel mode.

W. STORAGE When you get out of the platform, leave it all the way down.

CAUTION Never park the CONDOR® with platform raised.

MANUAL 92377-001 March 1998

NOTES ••

MANUAL 92377-001 March 1998

APPENDIX: DECALS ILLUSTRATION

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

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PARTIAL SECTION A APPLIES TO ALL MODELS

NOTES: MODEL V1833XL IS iLLUSTRATED, OTHER MODELS ARE SIMILAR.

MANUAL 92377-001

March 1998

APPENDIX: DECALS ILLUSTRATION

ITEM PART NUMBER

DESCRIPTION

••

QTY

*55892-104 Decal Kit, V1833XL Essential Ref. *55892-103 Decal Kit, V1833 Essential Ref. *55892-102 Decal Kit, V1433XL Ref. *55892-101 Decal Kit, V1433 Ref. *1 55890 Decal, V Upper Operator Instructions 1 55889 Decal, V XL Upper Operator Instructions 1 *2 55894 Decal, V General Caution 1 *3 54652-003 Decal, Guardrail/Chain Caution 1 *4 55944-600 Decal, 250/600 Rated Load V1433/XL 2 55944-500 Decal, 250/500 Rated Load V1833/XL 2 *5 55877-003 Decal, V14/18 Lower Operating Instructions 1 *6 55877-001 Decal, V14/18 Lower Controls 1 *7 55877-002 Decal, V14/18 Stop/Fuse 1 *8 54652-002 Decal, Arm Strand Caution 1 *9 54984-005 Decal, Rear Bumper 1 * 10 55882 Decal, Electrocution Hazard 2 *11 55871-001 Decal, V14/18 Upper Electrical Box Top 1 55856-001 Decal, V XL Upper Control Box Top 1 * 12 55871-002 Decal, V14/18 Upper Electrical Box Front 1 55856-002 Decal, V XL Upper Control Box 1 13 54984-007 Decal, Hydraulic Fluid 1 14 55940-023 Decal, CONDOR 3.45 x 23 2 15 55935 Decal, V1433XL 2 55936 Decal, V1833XL 2 16 55941-017 Decal, Condor Bird 2 17 53259 Tape, Non-Skid Jet Black 1 5OLF 18 66921 Coating, Non-Skid Jet Black 25GL 19 55892-DWG Dwg. V1418 Decal Installation 1 20 54984-006 Decal, 110 Volt Extention To Platform V14/18XL 1

Ref

.

31 51340

Namplate Scissors Indentification

Ref.

- Indicates Items Not Shown *Indicates Included In Essential Decals

2 1/4 MARGIN NO NON-SLIP COATING

,----'LANVIEW OF 000ELE-2 014.30 &

DART;AL REAR VIE' CF ,

MANUAL 92377-001 March 1998

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APPENDIX: DECALS ILLUSTRATION 1

••

OPERATING INSTRUCTIONS • TURN SWITCH, ON LOWER CONTROL BOX, TO "UPPER" POSITION, TO OPERATE FROM PLATFORM. • IN AN EMERGENCY, PUSH RED BUTTON. TO OPERATE FROM PLATFORM. BOTH RED BUTTONS. ON LOWER AND ON UPPER CONTROLS, MUST BE PULLED OUT. • TO RAISE AND LOWER PLATFORM, PUSH AND HOLD THE GREEN "ENABLE" BUTTON. AND PUSH THE "UP" OR "DOWN" BUTTON. RELEASE BUTTONS TO STOP MOVEMENT. • SELECT DRIVE SPEED WITH "FAST/SLOW/CREEP" SWITCH. A LIMIT SWITCH AUTOMATICALLY REDUCES DRIVE SPEED AS THE PLATFORM IS RAISED. • TO DRIVE FORWARD OR REVERSE, SQUEEZE GRIP SWITCH ON HANDLE, AND PUSH OR PULL HANDLE IN INTENDED DIRECTION OF TRAVEL. RELEASE LEVER SWITCH OR LET GO OF HANDLE TO STOP MOVEMENT. • BRAKES ARE AUTOMATICALLY RELEASED WHENEVER DRIVE MOVES. RELEASE GRIP SWITCH OR LET GO OF HANDLE TO AUTOMATICALLY SET BRAKES. TO STEER LEFT OR RIGHT, SQUEEZE GRIP SWITCH ON HANDLE, AND DEPRESS ROCKER SWITCHES ON TOP OF HANDLE IN INTENDED DIRECTION OF TRAVEL. STEERING IS NOT AUTOMATICALLY SELF-CENTERING. BE SURE STEERING WHEELS POINT IN DIRECTION YOU WANT BEFORE LETTING GO OF SWITCHES. ssaso

OPERATING INSTRUCTIONS • TURN SWITCH, ON LOWER CONTROL BOX, TO "UPPER" POSITION,

TO OPERATE FROM PLATFORM.

• IN AN EMERGENCY, PUSH RED BUTTON. TO OPERATE FROM PLATFORM, BOTH RED BUTTONS, ON LOWER AND ON UPPER CONTROLS, MUST BE PULLED OUT. • TO RAISE AND LOWER PLATFORM, PUT AND KEEP FOOT ON SWITCH, AND PUSH TOGGLE SWITCH IN "UP" OR "DOWN" DIRECTION. RELEASE SWITCH OR TAKE FOOT OFF SWITCH TO STOP MOVEMENT. • SELECT DRIVE SPEED WITH "FAST/SLOW/CREEP" SWITCH. A LIMIT SWITCH AUTOMATICALLY REDUCES DRIVE SPEED AS THE PLATFORM IS RAISED. • TO DRIVE FORWARD OR REVERSE, PUT AND KEEP FOOT ON SWITCH, AND PUSH OR PULL TOGGLE SWITCH IN INTENDED DIRECTION OF TRAVEL. RELEASE SWITCH, OR TAKE FOOT OFF SWITCH TO STOP MOVEMENT. • BRAKES ARE AUTOMATICALLY RELEASED WHENEVER DRIVE MOVES. RELEASE SWITCH OR TAKE FOOT OFF SWITCH TO AUTOMATICALLY SET BRAKES. • TO STEER LEFT OR RIGHT, PUT AND KEEP FOOT ON SWITCH, AND MOVE "STEERING" SWITCH IN INTENDED DIRECTION OF TRAVEL STEERING IS NOT AUTOMATICALLY SELF--CENTERING. BE SURE STEERING WHEELS POINT IN DIRECTION YOU WANT BEFORE LETTING GO OF SWITCH.

55E90

2

CAUTOON • DO NOT OPERATE THIS CONDOR'UNTIL YOU HAVE BEEN PROPERLY TRAINED AND HAVE COMPLETELY READ AND UNDERSTOOD THE OPERATOR'S MANUAL LOCATED ON THIS CONDOe • THIS CONDOR® IS NOT ELECTRICALLY INSULATED. SEE OPERATOR'S MANUAL FOR SAFE APPROACH DISTANCES TO ENERGIZED POWER LINES. • PRIOR TO EACH DAY'S USE, CHECK TO MAKE SURE ALL FUNCTIONS ARE OPERATING PROPERLY. PERFORM ALL INSPECTIONS REQUIRED BY SEC1TON 6 OF THE ANSI 92.6 STANDARD. • DO NOT USE THE CONDOR S , IF IT IS MALFUNCTIONING OR DAMAGED IN ANY WAY. OR IF THE WIND BLOWS OVER 15 MPH. • RAISE PLATFORM ONLY WHEN CDNDOR'IS ON FIRM, LEVEL GROUND. • DO NOT DRIVE ON A SLOPE UNLESS THE PLATFORM IS FULLY LOWERED. • ALWAYS LOOK IN THE DIRECTION IN WHICH THE PLATFORM IS MOVING. WATCH FOR, AND AVOID, OVERHEAD OBSTRUCTIONS AND ANYTHING ELSE THAT MAY STRIKE PLATFORM, PERSONNEL, CONTROLS, OR CONDOR'.

• FOLLOW INSTRUCTIONS IN OPERATOR'S MANUAL WHEN SERVICING BATTERIES. EACH REPLACEMENT BATTERY MUST WEIGH AT LEAST AS MUCH AS ORIGINAL EQUIPMENT.

• REPLACEMENT TIRES MUST BE SAME AS ORIGINAL EQUIPMENT. • IN CASE OF EMERGENCY, PUSH RED "EMERGENCY STOP" BUTTON. 5,8 9 4

MANUAL 92377-001 March 1998

APPENDIX: DECALS ILLUSTRATION

••

3

GUARDRAILS AND SAFETY CHAINS MUST BE SECURED AND USED AT ALL TIMES

4

RATED WORK LOAD ON DECK EXTENSION 250 LBS 55944

OPERATING INSTRUCTIONS • TO OPERATE FROM GROUND, TURN SWITCH TO "LOWER" POSITION. • IN AN EMERGENCY, PUSH RED BUTTON. TO OPERATE, BUTTON MUST BE PULLED OUT. • PUSH TOGGLE SWITCH TO MOVE PLATFORM. • TURN SWITCH TO "UPPER" POSITION, TO OPERATE FROM PLATFORM. 55877-0O3

6

r

7

PLATFORM RAISE

(EMERGENCY) STOP

DOWN FUSE 55877-002

UPPER OFF LOWER 55877-001

MANUAL 92377-001 March 1998

APPENDIX: DECALS ILLUSTRATION ••

8

CAL:r ON STAND CLEAR UNLESS ARM STAND IS IN PLACE 54652-002

9 EMERGENCY LOWERING BRAKE RELEASE

FORKLIFT POCKET

PULL T-HANDLE. TO LOWER PLATFORM.

ONLY ON FIRM, LEVEL GROUND,

RELEASE HANDLE TO STOP MOVEMENT.

ROTATE BOTH LEVERS TO RELEASE BRAKES.

' FORKLIFT ■

POCKET j s.s4—oos

10

g DANGi) ----.

----

C-ROC_- ON HAZARD

DEATH OR SERIOUS INJURY WILL RESULT FROM CONTACT \1V1TH THIS MACHINE IF IT SHOULD BECOME ELECTRICALLY CHARGED.

1.

K I--- r- P C IA

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13

HYDRAULIC FLUID

5 4964 -0071

MANUAL 92377-001 March 1998

APPENDIX: DECALS ILLUSTRATION

20

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0 _X E\SIO P AT =ORM 54984 - 006

8300 IMPERIAL DRIVE Solatishimaitalip,.. , TEXAS 76712 WACO TIME MANUFACTURING COMPANY MANUFACTURED IN U.S.A.

SERIAL NO.

CONDOR MODEL

RATED WORK LOAD

PLATFORM HEIGHT

' HYD. D RE c, SURE

SYSTEM VOLTAGE THIS UNIT IS NOT ELECTRICALLY INSULATED. THIS SELF — PROPELLED ELEVATING WORK PLATFORM CONFORMS TO ALL APPLICABLE REQUIREMENTS OF ANSI A92.6 - 1990 51340

MANUAL 92377-001

March 1998

TIME CONDOR Corporation

SELF-PROPELLED ELEVATING WORK PLATFORM

MODEL V1433XL, V1433 MODEL V1833XL, V1833 MAINTENANCE SECTION

SHIPPING ADDRESS

CONDOR®

TIME CONDOR Corporation

8300 IMPERIAL DRIVE

WACO, TEXAS 76712

(254) 420-5200 MANUAL 92377-002 March 1998

MAILING ADDRESS

CONDOR® TIME CONDOR Corporation

P.O. BOX 21447 WACO, TEXAS 76702-1447 (254) 420-5200

INTRODUCTION The primary purpose of this manual is to provide the user with a thorough understanding ofthe 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 ItIANUAL 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 YOURRESPONSIBILITY to understand and obey all federal, state, and local regulations regarding the operation and use of aerial work platforms. A copy ofthe ANSI/STA Manual ofResponsibilities is attached for your use: ANSI/SIA A92.5-1992 is provided for Boom-Supported Elevating Work Platforms, and ANSI/ SIA A92.6-1990 is provided for Self-Propelled Elevating Work Platforms.

TIME CONDOR 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 TIME CONDOR CORPORATION

SERVICE & MAINTENANCE

Many ofthe parts used in the manufacture ofthe CONDOR® have specific properties, and the manufacturer recommends that replacement parts be purchased through TIME CONDOR 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 TIME CONDOR Operation, Maintenance, & Parts Manual for information on service and maintenance ofthe CONDOR®.

NOTE: Please refer to the TIME CONDOR section ofthe Operation, Maintenance, & Parts Manual for information pertaining to your CONDOR®.

ll

TIME CONDOR Corporation

CONDOR® SERVICE INFORMATION

1. Ifyou need assistance or have any service or maintenance questions, TIME CONDOR Corporation service and parts personnel are always available by phone or fax. The telephone numbers are: (254) 420-5200 Telephone (254) 420-5298 Voice Mail (800) 443-5803 FAX 2. There are numerous written Maintenance Procedures available for this CONDOR®.

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

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

TIME 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 oftheir employer, but TIME CONDOR Service Schools help you provide this training.

4. TIME 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.

TIME CONDOR Corporation

8300 lIvLPERIAL DRIVE, P.O. Box 21447, WACO, TEXAS 76702-1447. 254-420-5200, 254-666-4544 FAX

ill

TIME CONDOR Corporation

Condor® Self-Propelled Booms and Scissors WARRANTY TIME CONDOR Corporation warrants to the purchaser that each new aerial work platform made by TIME CONDOR is free from defects in material and workmanship arising under normal use and service-in the case ofmaj or weldments, (chassis, turret, and booms), for a period of five (5) years after the original shipment of the aerial work platform from TIME CONDOR'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 TIME CONDOR's plant, whichever comes first.

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

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

Any operation of the equipment beyond rated capacity, improper use or application of the equipment, substitution upon it of parts not approved by TIME CONDOR or alteration or repair of the equipment by any person not authorized by TIME CONDOR shall, at TIME CONDOR's option, void this Warranty.

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

This Warranty is in lieu of all other warranties, expressed or implied, including but not limited to warranties of merchantibility 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 76702-1447.254-420-5200,254-666-4544 FAX Form No.513-3M-392

Effective Date 9/1/90 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 of components utilized in the product, and is offered for a fixed period of time following the purchase of the product by a customer.

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

These will be outlined in 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 TIME CONDOR Corporation, whichever comes first. In the case ofmajor weldments (chassis, turret, and booms), the Warranty Period is five (5) years following shipment from TIME CONDOR Corporation.

2.

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

3.

For parts sold 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 TIME CONDOR Corporation, 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 of the Warranty are for the Warranty Period applicable to the unit in which they were installed as if such parts were original components of the aerial work platform.

5 . During the Warranty Period, in addition to covering the parts replaced under Warranty, Condor Division 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 put the CONDOR@ into its rental fleet. In this situation, the Warranty Period begins the day the dealer puts the CONDOR@ into the fleet or when the CONDOR® is delivered to the end user.

The submittal of a warranty claim against a stock 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 TIME CONDOR Corporation'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 of the original recipient of the CONDOR® from TIME CONDOR Corporation, whether it will be the dealer or the end user, to complete this form and return it to TIME CONDOR Corporation's facility within 45 days from the date of receipt to set up the Warranty Account.

3.

Failure to complete the P.D.I. sheet and return it to TIME CONDOR Corporation within 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 TIME CONDOR Corporation. However, these are warranted by the component manufacturer. Some of these are: 1.

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

2.

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

3.

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

4.

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.

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

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

D. PROCESSING OF WARRANTY CLAIM

During the Warranty Period, should a component failure be encountered within the guidelines of the TIME CONDOR Corporation 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 TIME CONDOR Corporation for your stock and will utilize it for this replacement.

The above two methods will enable you to indicate on the claim the TIME CONDOR Corporation invoice number to substantiate the parts purchase and the amount to be credited. 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. TIME CONDOR Corporation 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 puchased from TIME CONDOR Corporation, part numbers with invoice numbers MUST be referenced in the appropriate section of the claim form.

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

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

NOTE: WARRANTY CLAIMS WILL NOT BE ACCEPTED BY TIME CONDOR Corporation AFTER 45 DAYS AFTER FAILURE

3 . 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.

E. RETURN AUTHORIZATION

1.

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

2.

It will be necessary for you to call the TIME CONDOR Corporation 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, of the 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 of the claim form, and the gold copy (R/A) of the form must be returned with the parts being returned.

NOTE: DO NOT SHIP ANY RETURN PARTS WITHOUT A RETURN AUTHORIZATION (RJA) 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 of the claim.

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

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

CONDOR® Model V14/1833/XL

MAINTENANCE MANUAL TABLE OF CONTENTS

INTRODUCTION CONDOR® SERVICE INFORMATION SELF-PROPELLED WARRANTY

ii

Table of Contents

1

Specifications

3

Recommended Tool List

4

Serial Number Location

5

Hydraulic System Description

7

Pressure Adjustment Procedures

11

Electrical System Description

15

Machine Options Description

19

Electrical Schematic

21

Battery Service

23

Preventive Maintenance

31

Hydraulic Fluid Specifications

41

Battery Charger Troubleshooting Guide

43

Bolt Torque Chart

53

MANUAL 92377-002 March 1998

0

NOTES

MANUAL 92377-002 March 1998

SPECIFICATIONS SPECIFICATIONS

V1433/XL V1833/XL

Maximum Working Height Platform Height Stowed Platform Height Overall Length Overall Width Overall Height Overall Height With Rails Removed Platform Size Platform Capacity Gross Weight

19'10" 13'10" 35.25" 63" 33" 74.25" 46.25" 63"x30" 600 lbs 2,100 lbs 2,200 lbs-XL 24 volt DC 235 amp hour 4 6 volt 25 amp 48.5" 14 x 4.5 (Solid Rib) 17' 75/1.5/3 mph 29%116° 15/19 sec.

Power System Battery Capacity Number of Batteries Battery Voltage Battery Charger Wheel Base Tires Inside Turning Radius Drive Speed Gradeability Lift/Lower Time

24 ft.

17'10" 39.25" 63" 33" 78.25" 49.75" 92.5" x30" 500 lbs.

2,400 lbs.

2,500 lbs-XL 24 volt DC 235 amp hour 4 6 volt 25 amp 48.5" 14 x 4.5 (Solid Rib) 17" .75/1.5/3 mph 29%/16° 22/28 sec

OPTIONS • • • • • •

Battery Condition Indicator Strobe Light 250 Amp Hour Deep Cycle Batteries Hour Meter Travel Alarm Larger Batteries

• • • •

Motion/Movement Alarm Descend Alarm 5° Slope Alarm Low Volt Warning/Interrupt Battery Protection System

The CONDOR® Model V1433/XL, V1833/XL is designed and built to conform to TIME CONDOR Corporation 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 ofthe CONDOR® read, understand and conform to these regulations. Ultimate compliance to prevailing OSHA regulations is the RESPONSIBILITY of the employer utilizing the equipment.

MANUAL 92377-002 March 1998

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

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

Volt/Ohm Test Meter Hydraulic Flow Meter, 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 ft/lbs 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, 1/4" to 3/4" 1/2" Drive Socket Set, 3/8" to 1-1/2" 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 not intended to be all inclusive of the tools 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 92377-002 March 1998

Serial Number Location

The CONDOR® Model V1433/XL, V1833/XL 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, at the rear between fork lift pockets.

2.

The second place to find the serial number is at the front steering knuckle kingpin.

MANUAL 92377-002 March 1998

This Page Intentionally Left Blank

MANUAL 92377-002 March 1998

HYDRAULIC SYSTEM DESCRIPTION The following is a detailed description of the hydraulic system used on the CONDOR® model V1433/XL, V1833/XL scissor, and how it 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 V1433/XL, V1833/XL consists primarily of a single manifold assembly, used to control all the hydraulic functions through the use of hydraulic cylinders and motors. The system is electric over hydraulic, meaning that the hydraulic valve assembly is activated by electrical signals from the function controls. The system is also of the 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. All lift and drive functions can be performed from the platform console, while ONLY lift functions are available from the lower control console.

HYDRAULIC TANK

The hydraulic tank is an "L" shaped weldment having a fluid capacity of 7 US gallons. The main portion of the tank is located between the batteries in the belly pan, with the smaller portion extending outward to the right side of the unit (See FIG. 1) next to the hydraulic pump. A filler neck and cap, and a sight glass are provided at the extended section of the tank for checking and maintaining the fluid level. Filtration of the hydraulic oil is provided through a 10 micron spin-on return filter, and a 100 mesh, 10 GPM, tank-mounted strainer. The filter, and strainer are located at the end of the tank, just behind the pump.

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 92377-002 March 1998

PUMP/.MOTOR The pump wall motor assembly is located in the right side ofthe belly pan, (See FIG. 2). A 24 volt DC motor drives a tandem pump, which consists of two separate pumps driven from the same shaft. Both sections have a size of .161 cubic inch per revolution, which equals to 2.25 GPM of hydraulic flow at 3600 rpm. One section of the pump is only used for drive, while the other pump section supplies fluid for steering, lift, or to increase the drive speed when directed to the drive circuit.

MAIN VALVE ASSEMBLY Located in the left side wall of the belly pan is the main valve assembly which performs all of the hydraulic functions of the machine (See FIG. 3). This assembly includes three directional control valves and a variety of cartridge valves to achieve the operation of the cylinders and motors for the machine functions.

These individual functions are described in detail below.

MACHINE FUNCTIONS The hydraulic functions ofthe CONDOR® model V1433/XL, V1833XL includes: forward and reverse drive with three selectable speeds at limited height, spring applied/hydraulically released brake cylinders, left and right steering, and platform raising or lowering. Each of these functions are performed by the main valve assembly via electrical control signals. A detailed description ofthe electrical controls and their circuits can be found in the Electrical System Description of this maintenance section.

DRIVE FUNCTION The drive function is only available at the platform controls. Movement of the drive control handle 13° from its center position in either direction will turn the pump motor on and energize the respective forward/reverse electrical circuit. The forward/reverse electrical circuits consist solely of the drive controller and the drive directional control valve located on top ofthe main valve assembly (see FIG. 4).

MANUAL 92377-002 March 1998

Drive Directional Control Valve

Descent Flow Control Valve Load Control Valves

Flow Divider/Combiner

Positraction Valve

Creep Speed Solenoid Valve

Deceleration Valve

Creep Speed Needle Valve

FIG. 4 DRIVE FUNCTION (cont'd) Pump flow circulates through the main valve assembly and back to tank if no functions are activated when the pump is running. Once the directional control valve shifts, fluid is directed to one ofthe load control valves in its free-flow direction, and then to the normally open positraction valve. Fluid flows through the positraction valve cartridge, then to both drive motors which each have an 8.0 cubic inch per revolution displacement and are located on the steer axle.

The deceleration valve is utilizedto cushion the braking action ofthe drive circuit. This is accomplished by letting fluid by-pass between the two drive motors. Since the deceleration valve is a 2-way normally open spool valve, it allows fluid to flow through it at all times. When the drive control handle is actuated, energizing the drive circuit, the deceleration valve becomes energized and closes, blocking the flow of fluid through it.

When the drive handle is released (circuit de-energized), the deceleration valve opens, and lets the drive pressure by-pass to the opposite drive motor, allowing the two drive motors to continue to roll momentarily without creating a hydrostatic lock in the circuit. A 0.040 dia. orifice, located under the deceleration valve, is used to control the amount of by-pass that occurs which affects the deceleration ofthe machine.

The V14/1833/XL has a creep speed which is either automatically activated atplatform heights above seven feet by a limit switch, or is operator selectable at heights below seven feet. Creep speed is a situation in the drive circuit whereas when the creep speed solenoid valve is energized, some ofthe drive flow is diverted back to the tank. The speed at which the machine travels when in creep, is controlled by the creep speed needle valve (See FIG. 4). The creep speed is factory set to obtain a travelspeed of80-100 sec/88 feet, on firm, level ground; (Ref. .75/.6 mph), (see note #2 on schematic at end of hydraulic section).

MANUAL 92377-002 March 1998

DRIVE FUNCTION (cont'd) When the speed selector switch is in the high position, the drive speed increases by the addition of the P2 pump's fluid displacement (steer/lift pump) being diverted to the drive circuit. This is accomplished by activation of the select directional control valve. The hydraulic pump contains two individual pump sections, one of which is used solely for the drive circuit.

The other pump section supplies fluid for the operation of lift and steer, and will supply fluid to the drive circuit when the machine is in high speed. A check valve cartridge is used to isolate the drive-only pump flow for use in the drive circuit (See FIG. 5).

Select Directional Control Valve (between drive and steer)

Steer Directional Control Valve

Check Valve Cartridge

Creep Valve

FIG. 5

STEERING FUNCTION Steering is accomplished with a cylinder, knuckle, and connecting arm arrangement, which in its configuration provides a tight turning radius. The drive motors are mounted to the steering knuckles, thus enhancing driveability.

The steering cylinder, located just behind the front bumper plate of the chassis, is controlled by the steer directional control valve on top of the manifold assembly (See FIG. 5&6).

Drive Motors

o

aL0 Chassis Front Bumper Plate

o

U.

IL• Connecting Arm Steer Cylinder

FIG. 6 LIFT FUNCTION Lifting of the platform is accomplished by energizing the select directional control valve.

This will direct fluid from the P2 pump to the base end of the lift cylinder, with the rod end of the lift cylinder being vented back to the tank.

Located on the cylinder body (See FIG. 7), is the holding valve, which consists of a manifold body, a 2-way normally closed cartridge with a manual override, and an electric coil. Attached to the cartridge is a cable assembly used for manually lowering the platform via a T-handle located at the rear of the machine, under the rear bumper plate. Descent speed is controlled by a flow control valve (See FIG. 3), in which clockwise rotation decreases descent speed, while counterclockwise rotation increases the descent speed.

MANUAL 92377-002 March 1998

PRESSURE ADJUSTMENT PROCEDURES NOTES: All pressure adjustments are to be made with the pump motor running, and with the hydraulic fluid at operating temperature. Ensure that the tank is filled to its recommended level, and that the batteries are fully charged. To simplify the adjustment procedure, install a pressure gauge at the "Gl" port, and install another pressure gauge at the "G2" port, which are both located at the creep valve end of the main valve assembly. All relief valves adjust in the same manner: clockwise increases pressure setting, and counterclockwise decreases pressure setting. All flow control cartridges adjust in the same manner: clockwise decreases flow, and counterclockwise increases flow. Refer to FIG. 8 for adjustments.

Drive Pressure Adjustment

1.

2.

3.

4.

Chock both drive wheels to prevent them from spinning in the forward drive direction.

With the drive speed selector in the low position, activate forward drive with the drive controller.

While drive is activated, adjust "RV1" to 2700 psi while observing the gauge reading from the "Gl" port.

After setting, lock the adjustment screw with the jam nut.

High Drive Pressure Adjustment

1.

2.

3.

4.

Select high speed at upper control box.

Observe the pressure reading at the "Gl" port while climbing a grade, and note pressure reading at which the high drive shifts to low.

Adjust the "SEQ" valve until the pressure reading is 1100 psi when high drive shifts to low.

After setting, lock the adjustment screw with the jam nut.

NOTE: The load control valves, "CB1" and "CB2", are factory set. If they are not functioning properly, they must be replaced; DO NOT ATTEMPT ADJUSTMENT. Lift Pressure/Descent Speed Adjustment

1.

2.

With pump running, and platform raised completely (cylinder bottomed out), observe the pressure reading on the gauge connected to the "G2" port. Adjust "RV2" to 2700 psi.

Adjust "FC I " to obtain a 25-35 second descent from a fully raised position.

MANUAL 92377-002 March 1998

ETh

To aid troubleshooting, some of the valves and cartridges are identical to others and can be swapped to help determine faulty components: 1.

"RV3" and "RV4" steer reliefs are identical with same pressure settings.

2.

"FC1" and "FC2" brake and descend flow control valves are identical while settings may differ.

3.

"CB 1 " and "CB2" are identical -- DO NOT ADJUST!

4.

"RV1" and "RV2" are identical with the same pressure settings.

5.

"CREEP" and "DECEL" solenoid cartridge valves are identical.

"G2" Gauge Port (Reads Steer/Lift/ High Drive Pressure) "G1" Gauge Port (Reads Drive Only Pressure)

_EL

"FC1" - Controls Platform Descent Speed "RV2" Relief For Steer/Lift ("G2" Gauge Port)

II 0

Ii DECEL "RV5" Secondary Lift Relief

10 ii

Creep Speed Adjustment "RV1" Relief For Drive Only ("Gl" Gauge Port)

"SEQ" (Sequence) Valve Controls High Drive Shifting

"CB1" and "CB2" Load Control Valves (DO NOT ADJUST)

II B1 ei TRAC

FD

FIG. 8

MANUAL 92377-002 March 1998

Hydraulic Schematic

0 LIFT CYLINDERS CYLINDERS V1433 55538 V1433XL 55539 2.5 DIA 1.75 ROD

30.75 STROKE

55221 FC VALVE ON "XL" ONLY

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DRIVE MOTORS 54644-003

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VOLUME.

_...,

MANUAL 92377-002 March 1998

This Page Intentionally Left Blank

MANUAL 92377-002 March 1998

ELECTRICAL SYSTEM DESCRIPTION The following is a detailed description of the electrical system used on the CONDOR® model V1433/XL, V 833/XL scissor, and how it 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 CONDOR® model V1433/XL, V1833/XL uses a 24 volt direct current (DC) electrical system consisting of four, 6 volt DC batteries, an electric motor to drive the hydraulic pump, and various electrical controls to operate the system. • Included in this system description is a Machine Options section, describing options which are available on the model V1433/XL, V1833/XL. All of the options contained in this description are electrical only, and do not affect the hydraulic performance of the machine.

BATTERIES The model V1433/XL, V1833/XL scissor uses four, 6 volt DC batteries, each having a 235 amp hour capacity. There are two batteries on each side of the belly pan nearest the steer axle. The four batteries are connected in series, combining their voltage, to make up the 24 volt DC system. The batteries are of the wet-cell type, and when filled with electrolyte, each battery weighs 66 lbs. 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 25 amp @ 24 volt DC nominal rating, and operates off of a 115 volt alternating current (AC), 160 Hz, 8 amp input. The charger features contains an ammeter for reading the DC amp output, and two LED status indicator lights; a red LED indicates the charger is on, charging, while a green LED indicates the charging is complete. The charger is located on the right side of the belly pan, between the pump/motor assembly and batteries (See FIG. 9). More detailed information of the charger can be found in the Battery Charger Troubleshooting Guide beginning on page 43.

CIRCUIT BREAKER/FUSE Located below the control selector switch on the lower control box (see FIG. 11), is a 15 amp fuse. This circuit fuse protects all the machine control circuits.

MANUAL 92377-002 March 1998

PUMP MOTOR The CONDOR® model V1433/XL, V1833/XL utilizes a pump motor which is a 24 volt DC unit, rated 6 hp @ 3600 rpm. Since the model V1433/XL, V1833/XL utilizes a gravity lowering system, the motor does not run while the lowering function is activated.

Electric Motor

0

Tandem Pump

FIG. 10 LOWER CONTROL FUNCTIONS Located above the left rear wheel is the lower control box, which provides a junction Emergency Stop Button connection through the use oftwo terminal strips, for the limit switch cable, the hydraulic valve cable, the pump motor contactor cable, and the Platform Lift Control 1 cable to the upper controls. At the lower controls are switches (see FIG. 11), to provide operation III of the lift function only; drive is not available Control Selector Switch iii LOWER from this control box. The lower control box contains an emergency stop button which must be 15 Amp Circuit Breaker/Fuse pulled out to supply power to both control boxes.

The control selector switch is a 3-position mainFIG. 11 tained rotary switch that directs power to either control box for operation of the machine, while the box not selected, will not have power. The platform lift control consists of two pushbuttons, which, through the use of contact blocks, energize the pump motor and selector valve for raising, or the holding valve for lowering. The pump motor does not run during lowering.

EMERGENCY

PLATFORM

RAISE

LOWER

CONTROLS

ER

~~

UPPER CONTROL FUNCTIONS (XL Models) The upper control box, located at the right hand forward corner of the platform, is a fiberglass enclosure which contains two slip-fit inserts on its underside that allow the box to press onto two pins which are part of the platform weldment. The control box is removeable by disconnecting the cable harness plug underneath, and lifting upward on the box assembly. The feature allows for disabling the machine, storage of the box, or ease of repair to the controls. Some of the controls used are identical to the those found at the lower control box (See FIG. 12), primarily the emergency stop button and the lift controls. The platform lift control buttons operate similar to the lower control pushbuttons. However, at this control box, the green "POWER" pushbutton must be depressed to supply power to either the raise or lower lift button. To provide electrical power to the upper control box, both emergency stop buttons must be in the "out" position, the control selector switch must be in the "UPPER" position.

MANUAL 92377-002 March 1998

UPPER CONTROL FUNCTIONS (XL Models cont'd)

Cut-Away View of Slip-Fit Insert Emergency Stop Button

Drive Controller w/Steer Rocker Switch

Lift Controls

Power Button (green)

Cable Harness Plug

Drive Speed Selector

Hidden View of Slip-Fit Insert

FIG. 15

Integrated in the forward edge ofthe drive handle is a grip lever which is a substitute for the foot switch commonly used on other machines. The grip lever must be squeezed to perform drive (movement of the handle), or steer (activation of the rocker switch) functions. This lever, however, does not affect the lift controls. Movement of the drive handle 13° in either direction will turn the pump motor on, and energize the drive directional control valve, thus initiating drive motion. Drive speeds are selectable from the drive speed selector switch. Selecting "fast" will energize the select directional control valve and increase drive speed by adding the second pump's flow to the drive hydraulic circuit. Selecting "low" will de-energize the select valve, and drive speed will then rely on the single pump output. Pressing the black positraction button energizes the positraction valve in the main manifold assembly, thus forcing hydraulic flow through the flow divider/combiner. When in "fast" or "low", the creep valve is always energized because it is a normally open valve. When "creep" speed is selected, or when the platform is above six to seven feet, it is de-energized, thereby letting fluid by-pass to tank through an adjustable needle valve.

MANUAL 92377-002 March 1998

NOTES

MANUAL 92377-002 March 1998

MACHINE OPTIONS DESCRIPTION The following descriptions are intended to be used with wiring diagrams at the end of this electrical section.

STROBE LIGHT (OPTION) This option is to indicate that the machine is on or ready to operate. The strobe has: a plug-in flash tube for easy replacement, an energy output of 2 joules, a power output of 3 watts, and a flash rate of 60 ± 10 flashes per minute. The strobe is energized whenever the control selector switch is in the "UPPER" or "LOWER" position and the lower control emergency stop button is pulled out.

5°SLOPE ALARM (OPTION) This option sounds an alarm when the V14/1833 is 5° or more out of level. A 5° omni-directional sensor is mounted in the belly pan to sense a 5° out-of-level condition. In this situation, a fast pulse/loud tone alarm at the upper control box (See FIG. 13), is activated until the machine is returned to a less than 5° condition. This serves as a warning, and does not inhibit any functions. The sensor is mounted on a spring loaded base which is adjustable to allow leveling. Testing of the system is accomplished by manually tilting the sensor against its spring tension mount, to physically put the sensor in a 5° out-oflevel condition, causing the alarm to sound. Power is supplied to the sensor, and the alarm, only when the machine is in the "UPPER" control position. When the sensor is activated (5° or greater), the sensor's white wire (connected to the alarm), becomes grounded after a few second delay, through circuits inside the sensor.

BATTERY CONDITION INDICATOR (OPTION) This option is to monitor the batteries' state-of-charge, (See FIG. 13). The indicator is wired directly to the batteries with the 15 amp circuit breaker, or fuse, included in the circuit.

Consisting of an analog 10-LED bar display, the indicator provides a visual reference for reading properly charged batteries (top LED lit), batteries at 70% depth-of-discharge (second from bottom LED flashes), and when the batteries have reached an 80% depth-of-discharge (bottom two LED's flash alternately).

Slope Alarm Battery Condition Indicator CuRll

'EMERGENCY STOP

AST

FORWARD

.

CFS:P REVERSE DRIVE SPEED

FIG. 13 SIGNAL HORN (OPTION) This option consists of a 133 db automotive type horn mounted in the chassis, and a white pushbutton on the side of the upper control box (See FIG. 14). The horn is only operable when the control selector switch is in the "UPPER" position.

MANUAL 92377-002 March 1998

LOW VOLTAGE BATTERY PROTECTION SYSTEM (OPTION) This option prevents operation when the batteries are in a low voltage condition. It beLow Volt Override Pushbutton Signal Horn comes energized whenever the control selector (w/Amber Indicator Lamp) Pushbutton (white) switch is in either "UPPER" or "LOWER" position (lower emergency stop button must be pulled out). While energized, the module monitors the batteries' voltage level, and will prevent the pump Tuor.=', motor contactor from being activated once the battery voltage reaches 12.5% undervoltage, or Slope Cable Harness Plug approximately 21 volts. This condition must be Alarm present for 21 seconds to activate the interrupt FIG. 14 system. Terminals 3 & 4 of the module are normally closed contacts which complete the pump motor contactor circuit, and it is these contacts which are opened during a low voltage condition.

Terminal 7 of the module is the battery input voltage, while terminal 6 is machine ground. Terminals 1 & 2 are normally open contacts which close during a low voltage condition and turns on an amber indicator light (pushbutton) at the upper control box. The system can be overridden by pressing the pushbutton on the side of the upper control box (See FIG. 14), which energizes terminal 5 ofthe module.

However, the override will only allow three repeated by-pass cycles of 2 minutes 30 seconds each. The LVI module will reset when the battery voltage reaches approximately 25.5 volts during re-charging.

Once the batteries have been properly charged and the LVI module has automatically reset, the CONDOR® can be operated once again.

LOW VOLTAGE

'UONT MSNCA TES MAT THE

f0 OPERATE

POTCER TURNS CTF, BUT,

TRAVEL ALARM (OPTION) This option indicates forward or reverse drive (travel) of the machine. The alarm signal is activated by the deceleration valve circuit since the deceleration valve is always energized during both forward and reverse drive.

DESCEND ALARM (OPTION) This option indicates descent (lowering) of the platform. The alarm signal is activated by the holding valve circuit, which is energized when lowering the platform.

MOTION ALARM (OPTION) This option indicates forward or reverse drive, and raising or lowering ofthe platform. The alarm signal is activated from two different circuits; one energizes the pump motor contactor, and the other energizes the holding valve for platform lowering (pump not running). A diode is used in each circuit to prevent unintended feedback.

HOUR METER (OPTION) This option is to record the "run time" of the machine for maintenance scheduling, rental usage, etc.. The meter runs only when the pump motor contactor is energized (pump running); therefore, the meter does not run when the machine is sitting idle, or when the platform is being lowered.

MANUAL 92377-002 March 1998

Electrical Schematic

RED

ED, ELK SLOPE SENSOR OPTION

HORN

I-

WHT

14

SLOPE ALARM OPTION

WHITE

12. BUT. SEE NOTE 3

HORN

SIGNAL OPTION

CD CD

LOW VOLT OPTION (SENSOR)

STROBE LIGHT OPTION

3-POS SELECTOR EMERGENCY STOP UPPER ( 5D

0

BATTERY CONDITION INDICATOR OPTION

cj-b-§ 42------•

15A FUSE

LOWER

RED BATTERy

5B

NTG

H

POT

5B PLATFORM uP

5G

•

FOUR 6VDC BATTERIES

1* PUMP MOTOR

—I I—

A

•

1• BATTERY DISCONNECT KEY SWITCH OPTION

1B

8B

LOW VOLT OPTION (INTERRUPT)

PUMP MOTOR CONTACTOR

BB

2

80

fTFl

HOUR METER OPTION

HORN I-1-• MOTION ALARM OPTION

PLATFORM DOWN

5C 9

VALVE ON LIFT CYL

HORN

DESCEND ALARM OPTION

A 7

RIGHT

STEER oj

0

b

(STEER VALVE)

6

LEFT

EMERGENCY STOP

2 GRIP

3A

FORWARD

B

(DRIVE VALVE)

•

DRIVE

3B

8D

KJ

GREEN

REVERSE

4

WE PLATFORM

TRAVEL ALARM OPTION

DOWN

3A

-

3C

9

ENABLE

81)

DECELERATION VALVE

PLATFORM

3C\

0

8

a

UP

LIFT PLATFORM

10A

3B

3B I

boB

1

3-POS SPEED SELECTOR

I (SELECTOR VALVE) FAST DRIVE SPEED

C

11A

CREEP DRIVE SPEED VALVE

SEE NOTE

3B

POSITRACTiON VALVE

GO

3A

o•

o 1 6

LOW VOLT OPTION (OVERRIDE)

15

LOW VOLT OPTION (WARNING)

SEE NOTE 2

NOTES: C.

2.

3.

4.

LIMIT STITCH SHOWN WITH PLATFORM BELOW 7'.

n THRU®REPRESENT TERMINALS OF OPTIONAL LOW VOLTAGE UNIT IN LOWER CONTROL BOX. FOR SIGNAL HORN, PLUS ALL OTHER OPTIONS, AGO RELAY. THIS SCHEMATIC SUPERCEDES 55566.

11

10A

MANUAL 92377-002 March 1998

,1/1 "Bjf

l 11

PosiTRACTION VALVE

SEE NOTE 3

MANUAL 92377-002 March 1998

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 of the 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.

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.

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

MANUAL 92377-002 March 1998

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

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

The second item in routine servicing of conventional batteries is to check the electrolyte level in all cells. If necessary, add clear, odorless, mineral free water to bring the liquid level to the level indicator in all cells. If the battery does not have a level indicator, bring the level to 1/2" (13mmj above the tops of the separators. Do not overfill any cell. When a cell is overfilled, the excess electrolyte may be forced from the cell by the gas formed in the battery. This will cause excessive corrosion of adjacent metal parts, reduced performance and shorter life.

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

STEP 1

—

VISUAL INSPECTION

For protection, wear a face shield. First, visually inspect the battery. Check for container, cover or terminal damage that might cause leakage of electrolyte or internal damage. If serious damage is found, replace the battery. Check the electrolyte level in each cell. If below the tops of the plates in any cells, fill all cells with water to just above the tops of the separators and charge for 15 minutes at 1525 amps to mix the water with the electrolyte. If electrolyte levels are above the tops of the 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. If the range (highest-lowest) is 50 points (0.050 sp. gr .) or greater or the lowest is less than 1.225 sp.gr., charge the battery at the recommended rate or until all cells are 1.225 sp.gr. or greater and the range is less than 50 points. If no amount of charging will achieve these

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 92377-002 March 1998

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

A cell voltage of 2.07 is equivalent to a specific gravity of 1.225.

STEP 3 — ADJUSTABLE LOAD TEST The following instructions are intended as guidelines. When available, the instrument manufacturer's instructions should be followed. Follow all precautions.

A.

Disconnect battery cables starting with ground cable.

B.

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

C.

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

D.

Connect current transducer (if necessary) to appropriate lead.

E.

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

F.

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

G.

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

H.

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

I.

If test voltage is below minimum, replace battery.

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

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

MANUAL 92377-002 March 1998

STEP 2 - FIXED LOAD TEST Some commercial battery testers do not have an adjustable load but measure the battery voltage under a heavy fixed load. The tester should include a selector switch or meter scale to choose among a variety of battery sizes. It should include some means of correcting for the battery temperature, either in automatic sensing circuit or a manually selectable one.

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

A.

Disconnect battery cables starting with ground cable.

B.

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

C.

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

D.

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

E.

Apply test load for 15 seconds.

F.

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

G.

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

H.

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

STEP 3

—

OPEN CIRCUIT VOLTAGE TEST

If the battery failed the load test, the state of charge must be checked. If a hydrometer is not available, the stabilized open circuit voltage can be used to indicate the state of charge. Allow at least 10 minutes after the load test for the voltage to stabilize, then measure and record the open circuit voltage.

Determine the approximate state of charge from the following chart (Battery temperature 60-100 degrees F.)

OPEN CIRCUIT VOLTS 12.6 or greater 12.4 - 12.6 12.2 - 12.4 12.0 - 12.2 11.7 - 12.0 11.7 or less

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

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

MANUAL 92377-002 March 1998

DETERMINING CAUSES OF BATTERY FAILURE

Whether the battery passes or fails either of the above tests, the results must be believed. If the battery passed the load test only after a recharge, the cause of the discharge condition should be determined.

Ifthe battery has been returned previously or is otherwise still questionable, one final test should be made.

Fully charge the battery and place it on open circuit stand for three days. If the loss in specific gravity of any cell is greater than 35 points or the open circuit voltage drops by more than 0.20 volts, replace the battery. If not, return the battery to service and determine the cause for the discharged condition.

The following should be checked: 1. Corroded Battery Terminals or Connectors

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

2. Electrical Circuit Leakage

There may be a fault in the equipment's electrical system that can discharge the battery even when all the accessories are turned off. To check for such leakage, turn off all accessories in the equipment.

Check for leakage using one of the following methods.

A.

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

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

B.

Ohmmeter Disconnect the positive cable at the battery. Connect an ohmmeterto the -

disconnected cable end and to the chassis. A resistance measurement of under 100 ohm indicates a load of 0.1 amp or more and indicates the equipment electrical system should be tested and repaired.

C.

Voltmeter Disconnect the ground cable (negative) at the battery. Connect a low -

resistance voltmeter (100 ohms - see Note 1) between the disconnected battery post and the chassis. A voltage measurement of 6 volts or more indicates a leak of 0.1 amp or more and the equipment electrical system should be tested and repaired.

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

3. Charging System

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

MANUAL 92377-002 March 1998

FIGURE: X

BATTERY TESTING CHART STEP 1

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

OBVIOUS DAMAGE

NO OBVIOUS DAMAGE

REPLACE BATTERY

CHECK ELECTROLYTE LEVEL

BELOW TOP OF PLATES IN ONE OR MORE CELLS

ELECTROLYTE LEVEL ABOVE TOP OF PLATES IN ALL CELLS - PROCED TO STEP 2

ADD WATER TO JUST ABOVE SEPARATORS. CHARGE FOR 15 MINUTES AT 15-25 AMPS. PROCEED TO STEP 2

STEP 2

HYDROMETER TEST

SPECIFIC GRAVITY LESS THAN 1.225 OR CELL VARIATION 50 POINTS OR GREATER.

SPECIFIC GRAVITY 1.225 OR GREATER OR CELL VARIATION LESS THAN 50 POINTS. DISCHARGE AT 150 AMPS FOR 15 SECONDS

I RECHARGE I SPECIFIC GRAVITY LESS THAN 1.225 OR CELL VARIATION 50 POINTS OR GREATER.

I REPLACE BATTERY

I

CONTINUE TO STEP 3

1

I

STEP 3

LOAD TEST

. PLACE THERMOMETER IN CENTER CELL. COVER BATTERY WITH A DAMP CLOTH. 2. CONNECT VOLTMETER AND AMPERE LOAD EQUAL TO 1/2 THE COLD CRANKING AMPERES AT 0°F (-18°C) RATING OF THE BATTERY FOR 15 SECONDS. 3. OBSERVE VOLTAGE AT 15 SECONDS WITH LOAD ON. 4. REFER TO VOLTAGE CHART BELOW.

1 I VOLTAGE BELOW CHART VALUE 1

I

VOLTAGE EQUAL TO OR ABOVE CHART VALUE - RETURN TO SERVICE

REPLACE BATTERY VOLTAGE CHART ,

ESTIMATED ELECTROLYTE TEMPERATURE

MINIMUM REQUIRED VOLTAGE UNDER 15 SEC. LOAD (USE 1/2 THESE VALVES FOR 6-VOLT BATTERIES)

70°F (21°C) & ABOVE 60°F (16°C) 50°F (10°C) 40°F (4°C) 30°F (-1°C) 20°F (-7°C) 10°F (-12°C) 0°F (-18°C)

9.6 9.5 9.4 9.3 9.1 8.9 8.7 8.5

MANUAL 92377-002 March 1998

. .,

FIGURE: Y

BATTERY TESTING CHART STEP 1

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

OBVIOUS DAMAGE I

NO OBVIOUS DAMAGE I

REPLACE BATTERY

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

I

STEP 2

FIXED LOAD TEST)

ATTACH TESTER CLAMPS TO BATTERY TERMINALS IN CORRECT POLAITY - USUALLY RED TO POSITIVE (+) AND BLACK TO NEGATIVE (-).

2. SET SELECTOR SWITCH ON LOAD TESTER TO 1/2 CRANKING AMPERAGE RATING OF BATTERY (AT 0°F, -18°C).

3. IF TESTER DOES NOT HAVE AN AUTOMATIC BATTERY TEMPERATURE COMPENSATOR, PLACE A THERMOMETER IN CELL, READ AND SET TEMPERATURE DIAL ON TESTER. WITHOUT ANY TEMPERATURE CORRECTION, MAKE LOAD TESTS ONLY ON BATTERIES ABOVE 60°F (16°C).

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

BATTERY PASSES LOAD TEST RETURN TO SERVICE.

BATTERY FAILS LOAD TEST I PROCEED TO STEP 3 1

STEP 3

I OPEN CIRCUIT VOLTAGE TEST . ALLOW 10 MINUTES FOR BATTERY VOLTAGE TO STABILIZE AFTER LOAD TEXT. . READ OPEN CIRUIT VOLTAGE.

UNDER 12.4 VOLTS-BATTERY SHOULD BE CHARGED AND LOAD TESTED AGAIN (REPEAT STEP2). IF BATTERY AGAIN FAILS THE LOAD TEST, REPLACE IT. IF IT PASSES, RETURN TO SERVICE AFTER PROCEEDING TO STEP 4.

STEP 4

12.4 VOLTS OR ABOVE - IF BATTERY DID NOT PASS THE LOAD TEST, IT SHOULD BE REPLACED - THEN PROCEED TO STEP 4.

CAUSES OF BATTERY FAILURE:

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

OR B) DISCONNECT THE BATTERY CABLE THAT GOES TO THE STARTER AND CONNECT AN OHMMETER BETWEEN THE CABLE AND THE GOUND (A RESISTANCE OF UNDER 100 OHMS WILL DRAIN THE BATTERY).

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

MANUAL 92377-002 March 1998

NOTES

MANUAL 92377-002 March 1998

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.

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 TIME 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 turn, turn 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 92377-002 March 1998

2. Hydraulic System Fluid Level:

Check level daily. Maintain fluid level so that it is visible between the marks on the sight glass with platform all the way down.

Return Filter:

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

Tank Breather:

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

Hydraulic Tank:

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

DO NOT MIX DIFFERENT HYDRAULIC FLUIDS 3. Battery Servicing FOR PROTECTION WHEN SERVICING BATTERIES, ALWAYS WEAR A FACE SHIELD AND DO NOT SMOKE! 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, corro sion, 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 in each cell. If necessary, add clear, odorless, mineral free water to bring the level to 1/2" above the top of the separators, or to the level indicator (if equipped), in each cell. Only add water after the charging cycle is complete.

MANUAL 92377-002 March 1998

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. TIME 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. 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:

terminal

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 connections with a spray corrosion inhibiter, or high temperature grease.

Hydraulic Fluid Leaks: Decals and Placards:

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

Verify that all decals and placards are in place and are legible. It is recom mended that any decals or placards which are torn, damaged, missing, or painted over, be replaced. Essential decals must be legible, or must be replaced.

B. FLUID LEVEL CHECK

Hydraulic Tank

Level:

Battery Electrolyte Level:

Check level daily. Maintain fluid level so that it is visible between the marks on the sight glass with platform all the way down.

For protection, wear a faceshield. Check electrolyte level in each cell.

If necessary add electrolyte or clear, odorless, mineral free water as required to bring the level to 1/2" above the tops of the separators or to the level indicators (if equipped), in each cell. Add only after the charging cycle is complete.

MANUAL 92377-002 March 1998

OPERATIONAL TEST Instrument Check Hour Meter:

Ensure that meter is recording properly.

Battery Condition Indicator: Ensure that indicator is monitoring the batteries state-ofcharge properly.

Lower Controls 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 Buttons:

Check that buttons and toggle switch return to their normal position when released, and that buttons and toggle switch properly operate the lift function.

Upper Controls Operation Check Emergency Stop Button:

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

Lift Control Buttons:

Check that buttons return to their normal position when released, and that buttons properly operate the lift function.

Make certain that lift function does not operate unless green power button is depressed.

Drive/Steer Functions:

Squeeze handle grip and operate drive and steer functions.

Drive Speed Selector:

Ensure that each speed selection works properly while driving.

Positraction Button:

Ensure that speed shifts to low when button is depressed (platform below seven feet), regardless of speed selector position.

Slope Alarm:

Tilt sensor more than 5° (located in belly pan), and check for audible alarm at platform control box. Selector switch must be in "UPPER" position.

MANUAL 92377-002 March 1998

PREVENTIVE MAINTENANCE DAILY INSPECTION DATE ITEM

MON TUES WED THURS FRI SAT 77 Z

HOURS/

_Z

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

OPERATIONAL TEST Hour Meter Battery Condition Indicator

LOWER CONTROLS Emergency Stop Button Control Selector Switch Lift Control Buttons

UPPER CONTROLS Emergency Stop Button Lift Control Buttons Drive/Steer Functions Drive Speed Selector Switch Positraction Button Slope Alarm

MANUAL 92377-002 March 1998

7

SUN

7/

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 Connecting Arm:

Check pins and retaining rings for proper installation. Ensure that arm does not bind or contact chassis throughout range of steering travel.

Steering Knuckles:

Inspect thrust washer for wear, and make certain that both pivot pin retainers are installed properly. Ensure there is no binding through out 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 Cylinders:

Check hydraulic lines for leakage. Check for proper brake operation. Check for proper brake release lever operation.

Inspect cylinders and retaining bolts for damage and proper installation.

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 to chassis weldment bolts for tightness and proper installation. Check for security of components.

Battery Charger:

Inspect for damage. Verify proper charging operation.

Wiring and Electrical Connections:

Inspect for damage, defective cables, fraying or cracked insula tion, tightness of terminal ends, loose connections, corrosion, cracked or swelling cases, or covers, loose hold downs or deformed terminal posts on batteries.

Electric Motor and Pump: Inpect motor and pump mounting hardware for tightness, cable connections for tightness, corrosion, fraying, or damage.

MANUAL 92377-002 March 1998

B.

Visual Inspection: Lift Cylinder Hoses and Fittings:

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

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 Cylinder:

Inspect for damage to chrome on lift cylinder rod, damage to cylinder body, and all welds for cracks. Inspect holding valve bolts for tightness.

Lift Cylinder Pins and Retaining Bolts: Limit Switch:

Upper/Lower Electrical Junction:

Armstack Bearing Pads (chassis):

C.

01)

ARMSTACK

Inspect cylinder pins and retaining bolts for security.

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

Remove terminal strip cover and inspect wiring for corrosion and tightness. If rust or corrosion are present, clean with a wire brush and coat terminal connections with a spray corrosion inhibiter 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 a graphite dry film lubricant.

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 antisieze compound.

Platform Entrance Lift Gate and Latch Assemblies: Inspect for damage. Ensure that gate slides (operates) freely and

MANUAL 92377-002 March 1998

. PLATFORM (cont'd) Extension Deck and Latch Assembly:

Inspect for damage. Ensure that deck slides freely and latch assembly functions properly.

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

D.

LOWER CONTROL BOX Visual Inspection External:

Inspect for proper mounting, damage to enclosure or controls, Ensure that enclosure lid seals watertight and that controls are secure.

Internal:

Inspect for tightness of terminal strip mounting, all wire ends, and cable strain reliefs. Ensure that no corrosion is present and that box drain holes are open.

Manual Tube Holder MDD:

E.

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

UPPER CONTROL BOX Visual Inspection External: Inspect for proper operation of electrical cable quick disconnect plug. Inspect for damage to enclosure or controls. Ensure that box fits snugly onto mounting posts and that controls are secure.

Internal:

Inspect for tightness of wire ends at all locations. Ensure that enclosure lid seals water tight, and lid hinges are not damaged.

MANUAL 92377-002 March 1998

PREVENTIVE MAINTENANCE 50 HOUR INSPECTION MON

.

DATE

ITEM

HOURS

CHASSIS

///

TUES WED

THURS

FRI

SAT

SUN

7/7/7/7

Visual Inspection Steering Cylinder Steering Connecting Arm Steering Knuckles Wheels Drive Motors Brake Cylinders 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 Cylinder Lift Cylinder Pins and Retaining Bolts Limit Switch Upper/Lower Electrical Junction Armstack Bearing Pads (chassis)

PLATFORM Visual Inspection

MANUAL 92377-002 March 1998

PREVENTIVE MAINTENANCE 50 HOUR INSPECTION (cont'd) MON DATE

ITEM

HOURS

PLATFORM (cont'd)

TUES

WED

THURS

FRI

7:7 77

Platform Pivot Shafts/Retaining Bolts Platform Bearing Pads Platform Entrance Lift Gate/Latches Extension Deck and Latch Assembly Electrical Cable Manual Storage Container

LOWER CONTROL BOX Visual Inspection--External Visual Inspection--Internal Manual Tube Holder

UPPER CONTROL BOX Visual Inspection--External Visual Inspection--Internal

MANUAL 92377-002 March 1998

SAT

SUN

/

HYDRAULIC FLUID SPECIFICATIONS FOR CONDOR® AERIAL WORK PLATFORMS

Shell Tellus - T32 Hydraulic Fluid

Viscosity SUS @ 100° F 155 SUS @ 210° F 47 Viscosity Index 154 Flash Point °F 325° Pour Point °F -54°

COLD TEMPERATURE OPERATION

For continuous operation in sub-zero temperatures, a fluid change is required. One of the following should be used:

A)

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

B)

Sun Low Temperature No. 3 Hydraulic Fluid Manufacturer: Sunoco, Inc., Toronto, Ontario, M55 254, Canada

C)

Fluids Conforming to MIL-H-5606C Specifications.

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

CAUTION DO NOT MIX DIFFERENT FLUIDS

MANUAL 92377-002 March 1998

NOTES

MANUAL 92377-002 March 1998

115 VAC BATTERY CHARGER TROUBLESHOOTING GUIDE To be able to use the troubleshooting guide effectively, it is important to read this guide completely before beginning any tests.

CAUTION REPAIRS BY QUALIFIED PERSONNEL ONLY.

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

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

SECTION 1 — CHARGER DOES NOT TURN ON In normal operation the charger DC output must be connected to the batteries in order to turn the charger on. A time delay of 2 to 5 seconds is provided to allow adequate time to make a secure connection before the charger turns on. After this time delay the power relay closes and an audible "click" should be heard. When the relay closes, AC power is supplied to the transformer primary coil. If operating properly, the transformer should hum and the ammeter should indicate the charge rate. If the charger does not turn on properly, refer to Part A, B, or C for specific test procedures.

WARNING Do not operate the charger if it is malfunctioning. Personal injury or

MANUAL 92377-002 March 1998

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

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

If the plug or receptacle is broken, twisted, bent or loose and does not make good electrical contact, have it replaced by a qualified serviceman immediately.

DO NOT USE THE CHARGER IN THIS CONDITION AS FIRE OR PERSONAL INJURY CAN RESULT.

Disconnect the power supply cord from its outlet. With the DC output connector still connected to the battery connector, measure the voltage at the battery connector using a suitable DC voltmeter. The voltage reading should be the same as the battery terminal voltage and must be between 24 and 50 volts DC in order to close the relay. If the DC voltage is within the above limits, remove the charger cover and verify that the charger is properly wired and you read the same voltage (24 to 50 volts DC) inside the charger where the white and black wires of the DC cord attach. If the battery DC voltage measured inside the charger is now below the above limits or not present, the DC plug or cordset has an internal break and must be replaced. If the charger is wired correctly and a satisfactory battery DC voltage is measured inside the charger, a malfunction in the Electronic Timer Kit has probably occurred. Due to its complexity, do not attempt to make field repairs to any part of the Electronic Timer Kit. If a malfunction exists, simply remove the entire Electronic Timer Kit and replace it with a new one. Refer to Part D - "Electronic Timer Kit Replacement" - for correct procedure.

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

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

MANUAL 92377-002 March 1998

CAUTION DO NOT charge batteries with the Electronic Timer Kit bypassed. The charger

will remain on as long as the power supply cord is connected to an outlet.

Severe overcharging and eventual damage to batteries will result.

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

PART B — RELAY CLOSES BUT NO TRANSFORMER HUM AND AMMETER DOES NOT REGISTER

Check to be sure the power supply cord is securely connected to a live AC outlet. When three-prong to two-prong adapters are used, they tend to work loose resulting in a poor connection. Check the AC line fuse or circuit breaker and, if possible, measure the AC line voltage at the outlet to be sure AC power is present.

If necessary, connect a functioning charger, utility light or other electrical appliance to the outlet to verify the presence of AC power.

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

PART C — RELAY CLOSES AND TRANSFORMER HUMS BUT AMMETER DOES NOT REGISTER

If the relay closes and the transformer hums, the charger AC circuit and Electronic Timer Kit are functioning properly. Ifthe ammeter does not register, a fault in the charger DC circuit exists and a continuity check must be performed. Disconnect the power supply cord from its outlet and the DC output connector from the battery connector, and check the charger fuse. If a fuse link is blown, refer to Section 2 - "Charger Fuse Blows" for further tests. If the fuse checks good, use a low voltage continuity tester to perform the following tests: 1. Connect the tester leads to the charger DC output connector and note the reading. Reverse the tester leads and check the output connector again. The circuit should be complete in only one direction. Ifthe circuit does not conduct in either direction and the fuse is good, individually check the continuity ofthe DC output cord, ammeter, diodes and all connections. If the circuit conducts in both directions, a "short" exists in the charger DC circuit. First check the DC output cord for a "short" between the two wires. It is more likely that one or both diodes have "shorted." Refer to Section 2 - "Charger Fuse Blows" for continuity test of diodes.

MANUAL 92377-002 March 1998

2.

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

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

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

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

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

CAUTION

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

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

3.

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

PART D — ELECTRONIC TIMER KIT REPLACEMENT

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

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

2.

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

3.

Install the replacement Electronic Timer Kit by reversing the disassembly procedures described in Step 2. When reconnecting the wires to the Electronic Timer Kit terminal tabs, support the terminal board to prevent damage to the electronic circuit board. Connect either transformer primary lead to terminal #2 and the remaining primary 1 lead to terminal #3.

MANUAL 92377-002 March 1998

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

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

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

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

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

B.

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

C.

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

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.

SECTION 2 — CHARGER FUSE BLOWS The charger fuse assembly consists of a dual element fuse link under a transparent cover mounted on the charger front panel. Each fuse element is electrically connected in series with a rectifier diode to provide protection for the transformer in the event of a diode failure. Visually inspect and electrically test the fuse to determine if one or both fuse links are blown and refer to Part A or Part B for test procedures.

LOCATE AND CORRECT CAUSE OF TROUBLE BEFORE REPLACING BLOWN FUSE. DO NOT attempt to repair the fuse link as inadequate protection will result.

MANUAL 92377-002 March 1998

PART A — SINGLE FUSE LINK BLOWS

This condition is normally caused by a short circuit failure of one diode. The fuse link will blow when the charger DC output connector is connected to the battery connector, regardless of whether the power supply cord is connected to an outlet. To check the diodes, disconnect the power supply cord from its outlet and the DC output connector from the battery connector, and then disconnect one transformer secondary coil lead from the diode terminal. Using a low voltage continuity tester, connect one tester lead to the diode mounting plate and the other tester lead to a diode terminal.

Note the reading and then reverse the tester leads and check each diode again. If a diode conducts current in both directions, it is "shorted" and the complete Heat Sink Assembly with Diodes (Part No. 09653S) must be replaced.

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

PART B — BOTH FUSE LINKS BLOW

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

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

MANUAL 92377-002 March 1998

SECTION 3 — AMMETER READS 30 AMPS FOR MORE THAN 30 MINUTES This high output condition is caused by misuse, connecting the charger to an incorrect battery system which is lower than 24 volts. A common error is to install one or more of the 6 volt batteries in a 24 volt battery pack reverse polarity. Using a suitable DC voltmeter, test to be sure all batteries in a battery pack are correctly wired and also test the battery pack voltage at the charging connector. After charging for 30 minutes at this excessive rate, the measured on charge voltage should rise to 22 to 26 volts DC for a 24 volt system. Voltage measurements, while charging, lower than this indicate an incorrect or failed battery pack that must be corrected before using the charger.

CAUTION

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

SECTION 4 — CHARGER OUTPUT IS LOW The most probable cause of low output is a single fuse link blowing as the result of a short circuit failure of one diode. Refer to Section 2 - "Charger Fuse Blows" for troubleshooting procedures. On rare occasions a short circuit failure of the transformer coils may cause the output to be low. Refer to section 7 - "Transformer Short or Burn Out" for test procedures.

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

SECTION 5 — CHARGER TURN OFF MALFUNCTIONS The Electronic Timer Kit turns the charger off as well as on. Proper charge time is determined by many factors, but the main elements are: (1) battery size, (2) depth of battery discharge and (3) finish charge rate. Large severely discharged batteries require more time to reach full charge than do smaller lightly discharged batteries.

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

The following timer malfunctions are occasionally due to factors other than the charger's performance. To help isolate the problem, it is often necessary to use the charger on a different set of batteries and the original set of batteries on another charger.

MANUAL 92377-002 March 1998

PART A — CHARGER TURNS OFF TOO SOON

Check to be sure the power supply cord is securely connected to a live outlet. If the power supply outlet is live, proceed with the next step.

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

The ammeter needle jumps smartly to between 20 and 25 amps and then tapers below 14 amps 1. within 15 minutes. This indicates that the batteries were truly charged. The apparent short charging time is in response to the batteries' ability to accept charge and the electronic timer is performing properly.

The ammeter needle jumps smartly to between 20 and 25 amps, but does not taper below 14 amps 2. within 15 minutes. If the batteries have been properly maintained and charged regularly, this generally indicates that the batteries were not fully charged. If possible, use a hydrometer to check the specific gravity of several battery cells. If the specific gravity readings are more than 30 points (.030) lower than normal full charge readings, the electronic timer has malfunctioned and the complete Electronic Timer Kit must be replaced. Refer to Section 1, Part D - "Electronic Timer Kit Replacement" for correct procedures.

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

As batteries age, individual cells may weaken, causing a reduction in battery capacity. This condition normally results in a finish charge higher than 10 Amps and less time is required to fully charge the batteries. Do not interput this shorter charging time and reduced battery capacity as being caused by the charger turning offtoo soon. The battery is aging naturally and the charger is working properly. When the batteries will no longer perform as required, they should be replaced.

PART B — CHARGER DOES NOT TURN OFF

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

If the charger remains on longer than the specified maximum time, check to see if the charger turns on immediately when the DC output cord is connected without the normal two to five second delay. If the charger turns on instantly without the two to five second delay the Electronic Timer Kit has probably failed. This type of malfunction generally results in the charger not turning off and the complete Electronic Timer Kit must be replaced. Refer to Section 1, Part D - "Electronic Timer Kit Replacement" for correct procedures.

MANUAL 92377-002 March 1998

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

If a precision digital type DC voltmeter is available, a test to verify that the Electronic Timer has malfunctioned can be made. Connect the charger to the batteries and allow to charge normally. After the charge rate has tapered to its lowest point, measure the battery terminal voltage using a DC voltmeter capable of reading in increments of .001 volts. Continue charging and check the battery voltage reading every hour. Ifthe battery voltage increases less than .012 volts, or ifthe battery voltage decreases between successive hourly readings, the charger should turn off. If the charger does not turn off, the Electronic Timer has malfunctioned and the complete Electronic Timer Kit must be replaced.

PART C — CHARGER RUNS TOO LONG BUT DOES TURN OFF

In the event of AC power interruption when the charger is on, the charger will automatically restart when AC power is restored. This power outage can make the apparent charge time seem longer than the actual charge time. To check for AC power interruptions, plug an electric clock into the same outlet to which the AC cord is connected. Charge normally and note any time difference between the test clock time and the actual time.

SECTION 6

—

AC LINE FUSE OR CIRCUIT BREAKER BLOWS

If this occurs when the charger power supply cord is connected to an outlet, without the DC output connector connected to the battery connector, the charger power supply cord may be shorted. Disconnect the power supply cord from its outlet and the DC output connector from the battery connector, then check to be sure the Electronic Timer Kit is NOT bypassed. With a suitable continuity tester, check the circuit across the power supply cord prongs as shown. THE CIRCUIT SHOULD NOT BE COMPLETE. If the circuit is complete, check the relay contacts to be sure they are open and have not welded closed. If the relay contacts are open, the power supply cord is shorted and must be replaced. Ifthe power supply checks good, the transformer coils may be shorted. Refer to Section 7 - "Transformer Short or Burnout" for test procedures.

SECTION 7

—

TRANSFORMER SHORT OR BURNOUT

Failure of the transformer can be the result of natural aging, premature shorting of adjacent coil turns or overheating damage. The most common cause of transformer overheating and premature burnout is the result of misuse, connecting the charger to a battery system of lower voltage than specified on the charger (See Section 3). Darkening of all the transformer secondary coil windings is an indication of possible overheating damage. A low or complete lack of output would be observed on the ammeter, however, the transformer may hum or the AC line fuse or circuit breaker may blow when the charger is turned on. To test the transformer, disconnect the power supply cored from its outlet and the DC output connector from the battery connector. Then disconnect the transformer secondary coil leads #1 and #4 from the diode terminals and disconnect the transformer capacitor coil leads from the capacitor terminals.

Use care when disconnecting the capacitor lead so the wires do not break.

MANUAL 92377-002 March 1998

HIGH VOLTAGE: With the charger operating, the charger capacitor voltage is

approximately 650 volts AC. Use extreme caution when working near the capacitor terminals.

In order to apply AC power directly to the transformer primary coil, the Electronic Timer Kit must be bypassed. Refer to Section 1, Part A for by-pass procedures. With the Electronic Timer Kit bypassed take caution in connecting the power supply cord to an outlet. Ifthe AC line fuse or circuit breaker blows, the transformer is shorted internally and must be replaced. If this does not occur, check the transformer secondary and capacitor coil voltages as shown in Figure 6, using a suitable AC voltmeter. Ifthe measured voltages are substantially lower than those shown, the transformer is shorted internally and must be replaced.

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

The correct voltage reading is shown in Figure 7. Ifthe transformer secondary voltage reading is the same as measured with the capacitor disconnected, from Figure 6, the capacitor may be open, the capacitor coil may be open or the capacitor coil terminals may not be making proper electrical contact. Refer to Section 1, Part C, Item 2 for capacitor test procedures. If the voltage readings are correct, both the transformer and capacitor are good, refer to Section 1, Part C, Item 1 for further tests of the DC circuit.

If it should become necessary to replace a terminal on one of the transformer leads, the new terminal must be crimped AND soldered. NOTE: Some transformer leads may be aluminum wire and a solder must be used on these wires that is intended for use on aluminum, such as Alcoa #807 solder with Alcoa #69 flux. If these materials are not available locally, contact the Lester factory.

MANUAL 92377-002 March 1998

APPENDIX A

TIME CONDOR Corporation

BOLT TORQUE CHART BASIC STRESS TENSILE STRENGTH (T) MIN NOMINAL THREADS

MAJOR AREA DIA SQ. IN INCH /

4-40 4-48 6-32 6-40 8-32 8-;36 10-24 10-32 1/4-20 1/4-28 5/16-18 5/16-24 3/8-16 3/8-24 7/17-14 7/16-20 1/2-13 1/2-20 9/16-12 9/16-18 5/8-11 5/8-18 , 3/4-10 3/4-16 7/8-9 7/8-14 1-8 1-12 1 1/8-7 1 1/8-12 1 1/4-7 1 1/4-12 1 3/8-6 1 3/8-12 I 1/2-6 1 1/2-12

SAE GRADE 5

PROOF LOAD (P) SAE GRADE (1957) GRADE 8 GRADE 5 T

P

T

CLAMP LOAD LBS.

P

,

SAE GRADE 8

ASSEMBLY TORQUE R=.200 DRY X.=.150 LUB

CLAMP LOAD LBS.

ASSEMBLY TORQUE R=.200 DRY R=.150 LUB

.1120

.00604

120KSI

85KSI

150KSI

120KSI

380

8LB-1N

6LB-IN

540

12LB-IN

9LB-IN

.1120

.00661

120KSI

85KSI

150KSI

120KSI

420

9LB-IN

7LB-IN

13LB-IN

10LB-IN

.1380

.00909

120KSI

85KSI

150KSI

120KSI

580

16LB-IN

12LB-IN

_ 600 820

23LB-IN

17LB-IN

.1380

.01015

120KSI

85KSI

150KSI

120KSI

640

18LB-IN

13LB-IN

920

25LB-IN

19LB-IN

.1640

.01400

120KSI

85KSI

150KSI

120KSI

900

30LB-IN

22LB-IN

1260

41LB-1N

31LB-IN

.1640

.01474

120KSI

85KSI

150KSI

120KSI

940

31LB-IN

23LB-IN

1320

43LB-IN

32LB-IN

.1900

.01750

120KSI

85KSI

150KSI

120KSI

1120

43LB-IN

32LB-IN

1580

60LB-IN

45LB-IN

.1900

.0200

120KSI

85KSI

150KSI

120KSI

1285

49LB-IN

36LB -IN

1800

68LB-IN

.2500

.03180

120KSI

85KSI

150KSI

120KSI

2020

8LB-FT

75LB-IN

2860

12LB-FT

9LB-FT

.2500

.03640

120KSI

85KSI

150KSI

120KSI

2320

IOLB-FT

86LB-IN

3280

14LB-FT

10LB-FT

.3125

.05240

120KSI

85KSI

150KSI '

120KSI

3340

17LB-FT

13LB-FT

4720

25LB-FT

18LB-FT

.3125

.05800

120KSI

85KSI

1501(81

120KSI

3700

19LB-FT

14LB-FT

5220

25LB-FT

20LB-FT

7000

45LB-FT

35LB-FT

7900

50LB-FT

35LB-FT

.

r

51LB-IN

3750

.07750

120KSI

85KSI

150KSI

120KSI

4940

30LB-FT

23LB-FT

.3750

.08780

120KSI

85KSI

150KSI

120KSI

5600

35LB-FT

25LB-FT

.4375

.10630

120KSI

85KSI

150KSI

120KSI

6800

, 50LB-FT

35LB-FT

9550

70LB-FT

55LB-FT

.4375

.11670

120KSI

85KSI

150KSI

120KSI

7550

55LB-FT

40LB-FT

10700

80LB-FT

60LB-FT

.5000

.14190

120KSI

85KSI

150KSI

120KSI

9050

75LB-FT

55LB-FT

12750

1 IOLB-FT

80LB-FT

.5000

.15990

120KSI

85KSI

150KSI

120KSI

10700

90LB-FT

65LB-FT

14400

120LB-FT

90LB -FT

..,

.5625

.18200

120KSI

85KSI

150KSI

120KSI

11600

110LB-FT

80LB-FT

16400

150LB-FT

110LB-FT

.5625

.20300

120KSI

85KSI

150KSI

120KSI

12950

120LB-FT

90LB-FT

18250

170LB-FT

130LB-FT

.6250

.22600 ' 120KSI

85KSI

150KSI

120KSI

14400

150LB-FT

110LB-FT

20350

220LB-FT

170LB-FT

.6250

.25600

120KSI

85KSI

150KSI

120KSI

16950

180LB-FT

13OLB-FT

23000

240LB-FT

180LB-FT 280LB-FT

.7500

.33400

120KSI

85KSI

150KSI

120KSI

21300

260LB-FT

200LB-FT

30100

380LB-FT

.7500

.37300

120KSI

85KSI

150KSI

120KSI

23800

300LB-FT

220LB-FT

33600

420LB-FT

320LB-FT

.8750

.46200

120KSI

85KSI

150KSI

120KSI

, 29500

520LB-FT

390LB-FT

41600

600LB-FT

460LB-FT

.8750

.50900

120KSI

85KSI

150KSI

120KSI

32400

570LB-FT

430LB-FT

45800

660LB-FT

500LB-FT

1.000

.60600

120KSI

85KSI

150KSI

120KSI

38600 ,

770LB-FT

, 580LB-FT

54500

900LB-FT

680LB-FT

1.000

.66300

120KSI

85KSI

150KSI

120KSI

42300

850LB-FT

630LB-FT

59700

1000LB-FT

740LB-FT

1.1250

.76300

105KSI

74KSI

150KSI

120KSI

42300

800LB-FT

600LB-FT

68700

1280LB-FT

960LB-FT

1.1250

.85600

105KSI

74KSI

150KSI

120KSI

47500

880LB-FT

660LB-FT

77000

1440LB-FT

1080LB-FT

1.2500

.96900

105KSI

74KSI

150KSI

120KSI

53800

1120LB-FT

840LB-FT

87200

1820LB-FT

1360LB-FT

1.2500

1.0730

105KSI

74KSI

150KSI

120KSI

59600

1248LB-FT

920LB-FT

96600

2000LB-FT 1:5 00 LB - F T

1.3750

1.1550

105KSI

74KSI

150KSI

120KSI

64100

1468LB-FT

1100LB-FT

104000

2380LB-FT Y780LB-FT

1.3750

1.3150

105KSI

74KSI

150KSI

120KSI

73000

1680LB-FT

1260LB-FT

118400

2720LB-FT

2040LB-FT

1.5000

1.4050

105KSI

74KSI

150KSI

120KSI

78000

1940LB-FT

1460LB-FT

126500

3160LB-FT

2360LB-FT

1.5000

1.5800

105KSI

74KSI

150KSI

120KSI

87700

2200LB-FT

1640LB-FT

142200

3560LB-FT

2660LB-FT

.

NOTES: 1.THIS CHART SHOWS RECOMMENDED BOLT TORQUES. 2.TORQUE =RXDXT 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% PROOF LOAD X STRESS AREA

MANUAL 92377-002 March 1998

APPENDIX B

TIME CONDOR Corporation

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 LUBRICATED THREADS THREADS

DRY THREADS

LUBRICATED THREADS

DRY THREADS

LUBRICATED THREADS

DRY THREADS

LUBRICATED THREADS

M4

27.5*

17*

30*

18*

38.5*

24*

53*

32.5*

M5

56.5*

33.5*

61*

37*

78*

47*

107*

65*

M6

95*

57.5*

103*

61*

132*

79*

180*

109*

M8

19

12

21

13

27

16

37

22

M10

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

MANUAL 92377-002 March 1998

TIME CONDOR Corporation

SELF-PROPELLED ELEVATING WORK LATFORM

MODFL V1433/1433XL MODI41,1, V18331833XL ILLUSTRATED PARTS MANUAL

SITIPPINGADDRESS

MAILING ADDRES S

TIME CONDOR Corporation

TIME CONDOR Corporation

8300 IMPERIAL DRIVE WACO, TEXAS 76712 (254) 420-5200

P.O. Box 21447 WACO, TEXAS 76702-1447 (254) 420-5200

MANUAL 92377-003 March 1998 Revised1/99

CONDOR® MODEL V14/1833XL & V14/V1833 ILLUSTRATED PARTS MANUAL

TABLE OF CONTENTS Introduction Service Information Table of Contents FIGURE

ii 1 DESCRIPTION

A B C 1.1 1.2 1.3 1.4

PAGE

Serial Number Location How to Order Parts Recommended Spare Parts List

3 4,5

Final Installation V14/1833/XL-01 Final. Installation V14/1833/XL-02 Final Installation V14/1833/XL-03 Decal Installation

8 10 12 L4

2.1 Carriage Assembly 2.2 Steer Cylinder 2.3 Brake Cylinder

2.4 Hub Assembly 2.5 Hub Motor Assembly 2.6 Rear Hub Assembly 2.7 Tire & Wheel Assembly

16 22 23 24 26 27 28

3.1

30

Hose Installation

4.1 4.2 4.3 4.4 4.5 4.6

4.7 4.8 4.9 4.10 4.11

Belly Pan Assembly Cable Kit Motor & Pump Assembly Pump Parts Motor Tube Assembly Valve Installation Valve Assembly Jumper Assembly Charger Assembly Charger

36 42 44 45 46 48 49 50 51 52 53

5.1..

5.2

Wiring Installation Wiring Installation XL

54 56

6.1

Lower Box Assembly

58

7.1 7.2 7.3 7.4 7.5 7.6 7.7

Arm Stack 1433/XL 78 Arm Stack 1833/XL 82 Arm Stack Lift Cylinder 1433 86 Arm Stack Lift Cylinder 1433XL 87 Arm Stack Lift Cylinder 1833XL 88 Arm Stack Lift Cylinder 1833

89 .Manifold Assembly 90 MANUAL 92377-003 March 1998 Revised1/99

Q FIGURE 7.8

7.9 7.10 7.11 8.1 8.2 8.3 8.4 8.5 8.6 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10

DESCRIPTION Harness Assembly Harness Assembly Harness Assembly Harness DWG

PAGE 91

92 93 94

Platform Assembly 96 Platform AssemblyXL 98 Upper Control Box V14/1833-01 100 Upper Control Box V14/1833XL-01 102 Upper Control BoxVl4/1833-02 -03 106 Upper Control Box V14/1833XL-02 -03 108 110 Volt Extension To Platform Travel Alarm Motion Alarm Strobe Light Descend Alarm Slope Alarm Hour Meter

Battery Condition Indicator Low Voltage Warning Interrupt Larger Batteries

MANUAL 92377-003 March 1998 Revised 1/99

112 114 115 116 117 118 119 120 121 122

FIGURE A—SerialNumber Location •

The CONDOR® Model V1433XL/1433 & V1833XL/1833 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, at the rear between fork lift pockets.

2.

The second place to find the serial number is at the front steering knuckle kingpin.

MANUAL 92377-003 March 1998 Revised1/99

FIGURE B—How to Order Parts 1.

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

2.

If known, please specify the TIME CONDOR 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 TIME CONDOR Parts Department. Credit will be authorized through the Service Department after a Warranty Claim has been submitted to TIME CONDOR A Warranty Claim is to be filed for any part received as "defective". See Maintenance Manual for Warranty Procedures.

5.

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

6 TIME CONDOR Corporation classifies its orders in the following ways: 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.

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

8.

All price quotations will be valid for 90 days.

9 Parts shown as shipped on the TIME CONDOR 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.

MANUAL 92377-003 March 1998 Revised1/99

•

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

PURCHASER

ACCOUNT#

NAME AME ADDRESS 0

CITY

44P4

PHONE

( ) CUST. PURCHASE ORDER NO.

ZIP

STATE

S ADDRESS HT I 0 p CITY

STATE ZIP

PHONE

FAX ( ) ORDER DATE

FAX

( ) ( ) REQUEST DATE SPECIAL MARKS & NUMBERS

SHIPPING INSTRUCTIONS

PART NUMBER

DESCRIPTION

QTY.

FOR ORDER STATUS PLEASE CHECK APPROPRIATE BOX BELOW EMERGENCY STOCK MANUAL 92377-003 March 1998 Revised1/99

NOTES

FIGURE C—Recommended Spare Parts List CONDOR® MODEL V14/1833XL V14/1833 (1 UNIT-1 YEAR OPERATION)

PART NUMBER DESCRIPTION

V14 V18 V14XL V18XL QTY QTY QTY QTY

91023 Nut Lug 1/2" 5 5 5 55363-001 Stud Wheel 1/2"-20 x 1 3/4" 5 5 5 54783-001 Cable Assembly, Emergency Lowering 1 1 1 54798 Coupling Nut, 10-32UNF 1 1 1 55241 .Spring Loaded Pull-Up Latch N/A N/A 3 54048 Latch Door 2 2 2 67408 110 -- 1 Element, Hydrdaulic Filter P/N 33430 5 5 5 55861 Fitting, Swivel 90° Elbow 6-6 2 2 2 54910-102 Upper Control Connector N/A N/A 1 54910-104 Upper Control Connector N/A N/A 1 51036 Switch Limit Body Only 1 1 1 51037 Offset Head Limit Switch 1 1 1 51039-002 Limit Switch, Arm, Short 1 1 1 54589 Controller, Drive/Steer N/A N/A 1 54862 Fuse-175 Amp Non-Time-Delay 1 1 1 29163 Circuit Breaker, 15Amp 1 1 1 67939-015 Fuse, 15 Amp 1 1 1 67940 Fuse Holder 5 5 5 52138 Solenoid 24V 1 1 1 206-00001-00 Diode 9 9 9 54438 • Relay, 24V SPDT Bosch 1 1 1 34542 Jumper 4 4 4 55892-001 Decal Installation 1 N/A N/A 55892-002 Decal Installation N/A N/A 1 55892-003 Decal Installation N/A 1 N/A 55892-004 Decal Installation N/A N/A N/A 55888 Hose Kit 1 1 1 67758 Toggle Switch

1 1 N/A 50075 Switch 2. 2 N/A 51913 Operator, Red P-Pull 1 1 1 51914 Base, 1NC Contact 1 1 1 55901 Charger 1. 1 1 52671 Operator, 3 Pos. Rot. Key 1 1 1 52029 Base, 2NO Contacts 1 1 1 52670 Operator, 3 Pos. Rot. N/A N/A 1 34464 Base, NO/NC Contacts N/A N/A 1 52672 Base, 1 NO Contact N/A N/A 1 69146 Operator, Green P-Pull.

N/A N/A 1 54913 Operator, Blk/Blk Dbl. P-Button N/A N/A 1

MANUAL 92377-003 March 1998 Revised1/99

5 5 1 1 3 1 5 2 1 1 1 1 1 1 1 1 1 5 1 9 1 4 N/A N/A N/A 1 1 N/A N/A 1 1 1 1 1 1 1 1 1 1

•

This page intentionally left blank

MANUAL 92377-003 March 1998 Revised1/99

8

FIGURE 1 . 1 : Final Installation

Note: Model V1833XL Shown.

MANUAL 92377-003 March 1998 Revised1/99

FIGURE 1.1 : Final Installation V1433XL Serial Numb ers X11597050-X11597065 V1833XL, Serial Numbers X21567134, X21597001-X215972283 PARTNUMBER DESCRIPTION

QTY

Ref. M-V1433-01 Final Installation V1433-1 Ref. Ref. M-V1433XL-01 Final Installation V1433XL-1 Ref. Ref. M-V1833-01 Final Installation V1833-1 Ref. Ref. M-V1 833XL-01 Final Installation V1833XL-1 Ref. 1 55817 Chassis Assembly 1 -2 55669 BellypanAssembly 2 -3 55581 Armstack Installation V1433 1 55581XL Armstack Installation V1433XL 1 55659 Armstack Installation V1833 1 55659XL Armstack Installation V1833XL .1 4 55767 Platform Assembly 1 55646 Platform Assembly XL 1 5 55853 Lower Control Box Assembly 1 55853-XL Lower Control Box Assembly 1 -6 55837 Wiring Installation 2.

55847 Wiring Installation XL 2 7 55850 Uper Control Box Assembly 1 55851 Upper Control Box Assembly XL 1 -8 55888 Hose Kit 1 -9 67837-007 Tie, Nylon - 7 1/2" Black 10 -10 54783-001 Emergency Lowering Cable Assembly 1 -11

Hydraulic Oil Tellus T32 6GL. 12 55859 Left Side Cover Weldment 1 13 55864 Right Side Cover Weldment 1 14 54048 Latch Door 2 15 34354 Saftey Manual Holder - Black Caps.

1 -16 67793 Cable Clamp 2 -17 B OW31401 Washer Flat .25 ID x 63 OD

2 -18 BOW34272 Nut, Hex Lock 25-20UNC 2 -19 92377-001 Operators Manual V1433XL 1 -20 V630-V14/18 Operator/Service/Parts Manual 1 -21

Nameplate Scissor Indentification

1 -22 55892-001 Decal, Kit V1433 1 55892-002 Decal, Kit V1433XL 1 55892-003 Decal, Kit V1833 1 55892-004 Decal, Kit V1833XL 1 -23 55883 110 Volt Ext. To Platform Installation 1 -24 55843 Schematic, V Electrical 1 55844 Schematic, V XL Electrical 1 -25 55836 Schematic, V14/1833 Hydraulic 1 -26 55888-DWG Drawing, V14/18 Hose Installation 1 -27 55892-DWG Drawing, V14/18 Decal Installation 1 -28 55582-008 Pin, Arm V14/18 26 62"LG 2 -29 55598 Pad, Arm/Chassis Slide V14/18 2 -30 55577 Pad, Arm/Platform Slide V14/18 2 -31 55582-012 Pin, Arm V14/18 19 88"LG 2 -32 BOW30010 Bolt, Hex 25-20UNC x 2 500 4 -33 BOW31431 Washer, Flat .25 ID x .63 OD 4 -34 B OW34272 Nut, Nylon Lock 25-20UNC 4 .

- Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

.

.

10

FIGURE 1 .2: Final Installation

Note: Model V1833 Shown.

MANUAL 92377-003 March 1998 Revised 1/99

FIGURE 1.2: Final InstallationV1433XL S erial Numbers X11597066-X11597075 V1833XL Serial Numbers X21597162, X21597177-X21597506 HIM PARTNITIMER DESCRIPTION

QIY

Ref. M-V1433-02 Final Installation M-V1433-02 Ref. M-V1433XL-02 Final In.stallation M-V1433 XL-02 Ref. M-V1833-02 Final Installation M-V1833-02 Ref. M-V1833XL-02 Final Installation M-V1833 XL-02 Chassis Assembly 1 56242 BellypanAssembly 2 55669 3 55581 Arrmstack Installation M-V1433-2 55581XL Arm stack Installation M-V1433XL-2 55659 Arrmstack Installation M-V1833-2 55659XL Armstack Installation M-V1833XL-2 Platform Assembly V14/1833-2 4 55767 55646 Platform Assembly V14/1833XL-2 Lower Control Box Assembly 5 55853 55853XL Lower Control Box Assembly Wiring Installation -6 55837 55847 Wiring Installation Upper Control Box Assembly 7 55850 Upper Control Box Assembly 55851 Hose Kit -8 55888 -9 67837-007 Tie, Nylon - 7 1/2" Black

-10 54783-001 Emergency Lowering Cable Assembly Hydraulic Oil Tellus T32

-11 Left Side Cover Weldment 12 55859 13 55864 Right Side Cover Weldment 14 54048 Latch Door 15 34354 Saftey Manual Holder 16 67793 Cable Clamp 17 BOW31401 Washer Flat 25 ID x 63 OD 18 B OW34272 Nut, Hex Lock 25-20UNC -19 92377-001 Operators Manual -20 A630-14/18 Operator/Service/Parts Manual

Nameplate Scissor Indentification -21 -22 55892-001 Decal, Kit V1433 55892-002 Decal, Kit V1433XL 55892-003 Decal, Kit V1833 55892-004 Decal, Kit V1833XL -23 55843 Schematic, V Electrical 55844 Schematic, V XL Electrical Schematic, V14/1833 Hydraulic -24 55836 -25 55582-008 Pin, Arm -26 55598 Pad, Arm/Chassis Slide -27 55577 Pad, Arm/Chassis Slide -28 55582-012 Pin, Arm -29 BOW30010 Bolt, Hex 25-20 x 2 50 -30 B OW31431 Washer, Flat .25 ID x .63 OD -31 BOW34272 Nut, Nylon Lock 25-20UNC -32 55883 110 Volt Ext. To Platform Installation

Ref. Ref. Ref. Ref. 1 1 1 1 1 1 1 1 1 .1 2.

2 1 1 L 10 1 6GL. 1 1 2 1 2 2 2 1 1 1 1.

1 1 1 L 1 1 2 2 2 2 4 4 4 1

-Indicates Item Not Shown MANUAL 92377-003 March 1998 Revised1/99

.

6

.4 FIGURE 1 .3 : Final Installation

Note: Model V1833 Shown.

MANUAL 92377-003 March 1998 Revised 1/99

FIGURE 1.3 : Final InstallationV143M, SerialNumbers X11597076-Above v1833)(1, SerialNumbers X21598001-Above HEM PARTNUMBER DESCRIPTION

QTY

Ref. M-V1433-03 Final Installation Ref. Ref. M-V 1833-03 Final Installation Ref. 1 56242 Chassis Assembly 1 2 56272 BellypanAssembly; V14/18/XL-03 1 3 55581 Arrmstack Installation M-V1433-2 1 55659 Arrrnstack Installation M-V1833-2 1 4 55767 Platform Assembly 1 5 55853 Lower Control Box Assembly i -6 55837 Wiring Installation 2.

7 55850 Upper Control Box Assembly 1 -8 55888 Hose Kit L -9 67837-007 Tie, Nylon - 7 1/2" Black 10 10 54783-001 Emergency Lowering Cable Assembly 1 -11

Hydraulic Oil Tellus T32 6GL. 12 56266 Cover Weldment V14/18-03 LH Side 1 13 56267 Cover Weldment V14/18-03 RH Side 1 14 54048 Latch Door 2 15 34354 Saftey Manual Holder 1 -16 67793 Cable Clamp 2 -17 BOW31401 Washer Flat .25 ID x 63 OD 2 -18 B OW34272 Nut, Hex Lock 25-20UNC 2 -19 92374-001 Manual V14/1833/XL-03 Operator 1 -20 A630-14/18-3 Manual M-V14/1833/XL-03 O/M/P 1 -21 51340 Nameplate Scissor Indentification 1 -22 55892-001 Decal, Kit, V1433 1 55892-003 Decal, Kit, V1833 1 -23 55843 Schematic, V Electrical L -24 55836 Schematic, V14/1833 Hydraulic 1 -25 55888-DWG DWG ,V14/18 Hose Installation 1 -26 55892-DWG DWG, V14/18 Decal Installation 1 -27 55582-008 Pin - V14/18 26 62"LG Arm 2 -28 55598 Pad -V14/18 Arm/Chassis Slide 2 -29 55577 Pad - V14/18 Arm/Platform Slide 2 -30 55582-012 Pin - V14/18 19 88" LG Arm 2 -31 BOW30010 Bolt 25-20UNC x 2 500 HEX 4 -32 BOW31431 Washer - .25 ID x .63 OD Flat 4 -33 B OW34272 Nut - 25-20UNC Nylon Lock

4 -34 56275 DWG, V1433-03 Final Assembly 1 56276 DWG, V1833-03 Final Assembly 1

p; L

I

MANUAL 92377-003 March 1998 Revised1/99

o

FIGURE 1 .4: Decal Installation

0 0 ° 0 12 0 Q 0 * 0 ° 0 ° 0 * 0 0 0 0 0 0 0 0 0 0 . 0 . 0 . 0 0 0 . 0 00 0 0 00 0 0 0

0

0 0

0°0°0°.°0°0

rii

0

0 0

° 0°.°0

l

\

7

-1 1 I

.0 0 411•1131 . a A

APPLY TO CHASSIS

PARTIAL SECTION A APPLIES TO ALL MODELS

NOTES: MODEL V1833XL IS ILLUSTRATED, OTHER MODELS ARE SIMILAR_

MANUAL 92377-003 March 1998 Revised1/99

FIGURE 1 .4: Decal Installation ITEM PART NUMBER DESCRIPTION

QTY

Ref. *55892-104 Decal Kit, V1833XL Essential Ref. *55892-103 Decal Kit, V1833 Essential Ref. *55892-102 Decal Kit, V1433XL Essential Ref. *55892-101 Decal Kit, V1433 Essential Ref. *1 55890 Decal, V Upper Operator Instructions 1 55889 Decal, V XL Upper Operator Instructions 1 *2 55894 Decal, V General Caution ' 1 *3 54652-003 Decal, Guardrail/Chain Caution 1 *4 55963-600 Decal, 250/600 lbs. Rated Load V1433/XL-1 -3 2 55963-500 Decal, 250/500 lbs Rated Work Load V1833/XL-1 -3 2 55944-600 Decal, 250/600 lbs. Rated Work Load V1433/XL-2: 2 55944-500 Decal, 250/500 lbs. Rated Work Load V1833/XL-2 2 *5 55944 Decal, 250 RWL on EXT I *6 55877-003 Decal, V14/18 Lower Operating Instructions 1 *7 55877-001 Decal, V14/18 Lower Controls 1 *8 55877-002 Decal, V14/18 Stop/Fuse 1 *9 54652-002 Decal, Arm Stand Caution 1 *10 54984-005 Decal, Rear Bumper 1 *11 55882 Decal, Electrocution Hazard 2 *12 55871-001 Decal, V14/18 Upper Electrical Box Top 1 55856-001 Decal, V XL Upper Control Box Top 1 * 13 55871-002 Decal, V14/18 Upper Electrical Box Front 1 55856-002 Decal, V XL Upper Control Box 1 14 54984-007 Decal, Hydraulic Fluid 1 15 55940-023 Decal, CONDOR 3.45 x 23 2 16 55935 Decal, V1433XL

2 55936 Decal, V1833XL 2 17 55941-017 Decal, Condor Bird 2.

18 53259 Tape, Non-Skid Jet Black 1 5OLF 19 66921 Coating, Non-Skid Jet Black 25GL 20 55892-DWG Dwg. V1418 Decal Installation 1 21 54984-006 Decal, 110 Volt Extension To Platform V14/18XL 1 31

Nameplate Scissors Identification

- Indicates Items Not Shown Indicates Included In Essential Decals

2 1/4 MARGIN — NO NON—SLIP COATING

PLANVIEW OF

MODELS V1433 & V1833

MANUAL 92377-003 March 1998 Revised1/99

PARTIAL REAR VIEW OF MODELS V1433 & V1833

Ref.

FIGURE2.1. Carriage Assembly

RIGHT

LEFT

REF

2 PL-REF SEE NOTE 2 • It,

SEE NOTE 3

SEE NOTE 1

4 PL 2 PL

2 PL

2 PL

2 PL I2FL

10 PL

2 PL

4 PL

2 PL REF

TOP VIEW OF RH CHASSIS FRONT

2 PL — INCLUDES NUT 54644-104

3 PL

NOTE: 1. BRAKE RELEASE HANDLES (ITEM 24) MUST SWING FREELY. DO NOT TIGHTEN ITEMS 26, 27, & 28 ANY MORE THAN SNUG FIT (2 PL).

2. SPINDLE ASSY INCLUDES SPINDLE, CASTLE NUT & COTTER PIN. SPINDLE ASSY IS PART OF CHASSIS WLDMNT. 3. EACH HUB ASSY INCLUDES FIVE LUG NUTS.

MANUAL 92377-003 March 1998 Revised1/99

FIGURE 2.1: Carriage Assembly V1433XL SerialNumbers X11597050-X11597065 V1833XLSerialNumbersX21567134,X21597001-X21597283 ITEM PART NUMBER DESCRIPTION

QTY

Ref. 55817 Chassis Assembly V14/1833-1 Ref. 1 55709 Chassis Weldment, V14/1833 1 2 81368-05-20 Gar-Max Bushing 2 3 34145 Bearing, 1.50 ID x 1.50 L x 1/8" W 4 4 55792 Knuckle Weldment, V14/18 LH Steer 1 5 55793 Knuckle Weldment, V14/18 RI-I Steer 1 6 55798 Washer, V1433 Kingpin Thrust 2 7 55812 Retainer, V14/18 Kingpin 2 8 BOW39054 Hex, Hd. Bolt /8'- 1 6 x 1 GR8 2 9 54644-001 Motor, -11 9 20/2633 Hydraulic Wheel 2 10 BOW30109 Bolt, Hex 50-13UNC x 2 25 8 11 BOW36605 Nut, 1/2"-13UNC 8 12 55302 Drive Hub, 1 25 Taper w/Studs 2 13 02593 Tee

2 14 55576 Cylinder, V1433 2" Dia. x 5 31 Steer 1 15 02236 Elbow 90° M004 MJ04 6 16 54035 Pin, Steering Cylinder 23/16" 2 17 BOW31438 Washer, Flat 3/4" SAE Thick 3 18 BOW38320 Pin, Cotter 125 Dia. x 1 25 4 19 55815 Link, V1433 Steering 1 20 81368-01-08 Bearing, 75 ID x 1 13 R x 88 Stroke 2 21 BOW36708 Washer, Flat 750 ID x 1 00 OD x 50 LG 4 22 54714 Cylinder, 1 75B x 1 13R x 88 Stroke 2 23 BOW30059 Bolt, Hex .38-16UNC x 2.250 GR5 2 24 54796-001 Pin, - 9 3/8" Lg .2 25 BOW36063 Bolt, 38-16UNC x 3.25 Hex 2 26 BOW36703 Washer, 37ID, 810D Gr8 SAE Flat 4 27 BOW34274 Nut, 3/8-16 UNC Hex Lock 1 28 56221 .Hub Assy - V14/18-02 Rear 2 29 55861 Swivel, 90 MJ06 M006 4 30 55860-001 Adapter, 0.625" Lg M010 F006 1 31 55860-002 Adapter, 1 25" LG M010 F006 1 32 55860-003 Adapter, 1.875" Lg M010 F006 1 33 55860-004 Adapter, 2 500" Lg M010 F006 1 34 55816 Tire & Wheel (Assy) V14/18 4 35 91029 Nut, 50-201.JNF (R#30288) Wheel 10 36 02593 Tee MJ04 MJ04 M004 2 37 56197 Insert - Stud 10 38 55813-DWG 14/18 Rear Hub Assy Dwg 1 39 55817-DWG Dwg, Chassis Assy V14/18 1

MANUAL 92377-003 March 1998 Revised1/99

FIGURE2.1: Carriage Assembly TOP VIEW OF 'REAR AXLE

RIGHT

LEFT

REF 2 FL-REF SEE NOTE 2

a

,

1

iUj

2 PL - INCLUDES LUG BOLTS

0'2 PL SEE NOTE 1

000

2 PL

2 PL

2 PL - INCLUDES NUT 54644-104

4 PL

3 PL 2 PL

REF NOTE:

TOP VIEW OF RH CHASSIS FRONT

1. BRAKE RELEASE HANDLES (ITEM 24) MUST SWING FREELY. DO NOT TIGHTEN ITEMS 26. 27, & 28 ANY MORE THAN SNUG FIT (2 FL).

2. SPINDLE ASSY INCLUDES SPINDLE, CASTLE NUT & COTTER PIN. SPINDLE ASSY IS PART OF CHASSIS WLDMN T. 3. EACH HUB ASSY INCLUDES FIVE LUG NUTS.

MANUAL 92377-003 March 1998 Revised 1/99

FIGURE 2.1: CarriageAssembiy V1433XL SerialNumbers X11597066-X11597065 V1833XL SerialNumbers X21597162,X21597177-X21597506 ITEM PART NUMBER DESCRIPTION

Chassis Assembly V14/1833/XL-2 Ref. 56242 1 55709 Chassis Weldment, V14/1833 2 81368-05-20 Gar-Max Bushing ' 3 34145 Bearing, 1 50 ID x 1 50 L x 1/8" W Knuckle Weldment, V14/18 LH Steer 4 55792 5 55793 Knuckle Weldment, V14/18 RH Steer 6 55798 Washer, V1433 Kingpin Thrust 7 55812 Retainer, V14/18 Kingpin 8 BOW39054 Hex, Hd. Bolt V8"-16 x 1 GR8 9 54644-001 Motor, 11 9 20/2633 Hyd Wheel 10 BOW30109 Bolt, Hex .50-13UNC x 2.25 11 BOW36605 Nut, 1/2" -13 UNC 12 55302 Drive Hub, 1 25 Taper w/Studs 13 02593 Tee, MJ04 MJ04 M004 14 55576 Cylinder, V1433 2" Dia. x 5 31 Steer 15 02236 Elbow 90° M004 MJ04 16 54035 Pin, Steering Cylinder 2 3 /16" 17 BOW31438 Washer, Flat .75 x 1 500D Gr 5 SAE Flat 18 BOW38320 Pin, Cotter 125 Dia x 1 25 Link, V1433 Steering 19 55815 20 81368-01-08 Bearing, .75 ID x 1 13 R x .88 Stroke 21 BOW36708 Washer, Flat .750 ID 22 54714 Cylinder, 1 75B x 1 13R x 88 Stroke 23 BOW30059 Bolt, Hex 38-16UNC x 2 250 GR5 24 54795 Handle Weldment, Bdrake Release 25 54796 Brake Pin

26 BOW36063 Bolt, Hex .38 - 16UNC x 3.25 27 BOW36703 Washer Flat ; 37 ID x 81 OD Gr8 SAE 28 BOW34274 Nut, Hex Lock .38 0 16UNC 29 56221 Hub Assembly, V14/18 Rear 30 55861 Swivel, 90° MJ06 M006 31 55860-001 Adapter, M010 F006 .625 32 55860-002 Adapter, M010 F006 1.25 33 55860-003 Adapter, M010 F006 1.875 34 55860-004 Adapter, M010 F006 2.5

35 55816 Tire & Wheel V14/18 36 91029 Lugnut, 1/2"-20UNF 81 Hex .62111 -37 56197-DWG DWG, Rear Hub Assembly -38 56242-DWG DWG, Chassis Assembly 51 55925

Spindle Assembly, VV14/18

- Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

QTY

Ref. 1 2.

4 1 1 2 2 2 2 8 8 2 2 1 6 2 3 4 1 2 4 2 2 2 2.

2 8 8 2 4 1 1 1 1 4 10 1 1 .

2

FIGURE 2. 1 : Chassis Assembly

,57

RIGHT

TOP VIEW OF REAR AXLE

LEFT

2 PL—REF SEE NOTE 2

2 PL — INCLUDES LUG BOLTS

4 PL

2 PL — INCLUDES NUT 54644 - 104

4 PL

2 Pt

REF NOTE:

TOP VIEW OF RH CHASSIS FRONT

1, BRAKE RELEASE HANDLES (ITEM 24) MUST SWING FREELY, DO NOT TIGHTEN ITEMS 26, 27, & 28 ANY MORE THAN SNUG FIT (2 PL).

2, SPINDLE ASSY INCLUDES SPINDLE, CASTLE NUT (Sc. COTTER PIN. SPINDLE ASSY IS PART OF CHASSIS WLDMNT. 3. EACH HUB ASSY INCLUDES FIVE LUG BOLTS.

MANUAL 92377-003 March 1998 Revised1/99

FIGURE 2.1: Chassis Assembly V1433 XL SerialNumbers X11597076-Above vi 833XL SerialNumbers X21598001-Above ITEM PART NUMBER DESCRIPTION

QTY

Ref. 56242 Chassis Assembly V14/1833-03 Ref. 1 55709 Chassis Weldment, V14/1833 1 2 81368-05-20 Gar-Max Bushing 2 3 34145 Bearing, 1.50 ID x 1.50 L x 118" W 4 4 55792 Knuckle Weldment, V14/18 LH Steer 1 5 55793 Knuckle Weldment, V14/18 RH Steer 1 6 55798 Washer, V1433 Kingpin Thrust 2 7 55812 Retainer, V14/18 Kingpin

2 8 BOW39054 Hex, Hd. Bolt 3/8"- 16 x 1 GR8 2 9 54644-001 Motor, 11 9 20/2633 Hyd Wheel 2 10 BOW30109 Bolt, Hex 50-13UNC x 2 25 8 11 BOW36605 Nut, 1/2"-13UNC

8 12 55302 Drive Hub, 1.25 Taper w/Studs 2 13 02593 Tee, MJ04 MJ04 M004 2 14 55576 Cylinder, V1433 2" Dia. x 5 31 Steer 1 15 02236 Elbow 90° M004 MJ04

6 16 54035 Pin, Steering Cylinder 2 3 46" 2 17 BOW31438 Washer, Flat .75 x 1 500D Gr 5 SAE Flat 3 18 BOW38320 Pin, Cotter 125 Dia. x 1.25 4 19 55815 Link, V1433 Steering 1 20 81368-01-08 Bearing, .75 3 21 BOW36708 Washer, Flat .750 ID 4 22 54714 Cylinder, 1 75B x 1 13R x 88 Stroke 2 23 BOW30059 Bolt, Hex 38-16UNC x 2 250 GR5 2 24 54795 .Handle Weldment, Bdrake Release 2 25 54796 Brake Pin 2 26 BOW36063 Bolt, Hex .38 - 16UNC x 3.25 2 27 BOW36703 Washer Flat ; .37 ID x 81 OD Gr8 SAE 8 28 BOW34274 Nut, Hex Lock 38 0 16UNC 8 29 56221 .Hub Assembly, V14/18 Rear 2 30 55861 Swivel, 90° MJ06 M006 4 31 55860-001 Adapter, M010 F006 .625 1 32 55860-002 Adapter, M010 F006 1.25 1 33 55860-003 Adapter, M010 F006 1.875 1 34 55860-004 Adapter, M010 F006 2.5 1 35 55816 Tire & Wheel V14/18 4 36 91029 Lugnut, 1/2"-20UNF .81 Hex .62 HI 10 -37 56221-DWG DWG, Rear Hub Assembly 1 -38 56242-DWG DWG, Chassis Assembly 1 -39 BOW30055 Bolt 38-16UNC x 1 25" HEX 2 -40 BOW30057 Bolt 38-16UNC x 1 75 HEX 2 51 55925

Spindle Assembly, VV14/18

- Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revisateiettthl1St9)98

2

FIGURE 2.2,: Steer Cylinder

0 CM,

AIL AirArtmearivireimmowArwArAwArAmmilmtiminreN \

ITEM PART NUMBER DESCRIPTION

Ref. 55576 Cylinder, Steer V14/1833 -1 55111-100 Seal Kit 2 55111-101 Lock Nut 3 55576 Piston (Aluminum) 4 5 55576-102 Piston Rod , 6 55111-105 Gland Nut 7 B OW32287 Nut, Hex Jam 5/8"-18UNC 8 55111-106 Clevis Weldment - Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised 1/99

QTY

Ref. 1 2.

1 L. 1.

1 1

FIGURE 2.3 : Brake Cylinder

0 00

7/16-20 0—RING PORT TYP

o no

1•111111111111•11111M111,

PArrorrimmirmorsiawAmorAritrimpOpreepo .0" cUttfil

nn

••••..

1id 111 111 64 04* BMW

3.06 10.18 EXTENDED 9.31 RETRACTED

ITEM PART NUMBER DESCRIPTION

QTY

Ref. 54714 Cylinder, 1.75B x 1.13R x .88 Stroke Ref. 54714-100 Seal Kit 1 1 54714-101 Jacket Assembly 1 2 54714-102 Piston Rod 1 3 54714-103 Spring 1 4

Teflon Backup (Included in Seal Kit 54714-100) 1 5

Polypak (Included in Seal Kit 54714-100) 1 6 54714-104 Piston (Alum) 1 7

()Ring (Included in Seal Kit 54714-100) 1 8

Polypak (Type V) (Included in Seal Kit 54714-100) 1 9

Offing (Included in Seal Kit 54714-100) 1 10 54714-105 Gland Nut 1 11

Rod Wiper (Included in Seal Kit 54714-100) 1 - Indicates Items Not Shown MANUAL 92377-003 March 1998 Revised1/99

.

.

FIGURE 2.4: Hub AssemblyV1433XL SerialNumbers X11597066-X11597075 V1833XL, Serial Numbers X21597162, X21597177-X21597506

Drawing Not Availaible at this Time.

ITEM PART NUMBER DESCRIPTION

Ref. 55813 Hub Assy, V14/18-02 Rear 1 55813-101 Inner Cup 2 55813-102 Inner Cone 3 55813-103 Outer Cup 4 55813-104 Outer Cone 5 55813-105 Dust Cap 6 55813-106 Seal 7 56221-101 Lug Bolt, 1/2 - 20UNF 8 56221-102 Hub, Cupped & Studded - Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

QTY

Ref. 1 1 1 1 1 1 6

.

.

.

.

FIGURE 2.4: Hub AssemblyV1433XL SerialNumbers X11597076-Above VI 833XL SerialNumbersX21598001-Above

5 PL

ITEM PART NUMBER DESCRIPTION

Ref. 55302 .Hub Assembly -03 1 289-00003-00 Hub, 1 25 Taper Wheel 2 55363-001 Stud, Wheel 1/2-20 x 1 3/4 - Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised 1/99

QTY

Ref. 1.

5

FIGURE 2.5 : Hub Motor Assembly 10

ITEM PART NUMBER DESCRIPTION

QTY

Ref. 54644-001 Motor, 11.9 Hydraulic Wheel Ref. 1 54644-100 Seal Kit For Wheel Motor 1 2 54644-101 Housing, Bearing 1 3 54644-102 Shaft & Bearing Kit (1 1/4 in Tapered) 4 4 54644-103 Key (For Tapered Shaft) 1 5 54644-104 Nut, Hex ( For Tapered Shaft) 1 6 54644-105 Plate, Wear 1.

7 54644-106 Drive 1 8 54644-107 Geroler 1 9 54644-108 Drive, Valve

1.

10 54644-109 Plate Valve 1.

11 54644-110 Valve 1 12 54644-111 Balance Ring 1.

13 54644-112 Pin 2 14 54644-113 Spring 2 15 54644-114 Bolt 4 16 54644-115 Housing, Valve (7/8-14 Staggered Ports) 1 17 54644-116 Plug Assembly 7/16-20UNF 1 - Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

FIGURE2.6: RearHub Assembly ITEM PART NUMBER DESCRIPTION

Rear Hub Assembly Ref. 56221 - 1 56221-102 Hub, Cupped & Studded -2 56221-101 Lug Bolt, 1/2-201.JNF -3 55813-106 Seal -4 55813-105 Dust Cap -5 55813-104 Outer Cone -6 55813-103 Outer Cup

-7 55813-102 Inner Cone -8 55813-101 Inner Cup

- Indicates Items Not Shown Drawing Not Available At This Time

MANUAL 92377-003 March 1998 Revised1/99

QTY

Ref. 1.

5.

L. 1.

1.

1

AI gluossV Poil.M. 2S, al!' :L *Z affl-DIA

SPECIFICATIONS: 14" OVERALL DIAMETER 4,5" NOMINAL OVERALL WIDTH •-•

TIRE IS MOLDED—ON WHEEL 80 DUROMETER "SCISSOR'S COMPOUND" 5 HOLES FOR LUGNUTS, EQUALLY SPACED ON 4.5 DIA B.C. 21 lbs. ACTUAL TOTAL WEIGHT

sr

.09" OFFSET MOUNTING SURFACE IS INBOARD CENTERLINE TIRE

UNLESS OTHERWISE NOTED:

DIVISION OF TIME MFG. CO .

8300 IMPERIAL DRIVE WACO, TEXAS 76712

TOLERANCES: DECIMALS FRACTIONS ± 1/16 .X ± .1 ANGLES ± 1' . XX ± .03 . XXX ± .010 TITLE SURFACE FINISH "V PROJECTION OF VIEWS © C:j

WHEEL, V14/18 TIRE &

ALL DIMENSIONS ARE IN INCHES LOW

D.C. N. NO.

DATE

APPR.

LTR.

D.R.N. NO.

DRAWN CHECKED

10160 DATE

APPR,

APPROVED

A. HITTLE

12/20/ 96

SIZE

A SCALE

DRAWING NO.

1:1

REV.

55816 SHEET 1

OF 1

This page intentionally left blank

MANUAL 92377-003 March 1998 Revised1/99

FIGURE 3 . 1 : Hose Installation

LEFT

FRONT AXLE DRIVE MOTORS

RIGH T

L

AO

VALVE ASSY SIDE VIEW

0

d

_J

H-

U-

• SEE NOTE 1

BRAKE CYLS REAR AXLE NOTES: 1. TAG EACH HOSE ASSEMBLY WITH PART NUMBER.

MANUAL 92377-003 March 1998 Revised1/99

7 0

BOTTOM VIEW OF VALVE ASSY

FIGURE 3.1: Hose InstallationV1433XL SerialNumbersX11597050-X11597065 V1833 SerialNumbersX21567134,X21597001-X21597283 ITEM PART NUMBER DESCRIPTION Ref. 55888 Hose Kit V14/1833-01 1 66702-025.00 Hose Assembly, #10 66137 J37 ST-ST 2 66698-026.00 Hose Assembly, #06 66645 J37 ST-ST 3 66698-029.00 Hose Assembly, #06 66645 J37 ST-ST 4 66696-030.00 Hose Assembly, #04 66646 J37 ST-ST 5 66696-030.00 Hose Assembly, #04 66646 J37 ST-ST 6 66759-030.00 Hose Assembly, #04 66646 J37 ST-SIT 7 66759-028.00 Hose Assembly, #04 66646 J37 ST-STJ 8 66759-027.00 Hose Assembly, #04 66646 J37 ST-STJ 9 66759-029.00 Hose Assembly, #04 66646 J37 ST-STJ 10 66696-102.00 Hose Assembly, #04 66646 137 ST-ST 11 66043-120.00 Hose Assembly, #03 67684 137 STJ-STJ 12 66697-016.00 Hose Assembly, #08 66675 J37 ST-ST 13 66043-050.00 Hose Assembly, #03 67684 J37 STJ-STJ 14 66043-019.00 Hose Assembly, #03 67684 J37 STJ-STJ 15 66043-017.50 Hose Assembly, #03 67684 137 STJ-STJ 16 66043-018.25 Hose Assembly, #03 67684 J37 STJ-STJ - Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

QTY Ref. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

FIGURE3.1:HoseInstallation

LEFT

RICHT

FRONT AXLE DRIVE MOTORS

O 0

cto

7 VALVE ASSY SIDE VIEW

SEE NOTE 5 -

BRAKE CYLS REAR AXLE

MANUAL 92377-003 March 1998 Revised1/99

BOTTOM VIEW OF VALVE ASSY

FIGURE3.1: Hose Installation V1433XL S erial Numbers X11597066-X11597075 • V1833XL Serial Numbers X21597162,X21597177-X21597506 ITEM PART NUMBER DESCRIPTION QTY Hose Kit V14/1833-02 Ref. 55888 1 66702-025.00 Hose Assembly, #10 66137 J37 ST-ST 2 66698-026.00 Hose Assembly, #06 66645 J37 ST-ST 3 66698-029.00 Hose Assembly, #06 66645 J37 ST-ST 4 66696-030.00 Hose Assembly, #04 66646 J37 ST-ST 5 66696-030.00 Hose Assembly, #04 66646 J37 ST-ST 6 66759-030.00 Hose Assembly, #04 66646 J37 ST-STJ 7 66759-028.00 Hose Assembly, #04 66646 J37 ST-STJ 8 66759-027.00 Hose Assembly, #04 66646 J37 ST-STJ 9 66759-029.00 Hose Assembly, #04 66646 J37 ST-STJ 10 66696-096.00 Hose Assembly, #04 66646 J37 ST-ST 11 66043-120.00 Hose Assembly, #03 67684 J37 STJ-STJ 12 66697-020.00 Hose Assembly, #08 66675 J37 ST-ST 13 66043-050.00 Hose Assembly, #03 67684 137 STJ-STJ 14 66043-017.50 Hose Assembly, #03 67684 J37 STJ-STJ 15 66043-014.00 Hose Assembly, #03 67684 J37 STJ-STJ 16 66043-014.00 Hose Assembly, #03 67684 J37 STJ-STJ - Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

Ref. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

34

FIGURE3.1: Hose Installation

FRONT AXLE DRIVE MOTORS

LEFT

RICHT

/- BOTTOM VIEW OF VALVE ASSY

VALVE ASSY SIDE VIEW

t-133K,

HYD TANK

SEE NOTE 5

-

BRAKE CYLS REAR AXLE

MANUAL 92377-003 March 1998 Revised1/99

FIGURE3 .1 : Hose Installation V1433XL Serial Numb ers X11597076-Above vi 833XL SerialNumbers X21598001-Above ITEM PART NUMBER DESCRIPTION

QTY

Ref. 55888 Bose Kit V14/1833-03 Ref. 1 66702-025.00 Hose Assembly, #10 66137 J37 ST-ST 1 2 66698-026.00 Hose Assembly, #06 66645 J37 ST-ST .1 3 66698-029.00 Hose Assembly, #06 66645 J37 ST-ST 1 4 66696-030.00 Hose Assembly, #04 66646 J37 ST-ST 1 5 66696-030.00 Hose Assembly, #04 66646 J37 ST-ST. 1 6 66759-030.00 Hose Assembly, #04 66646 J37 ST-STJ 1 7 66759-028.00 Hose Assembly, #04 66646 J37 ST-STJ 1 8 66759-027.00 Hose Assembly, #04 66646 J37 ST-STJ. 1 9 66759-029.00 Hose Assembly, #04 66646 J37 ST-STJ 1 10 66696-096.00 Hose Assembly, #04 66646 J37 ST-ST 1 11 66043-120.00 Hose Assembly, #03 67684 J37 STJ-STJ _1 12 66697-020.00 Hose Assembly, #08 66675 J37 ST-ST 1 13 66043-050.00 Hose Assembly, #03 67684 J37 STJ-STJ 1 14 66043-017.50 Hose Assembly, #03 67684 J37 STJ-STJ 1 15 66043-014.00 Hose Assembly, #03 67684 J37 STJ-STJ 1 16 66043-014.00 Hose Assembly, #03 67684 J37 STJ-STJ 1 - Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

e,

FIGURE4.1:BellyPanAssembly

4 PL

©Q2

© z GROUND STUD

2 PL

,

©

8 PL

NOTES: 1. ITEMS 1 & 2 NOT ILLUSTRATED.

MANUAL 92377-003 March 1998 Revised 1/99

FIGURE4.1:BellyPan Assembly V1433XL SerialNumbersX11597050-X11597065 V1833 SerialNumbersX21567134,X21597001-X21597283 ITEM PART NUMBER DESCRIPTION Ref. 55669 Belly Pan Assembly V14/1833/XL-01 -1 55651 Belly Pan Weldment, V14/1833 & XL -2 55897 Cable Kit, V1433 3 55656 Tank Weldment, V1433 Hydraulic 4 50316 .Filler Cap Assembly & Lens Oil 5 52049 Gauge, Fluid Level 6 02407 Tee MJ04 MPO4 7 02674 Elbow 90° MJ10 MP12

8 33430 .Filter 9 00324 Elbow 90° MJ08 MP12 10 BOW30003 Bolt, Hex .25-2OUNC x .875 11 BOW31401 Washer, Flat .25 ID x .63 OD 12 55920 Tube, Filter To Tank Return 13 54989 .Motor/Pump Assembly V1433

14 02662 Elbow 90° MJ06 M006 15 04047 Elbow 90° MJ10 M008 16 55840 Valve Installation 17 55901 Charger Mod, V14/1833 115V/25A 18 52138 Solenoid 24V 19 55334 Jumper, 12 LG Wire 20 52627 Battery, 6V Trojan T-125 Wt. 21 BOW30027 Bolt, Hex 31-18UNC x 75 22 B OW31433 Washer, Flat 3 /8 " SAE

23 BOW34274 Nut, Hex Lock 3/8"-16UNC 24 BOW30029 Bolt, Hex 31-UNC x 1 00 25 BOW31432 Washer, Flat .31 ID x .68 OD 26 BOW34273 Nut, Lock Hex 5/16"-18UNC 27 BOW30003 Bolt, Hex 25-20UNC x 88 28 BOW31401 Washer, Flat .25 ID x .63 OD 29 BOW36780 Nut, Hex Lock 25-20UNC -30 02475 Elbow 90° MJ08 MPO8 -31 55669-DWG DWG, Bellypan Assembly V14/18

- Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

QTY Ref. 1 1 1 1 1 1 1.

1 3 2 2 1 .1 2 1.

1 1 1.

1 4 2 L 1 4 10 4 2 8 6 L 1

FIGURE4.1:BellyPanAssembly

17 2323 2 PL

2D) 4 PL

Ld NI

0 c

2 PL 27

>

2 PL

c.1

<

< cL

I

GROUND STUD

1

2 PL

PL

2

8 PL

NOTES: 1. ITEMS 1 &.: 2 NOT ILLUSTRATED.

MANUAL 92377-003 March 1998 Revised 1/99

FIGURE 4. 1 :B elly Pan Assembly V1433XL SerialNumbersX11597066-X11597075 V1833XL SerialNumbersX21597162,X21597177-X21597506

ITEM PART NUMBER DESCRIPTION

QTY

Ref. 55669 Belly Pan Assembly V14/1833/XL-02 -1 55651 Belly Pan Weldment, V14/1833 & XL -2 55897 Cable Kit, V1433 3 55656 Tank Weldment, V1433 Hydraulic 4 50316 .Filler Cap Assembly & Lens Oil 5 52049 Gauge, Fluid Level 6 02407 Tee MJ04 MPO4 Elbow 90° MJ10 MP12 7 02674 8 33430 Filter 110-2 Filter Head, Return Line 110-1 Element, Filter 9 00324 Elbow 90° MJ08 MP12 10 BOW30003 Bolt, Hex 25-20UNC x .875 11 BOW31401 Washer, Flat .25 ID x .63 OD 12 55920 Tube, Filter To Tank Return 13 54989 .Motor/Pump Assembly V1433 14 02662 Elbow 90° MJ06 M006 15 04047 Elbow 90° MJ10 M008 16 55840 Valve Installation 17 55901 Charger Mod, V14/1833 115V/25A 18 52138 Solenoid 24V - 19 55334 Jumper, 12 LG Wire 20 52627 Battery, 6V Trojan T-125 Wt. 21 02475 Elbow, 90° MJ08 MPO8 22 BOW34272 Nut, Hex Lock 25-20UNC 23 BOW31401 Washer, Flat .25 ID x .63 OD 24 BOW30029 Bolt, Hex .31-UNC x 1.00 25 BOW31432 Washer, Flat .31 ID x .68 OD 26 BOW34273 Nut, Lock Hex 5/16"-18UNC 27 BOW30003 Bolt, Hex 25-20UNC x 88

Ref. 1 1 1 1 1 .1.

1.

1 1_ 1.

2 2 2 1 1 2 1 1 1 1.

1 4 I_ 7 7 7 16 4 2

- Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

39

40

FIGURE4.1:BellyPanAssembly

GROUND STUD

8 PL

DO

0

(e_

DO

NOTES:

1. ITEMS 1 & 2 NOT ILLUSTRATED.

MANUAL 92377-003 March 1998 Revised1/99

0

FIGURE4.1:BellyPanAssembly V1433XL Serial Numbers X11597076-Above V1833XL SerialNumbersX21598001-Above

ITEM PART NUMBER DESCRIPTION Ref. 55669 Belly Pan Assembly V14/1833/XL-03 -1 56264 Belly Pan Weldment, V14/1833 & XL -2 55897 Cable Kit, V1433 3 55656 Tank Weldment, V14/1833 Hydraulic 4 50316 Filler Cap Assembly & Lens Oil 5 52049 Gauge, Fluid Level 6 02407 Tee MJ04 MPO4 7 02674 Elbow 90° MJ10 MP12 8 33430 .FilterAssembly 110-2 Filter Head, Return Line 110-1 Element, Filter 9 00324 Elbow 90° MJ08 MP12 10 BOW30003 Bolt, Hex 25-20UNC x 875 11 BOW31401 Washer, Flat .25 ID x .63 OD 12 55920 Tube, Filter To Tank Return 13 54989 .Motor/Pump Assembly V1433 14 02662 Elbow 90° MJ06 M006 15 04047 Elbow 90° MJ10 M008 16 55840 Valve Installation See Figure 4.7 17 55901 Charger Mod, V14/1833 115V/25A 18 52138 Solenoid 24V 19 55334 Jumper, 12 LG Wire 20 52627 Battery, 6V Trojan T-125 Wt. 21 BOW30027 Bolt 31-18UNC x 75 Hex 22 BOW31433 Washer 38 810D SAE GR 5 Flat 23 BOW34274 Nut-3/8-16 UNC Hex Lock 24 BOW30029 Bolt, Hex 31-UNC x 1.00 25 BOW31432 Washer, Flat 31 ID x .68 OD 26 BOW34273 Nut, Lock Hex 5/16"-18UNC 27 BOW30003 Bolt, Hex 25-20UNC x 88 -28 BOW31401 Washer- .25 ID x .63 OD Flat -29 BOW34272 Nut- 25-20UNC Nylon Lock -30 02475 Elbow 90 MJ08 MPO8 -31 56272-DWG Belly Pan Assembly DWG V14/18XL-03 - Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

QTY .Ref. 1 1 1 1 1 1.

1 1 1 1, 2 2 2 1 1 2 1 1 1 1 1 4 2 1 1 7 16 4 2 8 6 1 1

FIGURE 4.2: Cable Kit

GROUND STUD

• SOd

NVP0E1

CID

•

TROJAN WI

125 OS

03N NEC

SOd

•

• 10 TROJAN

11X0

•

Nvroui

•

era"

Ayr

\‘.

ON

1 25

WI

ell POS

MANUAL 92377-003 March 1998 Revised1/99

FIGURE4.2: CableKit ITEM PART NUMBER DESCRIPTION Ref. 55897 Cable Kit 1 54247-024.00 Cable Assembly 24" Battery 2 54247-007.00 Cable Assembly 7" Battery 3 54247-046.00 Cable Assembly 46" Battery 4 54247-021.00 Cable Assembly 21" Battery 5 54247-015.00 Cable Assembly 15" Battery - Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

QTY Ref. 1 2 2 1 1

FIGURE 4.3 : Motor & Pump Assembly

000000000 080808080 0 00 00 0 0 00 00 000000000 080808080

0 0 0 0 0

ITEM PART NUMBER DESCRIPTION

Ref. 54989 Motor/Pump Assembly 1 54761 Duplex Pump & Parts 2 BOW30029 Bolt, 31-18UNC x 1.00 3

Tag Nails 4 BOW31444 Washer, 5/16 Flat 5 54759 Motor, 24 Volt

6 54989-100 Gasket, Pump/Motor 7 54760 Coupling 8

Identification Plate - Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

QTY

Ref. 1 4 4 1.

1 1

FIGURE 4.4: Pump Parts SECTION A—A

HYDRAULIC SCHEMATIC

ITEM PART NUMBER DESCRIPTION

QTY

Ref. 54761 Pump Parts 1 54761-101 Idler Shaft 2 54761-102 Needle Bearing 3 54761-103 Gear Housing 4 54761-104 Gear Housing 5 54761-105 Stator 6 54761-106 Screw 7 54761-107 375 Gear Face 8 54761-108 Drive Pin 9 54761-109 Shear Pin 10 54761-110 Creascent Ring 11 54761-111 Woodruff Key 12 54761-112 Drive Shaft 13 * Oil Seal 14 * Gasket 15 * Gasket 16 * Plastic Plug 17 * Plastic Plug 18 * Lee Plug 19 54761-100 Seal Kit (indicated by*)

.Ref. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1.

1.

L 1

- Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

.

.

.

.

.

.

46

FIGURE 4. 5 : Motor 24VD C Assembly

000

V Aer yearo, 4011110:

16111

/1/ L. 16. 11,

1111■10■11.13111011, W11131,

000

:70 ....

6,47 1.

\"Tracmokg

11 111■2 1%1

II -FYN 4:10

NAMEPLATE

,•

/PA /111 /II AI

MANUAL 92377-003 March 1998 Revised 1/99

11

FIGURE 4.5 : Motor 24VDC Assembly ITEM PART NUMBER DESCRIPTION

QTY

Ref. 54759 Motor, 24VDC Assembly Complete Stator Assembly

1 Complete Terminal Assembly 2 NS S

Screw Hex FLD Cap 3 /8 "- 16 3 Jam Nut, Hex 3/8"-16 4

Jam Nut, Hex 3 /8" —16

5

Insulator 6 7 Insulator

Lock Washer, Split 3/8" 8 Lock Washer, Ext. TTH 3/8"

9 Field Coil Assembly 10

Field Pole 11

Screw, BTTN 1-ID Socket, /8 -16 x 5/8" 12 13 Field Coil Terminal

Loctite,222 14

Pulley Cover

15

Screw, Socket HD #10-32 xl 00" 16

17 54759-117 Complete Armature Assembly 18 54759-118 Fan

19 54759-119 Bearing, Pulley 20 54759-120 Bearing, Comm Complete Comm Cover Assembly 21

22 54759-122 Complete Brush Ring Assembly 23 54759-123 Brush Spring 24 54759-124 Brush Assembly Screw, RH Slotted #10-32 x 3/4" 25

26 Nut, Hex 410-32

Washer Bearing Spring 27

28 Screw, Hex HD #10-32 x 2 00"

29 54759-129 Brush Inspection Cover 30 Screw, PH HD #10-32 x 1- 3/4"

31 Nut, Square #10-32

32

Insulator Screw, RH Slotted 1/4"-20 x 3/8" 33

34 Lock Washer, Ext. TTH 1/411

Coupling Assembly 35 54760

.Ref. 1 2 2 2 2 4 2.

2 4 1 4 8 1

NSS - Not Sold Separately - Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

1 4 1 .1 1 1.

1 1 8

.

2.

4 4 L 4 1 .1 1 1 2 2 Ref

FIGURE 4.6:Tube Assembly

2 PL 2 PL

ITEM PART NUMBER DESCRIPTION

Ref. 55920 Tube Assembly 1 RMR00120 Hydraulic Tubing, #08 .50"OD x 065Wee 2 01218 Tube Nut, #08 (#318) 3 01216 Tube Sleeve, #08 (#319) - Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

QTY

Ref 1 97LF 2 2

FIGURE 4.7: Valve Installation

ITEM PART NUMBER DESCRIPTION Ref. 55840 1 55296 2 54892 3 02525 4 02448 5 00458 6 02576 7 04682 8 04003 9 00456 10 00236 11 02298 -12 55840-DWG - Indicates Items Not Shown

QTY

Valve Installation Ref Valve Assembly 1 Valve, Load Control 2 Straight, MJ04 M004 2 Straight, MJ06 M006 4 Straight, MJ08 M008 1 Tee, MJ06 M006 MJ06 1 Tee, MJ04 M004 MJ04 1 Nut, Cap #04 2.

Straight, MJ04 M006 1.

Elbow, 90° MJ04 M004 1 Elbow, 90° MJ06 FJO6 1 DWG-V 14/1 83 3/XL Valve Installation 1

MANUAL 92377-003 March 1998 Revised1/99

FIGURE 4. 8 : Valve Assembly

1 1

A FRONT VIEW

RIGHT END VIEW

im

H i

EL k

) (Z) LEFT END VIEW A—A

BACK VIEW B—B

ITEM PART NUMBER DESCRIPTION

Ref. 55296 Valve Assembly 1 55337-001 Manifold, Valve 2 546 6-004 Valve, Drive 3 466-001 Valve, Steer 4 54646-005 Valve, Select 5 54639 Cartridge, 2Way NO Spool Valve 6 54852-052 Orifice, 0.052 Dia. HF 10 7 54641 Cartridge, 4Way NO Spool Valve 8 54634 Cartridge, Flow Divider Valve 9 54890 Cartridge, Dir. Act Relief Valve 10 54640 Cartridge, Check Valve 11 54889 Cartridge, Flow Control Valve 12 54622 Cartridge, Needle Valve 13 54638 Cartridge, Sequence Valve - Indicates Items Not Shown MANUAL 92377-003 March 1998 Revised1/99

QTY

Ref. 1 1 1 1 2 1 1 1 2 1 1 1 1

NOTES: 1. FOR DIMENSIONS, AND TECHNICAL DATA, REFER TO MANNESMANN REXROTH CATLOG: RA 23 178/2.96 2. EST WT = 4.3 LB.

2633 SELECTOR BANG-BANG 2633 DRIVE BANG-BANG 2633 SELECTOR SLO-SHIFT 2633 DRIVE SLO-SHIFT 2633 STEERING SLO-SHIFT REFERENCE: USED FOR

54646-005

4WE6V6X/EG24N9K4

54646-004 54646-003

4WE6H6X/EG24N9K4 4WE6V5X/AG24N9K4/A07

54646-002 54646-001

4WE6H5X/AG24N9K4/A07 4WE6G6X/EG24N9K4

CALAVAR PART NUMBER

REXROTH ORDERING CODE

UNLESS OTHERWISE NOTED:

B

11854

A

8776

TIME CONDOR CORPORATION 8300 IMPERIAL DRIVE WACO, TEXAS 76712

DECIMALS TOLERANCES: FRACTIONS ± 1/16 .5 ± .1 .XX ± .03 ANGLES ± 1' .XXX ± .010 TITLE SURFACE FINISH 12V PROJECTION OF VIEWS CO E::1

11/15/95

LTR.

D.C.N. NO.

DATE

4732

01/16/95

LTR.

D.R.N. NO.

DATE

RAK

VALVE CHART, DO3

ALL DIMENSIONS ARE IN INCHES

APPR.

DRAWN A_HITTLE

RAI<

CHECKED

APPR. APPROVED RAK

SIZE

11/15/94

A

01/16/95

SCALE

DRAWING NO.

NONE

REV.

5 646

SHEET 1

OF 1

A

B

SERVICE PARTS: 55296-100 REXROTH QUAD RING KIT. 4 RINGS PER KIT. 55296-101 COIL, CONDOR #GAE01005 MODEL #6351020.

55296-002 BOLTS TO ATTACH VALVES TO MANIFOLD 4 BOLTS PER VALVE

10 ol

CONDOR 55296-001

FRONT VIEW

BACK VIEW B—B

RIGHT END VIEW

LEFT END VIEW A—A

E 10197 7/6/98 SEC

D 10240 1/29/97 RAK C

NOTES: 1. SEAL ALL OPENINGS WITH THREADED PLUGS. REF: 7/16-20 4 PL ,. 9/16-18 6 PL; 3/4-16 1 PL

10195 01/10/97 RAK

B 9135 02/23/96 RAN A 9003 01/23/96 RAK

54638

25

1.00

EA

12

54622

25

1.00

EA

CARTRIDGE, NEEDLE VALVE

11

54889

25

1.00

EA

CARTRIDGE, FLOW CONTROL VALVE

10

54640

25

1.00

EA

CARTRIDGE, CHECK VALVE

9

54890

25

2.00

EA

CARTRIDGE, DIR ACT RELIEF VALVE

8

54634

25

1.00

EA

CARTRIDGE, FLOW DIVIDER VALVE

7

54641

25

1.00

EA

CARTRIDGE, 4WAY NO SPOOL VALVE

6

54852-052

1.00

EA

ORIFICE, 0.052 DIA HF 10

5

54639

25

2.00

EA

CARTRIDGE, 2WAY NO SPOOL VALVE

4

54646-005

6.5

1.00

EA

VALVE, 2633 SELECT VALVE, 2633 STEER

3

54646-001

6.5

1.00

EA

2

54646-004

6.5

1.00

EA

VALVE, 2633 DRIVE

1

55337-001

1.00

EA

MANIFOLD, 2633/2648/3248 VALVE

ITEM

PART NUMBER

QTY

UM

DESCRIPTION

UNLESS OTHERWISE O.D:

DIVISION OF TIME MFG. CO .

8300 IMPERIAL DRIVE WACO, TEXAS 712

DECIMALS TOLERANCES: FRACTIONS 0 1/16 .X t .1 ANGLES 0 1' TLE .xx .01 0 D0TI ."x ,SR0JFEAcCnE .FNIN0ISFH viEZ 0 c:3 ±

:

VALVE ASSY, V14/26 ALL DIMENSIONS ARE IN INCHES

0 12499 10/5/98 SEC LIP.. D.C.N. NO, DATE APPR. DRAWN B.SEFCIK 11/10/95 F 12075 7/6/98 SEC - 5661

CARTRIDGE, SEQUENCE VALVE

13

CHECKED

LTR. D.C.N. NO. DATE APPR. LTR, D.R.N. NO. DATE APPR. APPROVED

500

DRAWING NO.

PEV

55296

RAK 02/26/95 SCALE 1:2.5

jSHEET

1 OF 1

FIGURE4.9:Jumper Assembly •

ITEM PART NUMBER DESCRIPTION

Ref. 55334 Jumper Assembly 1 58298 Wire, 16GA Green 2 67960-007 Term Ring 16-14 37 Stud 3 67960-006 Term Ring 16-14 #10 Stud - Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

QTY

Ref. 9LF 1 I.

• FIGURE 4.10: Charger 115V/60HZ-25AJ24VDC

c

BATTERY CHARGER RED

\-__________J

J \

-7

ITEM PART NUMBER DESCRIPTION Ref. 55901 Charger,Mod. 115V-25A 1 54908 Charger, 115V/60HZ-25A/24VDC 2 BOW23065 Ring Terminal, 12Ga 3 /8 " Stud - Indicates Items Not Shown

92377-003 March 1998 Revised1/99

MANUAL

QTY Ref. 1 2

FIGURE4.11: Charger 115V160HZ-25A/24VDC

ratarrIENV CIMINER

24 VOLT FULLY AUMPAt70©

AgvAr-Electrical 625 Wast A St, Lincoln, NE €8.522

10 20 0\111111*/ PERES

MAT T fa FPI PLMITY

St CELL SERI ES CONNECTED LEAD ACID SYSTEMS. 75 TO 110 USA MINUTES SC! PATNA).

AC VOLTS HERTZ MO DEL DMUS U.S. MT. NO. 3.79 4.$0 5

111 5 1

1 60 1

[ 8 I

I I

ACAMPS

To]

I 24 I

PHASE SERIAL MO. DCAMPS

I

25

I

OR. BR. PAT. NO. 1.41 4,36.

FR. MT. N0.2,203,144 W. G R. PAT. NO.2,161,669 JAPAN PAT. NO. 45133/19TS

O O

OPIERMANa READ THE INSTRUCTION MANUAL BEFORE OPERATING THE CHARGER. CONNECT THE POWER SUPPLY GORD 10 A PROPERLY GROUNDED AC OUTLET OF THE PROPER VOLTAGE AND FREQUENCY. CHAN:1ER TURNS ON AUTOMATICALLY AND RED 'CHARGING' UQHT WILL GLOW. WIONIKIR AMMETER FOR CORRECT INITIAL CHA

i

ITEM PART NUMBER DESCRIPTION

Charger,Mod. 115V-25A Ref. 54908 - 1 54908-110 AC Receptacle -2 54908-106 Fuel Assembly -3 54908-109 Cordset, DC, 75", No Plug -4 54908-108 Bushing, 7W-2, Insulator For Cordset -5 54908-105 Capacitor, 6.0 MFD, 660 VAC -6 54908-104 Electronic Timer Assembly -7 54908 103 Ammeter -8 54908-102 Heatsink Assembly, With Diodes -9 54908-101 Transformer Assembly -10 54908-107 Case Assembly -

- Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

QTY

Ref.

CABLE /HARNESS IS INCLUDED IN LOWER BOX

2 4 6 7 8 10A 8D 11A 12

COLOR BLU RED/BLK ORN ORN /E3LK W-IT DU< WHT/BLK RED GRN/BLK CRN

CONNECTION IN LOWER BOX

CIRCUIT DESCR PTION DRIVE FORWARD DRIVE VALVE DRIVE REVERSE STEER LEFT STEER VALVE STEER RIGHT RAISE PLATFORM SELECT VALVE FAST DRIVE SPEED DECELERATION VALVE CREEP DRIVE SPEED VALVE POSITRACTION VALVE SPARE

CIRCUIT 2 3 4

U)

B RED

4,;

9„.. RED, C,R N, CRN 'WHT 11 WHT., 1o6 Bt K , ' BLK

wriT . 10 , RED /BLK, WHT/BLK, C WHT BLU, ' BLK 9 BLK ---- 1 _____ - --, BLK „. --, :c eH,__ff_______cLF__) ,N

COLOR BUJ RED BLU/BLK ORN

1= BLK BC= WH MO ION 8D= WHT TRAVEL 9= WHT DESCEND

B

d

3 NM. 4 SPKR TERM

(4) CD

5 SPHR TERM POS

7 8 9 10 11 12

ORN /BD< WHT WHT/BLK BLK BLK/WHT GRN/BLK OWN RED /13LK

FUNCTION DRIVE FORWARD 24VDC POWER DRIVE REVERSE STEER I EFT STEER RIGHT RAISE PLATFORM LOWER PLATFORM FAST DRIVE SPEED CREEP DRIVE SPEED POSITRACTION SPARE CREEP DRIVE SPEED

0 OPTIONAL 16CA/2C ALARM 07295- 035 OPTIONS REF WELD STUD

#1= ORN

STROBE LICHT OPTION

113#,-11111:K 1

1= CRN

OPTIONAL 16GA/2C 67295-035

111=GRN #6= ORN

HARNESS IS INCLUDED IN ARM INST

1=BLK i/9= WHT ) VALVE ON CYL

#8= WH T #2=RLU

CHASSIS/ARM LIMIT SWITCH #10=BLK

#10B= WHT )

C3

#11= ORN

N, #11A= RED

6 P1 CABLE FROM LOWER CONTROL BOX

#12= GRN /BLK

8310 8

q:?)

DRIVE POSITRACTION

St

O

©

rt #8D= WEI T /91.K DE CE1

#4= RED/BLK #10A=BLK #7=ORN /BLK

STEER

Cc), ©

#14.= WHT/BLK SIGNAL 113= RED POWER 41. RED /BLK GROUND

WHT RED BLK

2 PL

5' SLOPE SENSOR OPTION

REF WELD STUD

\MAT SIGNAL

I

REF CRI CONTACTOR

GRN GROUND #1= ORN GROUND

OP TIONAL 16GA/8C 67295-024 CABLE

FROM LOWER CONTROL BOX. REFER TO STANDARD CABLE SHOWN BELOW

REF WELD STUD

REF CRi CONTACTOR

STANDARD CABLE FROM LOWER CONTROL BOX

B 10347 NOTES: 1. SEE 54918-DWG FOR 110V EXT 2. THIS DWG IS SIMILAR TO 55846.

A 10326 2/27/96 RAE

£8 IA/E£t7 IA-uogeffelsuIRaPIM:I

il

FIGURE 5. 1 : Wiring Installation - V143 3/V1 833 ITEM PART NUMBER DESCRIPTION

QTY

Wiring Installation - V14/1833 Ref. 55837 Ref. Jumper, 3" LG 1 55331 6.

2 55330-001 Jumper, 21 1/2"LG Wire 1_ 3 55879 Harness, Lift Cylinder Valve 1 4 55330-003 Jumper, 14 1/2"LG Wire 1.

5 55878 Switch Assembly, Chassis Limt .1 Spacer, Nylon 5 OD x #10 ID x 5L 6 55868 2 7 BOW31148 Screw Rnd Head #10-32 x 2 00 2 .2 8 B OW31233 Nut, Hex Keps #10-32 1 9 67837-006 Tie, Nylon - 6" Black Cover, Electrical Terminal 1 10 55222 1 11 34552-008 Terminal Strip 12 BOW31130 Bolt Rnd. Head #8-32 x .50 2 13 BOW31232 Nut, Hex Keps #08-32UNC 2

Jumper, Ground Wire

14 55872-001 1 15 BOW34272 Nut, Nylon Lock 25-20UNC V14/1833 -02 -03 3 3 BOW36780 Nut, Hex Nylon Lovk 25-20NC V14/1833-01 16 BOW31431 Washer, Flat .25 ID x .63 OD V14/1833 -02 -03 4 B OW31444 Washer, Flat .25ID x 630D V14/1833-01 4 17 65099-12 Clamp, Cush Loop 750 Dia 1 1 18 B OW30002 Bolt, Hex 25-20UNC x .750 19 55330-002 Jumper, 24LG Wire 1 -20 55837-DWG DWG-V14/1833-01Wiring Installation 1 Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

e)

PROP DRIVE OPTION 1 2 4 $ 7 8 10A TO 11A 12 13

COLOR ORN ELU ELUALK ORN ORN/BLK WHT ELK WH T /ELK ELK/WHT CNN/ELF RED RED/ELK

CABLE /HARNESS IS INCLUDED IN LOWER BOX

STANDARD

WIRING

CIRCUIT DESCRIPTION OPTION CROuND FOR PROP DRIVE DRIVE FORWARD DRIVE VALVE DRIVE REVERSE STEER LEFT STEER VALVE STEER RICHT RAISE PLATFORM SELECT VALVE FAST DRIVE SPEED DECELERATION VALVE CREEP DRIVE SPEED VALVE POSITRACTION VALVE PROPORTIONAL DRIVE SPEED OPTION SPARE OPTION

11 2 4 $ 7 N 10A EL) 11A 12

CONNECTION IN LOWER BOX

COLOR ORN ELu RED/ELK ORN ORN/BLK WHT RLK WHT/ELK RED ORN/BLK

•00

SPARE

0

CIRCUIT 1 2 3 4

o 11A

RED ORN WHT

'ELK

WHT

RED, GPM. WHT, TON ELK, To RED/ELK, TM-AT/ELK,

ELU,

5 6 7 8 9 TO 11

AT II

110- ig

#1=ELK

rata

ELK ELK :12 1 3 ORN, ,WHT

NEC■ 4 ,PKR 7E.

(11)

5 vo nerm

(

S.)

#8O=WHT MOTION 48D=WHT TRAVEL #9=WHT DESCEND

12

CRN=SPARE FOR 'STANDARD Vv1RINC ,#1=ORN=GROuND FOR PROPORTIONAL DRIVE OPTION

ALARM OPTIONS

13 14 15 16

#13= ANT #1=ELK A) STROBE LIGHT OPTION

#1=ORN

WHT/ELK ELK ELK/ANT

FUNCTION GROUND. OR. SPARE. IF NO OPTIONS DRIVE FORWARD + 24VDC POWER DRIVE REVERSE BATTERY CONDITION INDICATOR OPTION STEER LEFT STEER RICHT RAISE PLATFORM LOWER PLATFORM FAST DRIVE SPEED CREEP DRIVE SPEED

OWN/ELK

POSITRACTION

RED/ELK ORN ORN/ELK

MT

BELOW ARE LISTED CONDUCTORS IN CABLE THAT IS PART OF CERTAIN OPTIONS, (REF OPTIONAL 4 ' 6 G A /1 6 C 67295-003)

0 OPTIONAL 16C,'A/2C. 67295-035

COLOR ORN ELU RED ELU/ELK

RED/WHT ORN/WHT ELU/WHT ELK/RED

OPTIONAL 16(3A/2C 67295-035

#6=ORN

111= ELK

#8= WH T

119=WHT

-I') VALVE ON COL

#2=BLU CHASSIS/ARM LIMIT SWITCH

#12=GRN/ELK

N-

#2

#10=ELK #11=CRN

000

CABLE FROM LOWER CONTROL BOX

© ,VTIONAL©

PRof, TIONAL DRIVE vAivE RR/VICKERT

CONNECTOR 6, CABLE SUE-ASSY IS INCLUDED IN ARM INST.

2 PI

© DRIVE POSITRACTION

#4

eNoe 4.=v,HT) -oNco- #11A=RED

0

0

SELECT 0

STEER 0

J

WI 4= WHT/ELK SIGNAL 3=RED POWER #1=RED/ELK CROuND

WHT RED ELK

8e=wHT SIGNAL #1=CRN #1=ORN

An= WHT/BLK

5. SLOPE SENSOR OPTION

9

GROUND GROUND

REF WELD STUD

REF CONTACTOR

NOTES: 1, SEE 54918-DWG FOR 110V Da 2. THIS DWG IS SIMILAR TO 55870,

#13=RED FOR PROPORTIONAL DRIVE OPTION #5B=ELK POWER #5E=ELu POWER #4=RED/BLK FOR STANDARD WIRING ,.,4/4=ELVELK FOR PROPORTIONAL DRIVE OPTION .

j

OPTIONAL 16GA/8C. 67295-024 CABLE FROM LOWER CONTROL BOX. REFER TO STANDARD CABLE SHOWN EELOW

#10A-E K #7=ORIVELK

,#11A=RED FOR STANDARD WINO

8B=WHT SIGNAL

riA=ELK/wHT FOR PROPORTIONAL DRIVE OPTION

1=ORN GROUND

,,, RED/ELK=SPARE WITH PROPORTIONAL DRIVE OPTION #1= OWN

I

5E=ELK POWER SIGNAL HORN OPTION STANDARD CABLE FROM LOWER CONTROL EON

REF CONTACTOR

REF WELD STUD

PROPORTIONAL DRIVE SLOPE ALARM INDICATE LOW VOLT OVERRIDE LOW VOLT

OPTION OPTION OPTION OPTION

FIGURE 5 . 2 : Wiring Installation- V1433XLN1833XL ITEM PART NUMBER DESCRIPTION

QTY

Wiring Installation -V14/1833XL Ref. Ref. 55847 Jumper, 3 LG Wire 1 55331 6 2 55330-001 Jumper, 21 1/2" LG Wire 1 1 3 55879 .Hamess, Lift Cylinder Valve 4 55330-003 Jumper, 14 1/2" LG Wire 1 5 55878 Switch Assembly, V Chassis Limit 1 1 85LF 67295-037 -Cable, 16Ga /4 Conductor SJO 51036 -Switch Limit Body Only 1 -Offset Head Limit Switch 51037 1 51039-002 -Limit Switch Arm/Short 1 67114-003 -Strain Relief 1/2"NPT .371.5 1 8 BOW23028 -Terminal 8 Stud 16/14Ga Spade

Spacer, .50 OD x #10 ID x .18 L Nylon 6 55868-001

2 2 7 BOW31148 Screw Rnd Head 10-32 x 2 00 BOW31146 10-32 x 1.00 Slotted Round Head V14/1833XL-01 2 8 BOW31233 Nut, Hex Keps #10-32 2 1 9 67837-006 Tie, Nylon-6" Black Cover, Chassis Electrical Terminal 10 55222 1 1 11 34552-008 Terminal Strip 12 BOW31130 Bolt Rnd Head 8-32 x 50 2 13 BOW31232 Nut, Hex Keps #08-32UNC 2 1 14 BOW30002 Bolt, .25-20 UNC x .75 Hex 7 15 BOW34272 Nut, 25-20UNC Nylon Lock BOW36780 Nut, Hex 25-20UNC Nylon Lock V14/1833XL-01 8 16 BOW31431 Washer, 25"ID x 63"OD Flat

4 6 BOW31444 Washer, Flat 25ID x .630D V14/1833XL-01 17 65099-12 Clamp, .750 Dia Cush. Loop 1

6LF 18 67281-005 Wrapping, 3/4" Black/Spiral 1 19 55872-001 Jumper Assembly, 14"L Ground Wire 1 20 55330-002 Jumper Assembly, 24"L Wire

-Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

FIGURE 6 . 1 : B ox As s emb ly - Lower Control

SEE NOTE 5

OPERATING INSTRUCTIONS

.

1■34PSTSITTCN TO "Ir., 405, DON.

110ZaTTEZITOPNTUSRPSEBK06 OUT. •PVSH TOGGLE swir, TO MOvE TkATFORM.

,10"Oeg"ATE" TIt0:11L7T;OZAir'. ...r,...

• 00

NIG

711

MANUAL 92377-003 March 1998 Revised1/99

FIGURE6.1:Box Assembly LowerControl V1433)a, Serial Numbers X11597050-X11597065 -

V1833XL SerialNumbersX21567134,X21597001-X21597283

ITEM PART NUMBER DESCRIPTION

QTY

Ref. 55853 Box Assembly - Lower Control V14/1833-01 Ref. Ref. 55853-XL Box Assembly - Lower Control V14/1833XL-01 Ref. 1 55752 Box, V1433 Lower Control 1 2 55893 Decal, V1433 Lower Control Electrical Tags 1 3 51913 Operator-Push Pull 1 4 51914 Contact Block NC w/Base 1 5 a 16 Operator 3 Position Rotation Key ZB2-BG3 .1 •I -Key KK-0,1,0/ - 1 6 52029 Contact, 2N0 w/Base 1 7 50075 Switch, SPDT Toggle 1 8 54438 Relay, 24V SPDT Bosch 1 9 206-00001-00 Diode 8 10 67114-013 Strain Relief 1NPT 62/ 75 1 11 67114-008 Connector, Strain Relief 1 12 67114-009 Strain Relief 3 /4"NPT .621.75 2 13 37124-003 Connector, Locknut 1" 1 14 67124-002 Locknut Connector .75 3 15 67123-003 Seal, Connector Electrical 1" 1 16 67123-002 Seal, Connector Electrical 3/4" 3 17 34542 Jumper 5 -18 67837-006 Tie, Nylon-6"Black 8 -19 BOW31430 Washer, Flat #10 ID 1 20 BOW31129 Screw, Slotted Rnd. #8-32UNF x .375 1 21 BOW31232 Nut, Hex Keps #8-32 UNF 1 -22 BOW31124 Screw, Slotted Rnd. #6-32UNF x .50 4 23 B OW31231 Nut, Keps #6-32UNF 4 24 BOW31428 Washer, Flat #6 4 25 67295-024 Cable, 16Ga /8C 8LF 26 67295-023 Cable, 16Ga /10C 8.LF 67295-024 Cable, 16Ga /12C - XL 8LF 27 67295-022 Cable, 12Gal3C 6LF 28 34552-016 Terminal Strip 2 29 67940 Holder_ Fuse 1 30 67939-015 Fuse, 15A ' '14" x 1 1/4" AGC-15 1 -31 58282 Wire, 12Ga Black 4LF -32 58300 Wire, 16Ga Black LLF 33 66720-001 Disconnect, Sta-Kon Female 6 34 BOW23087 Terminal, Female Push-On 16-18 2 35 67960-006 Ring Terminal, 16Ga #10 Stud 2 36 BOW23024 Ring Terminal, 16Ga 1/4" Stud 1 37 BOW23025 Ring Terminal, 16Ga 5/16" Stud 1 38 BOW18578 Terminal, Piggyback Push-On 1 39 BOW23087-2 Terminal, Female Push-On 1 40 BOW23028 Terminal, 8 Stud 16/12Ga Spade 41 BOW23028 Terminal, 8 Stud 16/12Ga Spade - XL 43

.

51 A626-2633 Low Volt Alarm/Interrupt (Option) 52 A309-2633 Motion Alarm (Option) -53 A310-2633 Strobe Light (Option) MANUAL 92377-003 March 1998 Revised1/99

Ref. Ref. Ref.

5D

12 GA r,

12 GA

8 PL

K.9

5-

I

12 GA 5

"DOWN" 5G

0

8 "UP"

8E 8F SPARE

9

SEE NOTE 2

10

_2

I

CD

cr

11

3 UPPER"

LE FT S IDE

11A 12 13

"LOWER"

14 15

12 GA 3 5G

R IGH TS IDE

10A

16

0

12 GA 0 6)

5B=BLK

5 PL

4 PL

0 0 0

u 0 U

TO MOTOR CONTACTOR TO TB ON CHASSIS

TO HYD TO ARMS/ VALVES PLATFORM

NOTES: 1. THIS SHEET SHOWS "STANDARD", SEE SHEET 4 FOR OPTIONS. 2. CONNECT "RED/BLK" TO SPARE, AS SHOWN. 3. ALL WIRING TO BE 16 GA, EXCEPT CIRCUITS 1,3,5, & 5D AS MARKED. 4. SEE SHEET 3 FOR COLOR TO CIRCUIT NUMBER TABLES.

FIGURE 6. 1:Box Assembly- Lower Control V1433XL SerialNumbersX11597050-X11597065 V1833XL SerialNumbersX21567134,X21597001-X21597283

ITEM PART NUMBER DESCRIPTION

QTY

Ref. 55853 Box Assembly - Lower Control V14/1833-01 Ref. Ref. 55853-XL Box Assembly - Lower Control V14/1833XL-01 Ref. 1 55752 Box, V1433 Lower Control 1 2 55893 Decal, V1433 Lower Control Electrical Tags 1 3 51913 Operator-Push Pull 1 4 51914 Contact Block NC w/Base

1 5 L. r I 6 Operator, 3 Position Rotation Key ZB2-BG3 .1 52671 -Key 1 6 52029 Contact, 2NO w/Base 1 7 50075 Switch, SPDT Toggle 1 8 54438 Relay, 24V SPDT Bosch 1 9 206-00001-00 Diode 8 10 67114-013 Strain Relief 1NPT 62/ 75 1 11 67114-008 Connector, Strain Relief 1 12 67114-009 Strain Relief 3/4"NPT . 621.75 2 13 37124-003 Connector, Locknut 1" 1 14 67124-002 Locknut Connector .75 3 15 67123-003 Seal, Connector Electrical 1" 1 16 67123-002 Seal, Connector Electrical 3/4" 3 17 34542 Jumper 5 -18 67837-006 Tie,Nylon-6"Black 8 - 19 BOW31430 Washer, Flat #10 ID 1 20 BOW31129 Screw, Slotted Rnd. #8-32UNF x .375 1 21 BOW31232 Nut, Hex Keps #8-32 UNF 1 -22 BOW31124 Screw, Slotted Rnd. #6-32UNF x .50 4 23 BOW31231 Nut, Keps #6-32UNF 4 24 B OW31428 Washer, Flat #6 4 25 67295-024 Cable, 16Ga /8C &LF 26 67295-023 Cable, 16Ga /10C &LF 67295-024 Cable, 16Ga /12C - XL 8LF 27 67295-022 Cable, 12Ga /3C 6LF 28 34552-016 Terminal Strip 2.

29 67940 Holder, Fuse 1.

30 67939-015 Fuse, 15A 1/4" x I 1/4" AGC-15 1 -31 58282 Wire, 12Ga Black 4LF -32 58300 Wire, 16Ga Black 1LF 33 66720-001 Disconnect, Sta-Kon Female 6 34 BOW23087 Terminal, Female Push-On 16-18 2 35 67960-006 Ring Terminal, 16Ga #10 Stud 2 36 BOW23024 Ring Terminal, 16Ga 1/4" Stud 1 37 BOW23025 Ring Terminal, 16Ga 5/16" Stud 1 38 BOW18578 Terminal, Piggyback Push-On 1 39 BOW23087-2 Terminal, Female Push-On 1 40 BOW23028 Terminal, 8 Stud 16/12Ga Spade 41 BOW23028 Terminal, 8 Stud 16/12Ga Spade - XL 43 51 A626-2633 Low Volt Alarm/Interrupt (Option) 52 A309-2633 Motion Alarm (Option) -53 A310-2633 Strobe Light (Option) MANUAL 92377-003 March 1998 Revised 1/99

Ref. Ref. Ref.

TABLE 1

3

COLOR WHT/BLK RED

FUNCTION GROUND STROBE LIGHT OPTION

8D

WH T

8E

ORN

DECELERATE (VALVE) INHIBIT FAST DRIVE SPEED

S

GRN BLU

LOWER PLATFORM CREEP (SWITCH)

BLK RED/BLK

CREEP (VALVE) SEE NOTE 2 ON SHEET 4

11A

INSIDE BOX *

0

0 OPTIONAL CABLE 1 6GA/8C (REF) TO MOTOR CONTACTOR AND 5• SLOPE SENSOR OPTION

CABLE SHEATH

(REF) 67964-002 5• SLOPE SENSOR/WHT

#13 WH T/B LK

INSIDE BOX INSIDE

BOX

INSIDE BOX

(REF) 67964-002 5• SLOPE SENSOR/RED (REF) 6 7964-002 5' SLOPE SENSOR/BLK

N-

QT

0

T

(REF)

U)

(U

" CABLE SHEATH

TO TERMINAL BLOCK ON CHASSIS SEE TABLE I

+ 24VDC

STD CABLE TO MOTOR CONTACTOR

(REF) (REF) GROUND SIGNAL CON TAC TOR CONTACTOR

CABLE SHEATH

POWER CONTACTOR

58 BLK + 24VDC

1.0

3 RED

CABLE SHEATH V

TO HYDRAULIC VALVE MANIFOLD SEE TABLE 2

A

GROUND

SIGNAL

REF

NOTE: 1, LENGTHS, SHOWN AS ".", ARE TO BE PRO TO TYPED.

TABLE 2 CIRCUI T

COLOR

FUNCTION

RED

GROUND- OF TION DRIVE FORWARD

4

RED/BLK

DRIVE REVERSE

6

WHT

STEER LEFT

7 8

T/B LK BLU

STEER RIGHT

BD 10A

GRN ORN

DECELERATE DRIVE FAST

BLK

CREEP

GRN/BLK 2

11A

REF

.0

BLK/WHT CONNECT OPTIONS

1 2 3

FUNCTION

GRN/BLK

GROUND, OR, SPARE, IF NO OPTIONS DRIVE FORWARD 1- 24VDC POWER

4 5 6

BLU/BLK WHT

7 8

WHT/BLK BLU

DRIVE REVERSE BATTERY CONDITION INDICATOR OPTION STEER LEFT STEER RIGHT RAISE PLATFORM

9 10 Ti

GRN ORN BLK

12

BLK/WH T

PROPORTIONAL DRIVE OPTION

13

GRN/WHT RED/WHT

OPTION SLOPE ALARM OVERRIDE LOW VOLT OPTION

BLU/WHT

INDICATE LOW VOLT OPTION SIGNAL HORN OPTION

14

6 PL

COLOR RED ORN/BLK RED/BLK

15 16

RAISE PLATFORM

ORN/BLK SEE WIRING

BLU/BLK INS T DWG TO

TABLE 3 CIRCUIT

BLK/RED

LOWER PLATFORM FAST DRIVE SPEED CREEP DRIVE SPEED

I anuop Jamori - kictwassy xog : 1

CIRCUI T•

FIGURE6.1 :Box Assembly-Lower Control

V1433NL SerialNumbersX11597050-X11597065 V1833XLSerialNumbersX21567134,X21597001-X21597283

ITEM PART NUMBER DESCRIPTION

QTY

Ref. 55853 Box Assembly - Lower Control V14/1833-01 Ref. Ref. 55853-XL Box Assembly - Lower Control V14/1833XL-01 Ref. 1 55752 Box, V1433 Lower Control 1 2 55893 Decal, V1433 Lower Control Electrical Tags 1 3 51913 Operator-Push Pull 1 4 51914 Contact Block NC w/Base 1 5 AKK02016 Operator, 3 Position Rotation Key ZB2-BG3 .1 52671 -Key 1 6 52029 Contact, 2NO w/Base I. 7 50075 Switch, SPDT Toggle 1 8 54438 Relay, 24V SPDT Bosch 1 9 206-00001-00 Diode 8 1 10 67114-013 Strain Relief 1NPT 62/ 75 11 67114-008 Connector, Strain Relief 1.

12 67114-009 Strain Relief 3 /4"NPT . 621.75 2 13 37124-003 Connector, Locknut 1" 1 14 67124-002 Locknut Connector .75 3 15 67123-003 Seal, Connector Electrical 1" 1 16 67123-002 Seal, Connector Electrical 3/4" 3 17 34542 Jumper 5 - 18 67837-006 Tie,Nylon-6"Black 8 -19 BOW31430 Washer, Flat #10 ID 1 20 BOW31129 Screw, Slotted Rnd. #8-32UNF x .375 1 21 BOW31232 Nut, Hex Keps #8-32 UNF 1 -22 BOW31124 Screw, Slotted Rnd. #6-32UNF x .50 4 23 BOW31231 Nut, Keps #6-32UNF 4 24 BOW31428 Washer, Flat #6 4 25 67295-024 Cable, 16Ga /8C 8.LF 26 67295-023 Cable, 16Ga./10C 8.LF 67295-024 Cable, 16Ga /12C - XL 8LF 27 67295-022 Cable, 12Ga /3C 6LF 28 34552-016 Terminal Strip 2.

29 67940 .Holder, Fuse 1.

30 67939-015 Fuse, 15A 1/4" x 1 1/4 AGC-15 1 -31 58282 Wire, l2Ga. Black 4LF -32 58300 Wire, l6Ga. Black 1LF 33 66720-001 Disconnect, Sta-Kon Female 6 34 BOW23087 Terminal, Female Push-On 16-18 2 35 67960-006 Ring Terminal, 16Ga #10 Stud 2 36 BOW23024 Ring Terminal, 16Ga 1 /4 " Stud 1 37 BOW23025 Ring Terminal, 16,Ga 5/16" Stud 1 38 BOW18578 Terminal, Piggyback Push-On 1 39 BOW23087-2 Terminal, Female Push-On 1 40 BOW23028 Terminal, 8 Stud 16/12Ga Spade 41 BOW23028 Terminal, 8 Stud 16/12Ga Spade - XL 43 51 A626-2633 Low Volt Alarm/Interrupt (Option) 52 A309-2633 Motion Alarm (Option) -53 A310-2633 Strobe Light (Option)

MANUAL 92377-003 March 1998 Revised1/99

Ref. Ref. Ref.

FIGURE6.1:BoxAssembly -Lower Control

OPERATING INSTRUCTIONS

I

.TO OPERATE FROM CROUIJD, TURN SWITCH TO "LOWER POSITiON. AN EMEROENCY, PUSH PE D BUTTON. TO OPERATE, BUTTON MUST NE PULLED OUT, •PUSH TOOO1E SWITCH TO MOVE PLATFORM, • TURN TWITCH TO - PPER' posa014, TO OPERATE FROM PLATFORM,

f

1- PLATFORM RAISE

DOW PPER OFF LO ER

MANUAL 92377-003 March 1998 Revised 1/99

FIGURE 6. 1: Box Assembly- Lower Control V1433)(1, Serial Numbers X11597066-X11597075 V1833XL SerialNumbersX21597162,X21597177-X21597506

ITEM PART NUMBER DESCRIPTION

QTY

Ref. 55853 Box Assembly - Lower Control V14/1833-02 Ref. Ref. 55853-XL Box Assembly - Lower Control V14/1833XL-02 Ref. 1 55752 Box, V1433 Lower Control 1 2 55893 Decal, V1433 Lower Control Electrical Tags 1 3 51913 Operator-Push Pull 1 4 51914 Contact Block NC w/Base 1 5 52671 Operator, 3 Position Rotation Key ZB2-BG3 .1 6 52029 Contact, 2N0 w/Base 1 7 50075 Switch, SPDT Toggle 1 8 54438 Relay, 24V SPDT Bosch 1 9 206-00001-00 Diode 8 10 67114-013 Strain Relief 1NPT 62/ 75 1 11 67114-008 Connector, Strain Relief I. 12 67114-009 Strain Relief 3/4"NPT .62/75 2 13 67124-003 Connector, Locknut 1 1 14 67124-002 Locknut Connector .75 3 15 67123-003 Seal, Connector Electrical 1" 1 16 67123-002 Seal, Connector Electrical 3/4" 3 17 B OW23022 Ring Tongue 3 -18 67837-006 Tie,Nylon-6"Black 8 -19 BOW31430 Washer, Flat #10 ID 1 20 B OW31129 Screw, Slotted Rnd. #8-32UNF x .375 1 21 B OW31232 Nut, Hex Keps #8-32 INF 1 -22 BOW31124 Screw, Slotted Rnd. #6-32UNF x .50 4 23 BOW31231 Nut, Keps #6-32UNF 4 24 BOW31428 Washer, Flat #6 4 25 67295-024 Cable, 8 cond 16 AWG Type SO 8LF 26 67295-023 Cable, 10 Cond 16 AWG Type SO 8 3LF 67295-004 Cable, 16Ga /12C - XL 8 3LF 27 67295-024 Cable, 8 Cond 16 AWG Type SO 6LF 28 34552-016 Terminal Strip 2 29 67940 Holder, Fuse 1 30 67939-015 Fuse, 15A 1/4" x 1 1/4 AGC-15 1 -31 58251 Wire, 12Ga White 4LF -32 58292 Wire, 16Ga White 1LF 33 66720-001 Disconnect, Sta-Kon Female 6 34 BOW23087 Terminal, Female Push-On 16-18 2 35 67960-006 Ring Terminal, 16Ga #10 Stud 2 36 BOW23024 Ring Terminal, 16Ga 114" Stud 1 37 BOW23025 Ring Terminal, 16Ga 5/16" Stud 1 38 BOW18578 Terminal, Piggyback Push-On

1 39 BOW23087-2 Terminal, Female Push-On 1 40 BOW23028 Terminal, 8 Stud 16/14Ga Spade 41 BOW23028 Terminal, 8 Stud 16/14Ga Spade - XL 43 41 67961-006 Terminal, 8 Stud 12/10Ga Spade 10

MANUAL 92377-003 March 1998 Revised1/99

TABLE 1

ft 3 I0 1 118 9 11A

COLOR BUJ ORN

FUNCTION GROUND STROBE LIGHT

BLK WHT WI-IT /BLK GRN RED RED /BLK

"FAST" TO LIMIT SW TCH FROM LS TO INHIBIT FAST LOWER PLATFORM "CREEP" TO LIMIT RVVTTCH

--A

0

OPTION

0

CABLE FOR "XL" MODELS TO HYD VALVE ASSY SEE TABLE 2

FROM LS TO CREEP VALVE SEE NOTE 2 ON SHEET 4

6 PL

24' INSIDE B05

SPARE RED BLK 12" 18" 10" INSIDE INSIDE BOX BOX

0

uS

TO TERMINAL BOARD ON CHASSIS SEE TABLE 1

SEE

64" CABLE SHEATH

25

TABLE 3

J

#3 ORN 10"

B LU

MIN

0

63"

CABLE SHEATH

JOG

•

13

e

JOG

sr-

.

STD CABLE TO MOTOR CONTACTOR

.•••

8 PL

TO POD VALVE ASSY SEE TABLE 2

et

0 1\1 0:N/BLK

13

6 PL TABLE 3 = CABLE TO COLOR II GRN BLU 2 RED BLU /BLK 4

'171 0A 8LK 52" CABLE SHEATH

IC C

lily,

48-7

9 amit

IS) <(Ò

"XL" MODELS TABLE 2 STANDARD FUNCTION 11 FUNCTION COLOR FAST 10A FAST BLK 10A UP WH T UP 8 El 13 11 A PROP DR RED CREEP GROUND GRN SPARE LEFT ORN LEFT 6 FORWARD FOR WARD BLU 2 2 WHT /BLK DOWN DOWN 8D 8D SPARE RED /ELK REVERSE 4 12 7 4 1 1A

POSITRAC GRN /BLK ORN /BLK RIGHT RE VERSE BLU /BLK CREEP BLK /WH1

POSITRAC RI OH T

12 7

5 6

•

CT A

(REF) SIGN AL CONTACTOR

•

(REF) GROUND CON T ACTOR

•

0

•

I

LI

07 04

0 1 C

Cl CT

co r— C

(REF) + 24VDC POWER CONTACTOR

(REF ) 67964— 002 5' SLOPE SENSOR/BLK

44

••

S.

7

8 10

5)07 ,

12 13

T-

15 16

DI

(REF) 67064— 002 (REF) -- 5" SLOPE SENSOR/WHT 67064— 002 5• SLOPE SENSOR/RED

RE [)/BLK ORN ORN /BLK T WHT/BLK BLK BLK/WHT GRN /BLK

CONTROL BOX ON PLATFORM FUNCTION GROUND, OR. SPARE. IF NO OPTIONS DRIVE FORWARD + 24VDC POWER TO PLATFORM DRIVE REVERSE BATTERY CONDITION INDICATOR OPTION STEER LEFT STEER RIGHT RAISE PLATFORM LOWER PLATFORM FAST DRIVE SPEED CREEP DRIVE SPEED POSIT RACTION

RED/WHT ORN/WHT BLU/WHT BLK /RED

PROPORTIONAL DRIVE OPTION SLOPE ALARM OPTION INDICATE LOW VOLT OPTION OVERIDE LOW VOLT INTERRUPT OPTION

U141. ES'S OTHERYsiSt NOTE D..

(CI DON OF TIME MFO. CO. 8300 IMPERIAL 007 10 WACO. TE XAS. 7e1712

TOLE RAMC S.: DECIMAL S. FRACTIONS I 1/16 x .1 MCA. ES V .X X g .03 .X X X .010 T1 TL E SURFACE PROJECT. CF MEWS 0

DWG, V14/18 LWR EL BOX ASSY

ALL DIME NWIS ARE 11404ES 170.

10153 LTR.

2545.

DATE

APPR.

DRAM

12/23,96

RAK

CHECKED

APP,

APPROWD

DATE

/ /

A. HI TTLE

12 20 90

RAK

12/23/00

Si2E

DRAWING 50.

SCALE 1 /2

55853 50221 3044

REV.

E

FIGURE 6.1:Box Assembly Lower Control V1433XL SerialNumbers X11597066-X11597075 -

V1833XLSerialNumbersX21597162,X21597177-X21597506

ITEM PART NUMBER DESCRIPTION

QTY

Ref. 55853 Box Assembly - Lower Control V14/1833-02 Ref. Ref. 55853-XL Box Assembly - Lower Control V14/1833XL-02 Ref. 1 55752 Box, V1433 Lower Control 1 2 55893 Decal, V1433 Lower Control Electrical Tags 1 3 51913 Operator-Push Pull 1 4 51914 Contact Block NC w/Base 1 5 52671 Operator, 3 Position Rotation Key ZB2-BG3 .1 6 52029 Contact, 2N0 w/Base 1 7 50075 Switch, SPDT Toggle 1 8 54438 Relay, 24V SPDT Bosch 1 9 206-00001-00 Diode 8 10 67114-013 Strain Relief 1NPT 62/ 75 1 11 67114-008 Connector, Strain Relief 1 12 67114-009 Strain Relief 3/4"NPT .621.75 2 13 67124-003 Connector, Locknut 1 1 14 67124-002 Locknut Connector .75 3 15 67123-003 Seal, Connector Electrical 1" 1 16 67123-002 Seal, Connector Electrical 3/4 " 3 17 BOW23022 Ring Tongue a -18 67837-006 Tie,Nylon-6"Black 8 -19 BOW31430 Washer, Flat #10 ID 1 20 B OW31129 Screw, Slotted Rnd. #8-32UNF x .375 1 21 B OW31232 Nut, Hex Keps #8-32 UNF 1 -22 B OW31124 Screw, Slotted Rnd. #6-32UNF x .50 4 23 BOW31231 Nut, Keps #6-32UNF 4 24 B OW31428 Washer, Flat #16 4 25 67295-024 Cable, 8 cond 16 AWG Type SO 8LF 26 67295-023 Cable, 10 Cond 16 AWG Type SO 8 3LF 67295-004 Cable, 16Ga /12C - XL 8 3LF 27 67295-024 Cable, 8 Cond 16 AWG Type SO 6LF 28 34552-016 Terminal Strip 2 29 67940 Holder, Fuse 1 30 67939-015 Fuse, 15A 1/41 1 1/4" AGC-15 1 -31 58251 Wire, 12Ga White 4LF -32 58292 Wire, 16Ga White 1.LF 33 66720-001 Disconnect, Sta-Kon Female 6 34 B0W23087 Terminal, Female Push-On 16-18 2 35 67960-006 Ring Terminal, 16Ga #10 Stud 2 36 BOW23024 Ring Terminal, 16Ga 1/4" Stud 1 37 BOW23025 Ring Terminal, 16Ga 5 /16 " Stud 1 38 BOW18578 Terminal, Piggyback Push-On 1 39 BOW23087-2 Terminal, Female Push-On 1 40 BOW23028 Terminal, 8 Stud 16/14Ga Spade 41 BOW23028 Terminal, 8 Stud 16/14Ga Spade - XL 43 41 67961-006 Terminal, 8 Stud 12/10Ga Spade 10

MANUAL 92377-003 March 1998

Revised1/99

SPARE ISOLATE @ 0

3

3

Ti

SEE 3

12 GA

,0 p 10A

Iffil 1E 29 1.1

NOTE

Fuluop Jamoq - AT cituossy xog : 1

11

.

1

5G 2

7E111

i jl E lIP - les MIMI= .4

Emu= • Ea '13

14

10 16

REF: 8OW23087 5• SLOPE OPTION

RIGHT SIDE LEFT SIDE

TO MOTOR CON T ACTOR

TO ARMS/ PLATFORM TO HO) VALVES

TO TB ON CHASSIS

NOTES:

1. THIS SHEET SHOWS ALL OPTIONS, SEE SHEET 2 FOR "STANDARD" WIRING. 2 ALL WIRING TO BE 16 GA, EXCEPT CIRCUITS 3,5 & SD, AS MARKED.

BOTTOM

SEE NOTE 4 15

3. • IF NO ALARM OPTION, OR IF DESCEND ALARM OPTION, THEN CONNECT "RED/BLK" TO "BLANK AS SHOWN. IN THIS CASE THE RED/BLK CONDUCTOR IN THE CABLE TO THE TERMINAL BOARD ON THE CHASSIS, IS A SPARE, DESCEND ALARM IS CONNECTED TO CIRCUIT #9 ON THE TERMINAL BOARD ON THE CHASSIS. • FOR MOTION ALARM OPTION, MOVE "RED/BLK" TEl TERMINAL 8C AND ADD TWO DIODES TO TERMINAL 8C AS SHOWN. • FOR TRAVEL ALARM OPTION, JUMPER "BLANK" TO 8D AND MOVE WI-IT/BLK CONDUCTOR, IN CABLE TO HYD VALVES, FROM 8D TO "BLANK" TERMINAL. 4. IF LOW VOLT OPTION IS USED, THEN REMOVE \JUMPER BETWEEN 8A AND 8B,

INTERRUPT

0 4 0 5 RESET 7-

5E1

UNLESS OTHERVASE NOTED:

6 GROUND 7 POWER

TOLERANCES:

COVER

,,tiRFACE FINP,44 PROJECT. OF MEWS @ D.O.N. NO. 10153 LTR.

EI,R,N. NO,

DATE 12/23/96

DATE

APPR.

DRAM

RAP

CHECKED

APPR,

APPROVED

OF TiME WO. CO. -1U 81)13%."4 114PERt..AL7,[17,,2E WACO. TEX,

XIX .010 TiT LE

DWG, V14/18 LWR EL BOX ASSY

ALL DIMENSIONS ARE INCHES LTF2.

a_T_ELL4

DECIMALS

A. HI TTLE

12 /20 /90

RAP

12 /23/96

DRA000 NO

SCALE

1/2

REV.

55853 !SHEET -4

E

OF 4

FIGURE 6.1: Box Assembly - Lower Control V1433XL Serial NumbersX11597066 X11597075 -

V1833XLSerialNumbersX21597162,X21597177 X21597506 -

ITEM PART NUMBER DESCRIPTION

QTY

Box Assembly - Lower Control V14/1833-02 Ref. Ref. 55853 Ref. 55853-XL Box Assembly - Lower Control V14/1833XL-02 Ref. Box, V1433 Lower Control 1 55752 1 Decal, V1433 Lower Control Electrical Tags 1 2 55893 Operator-Push Pull 1 3 51913 4 51914 Contact Block NC w/Base 1 Operator, 3 Position Rotation Key ZB2-BG3 .1 5 52671 6 52029 Contact, 2NO w/Base 1 7 50075 Switch, SPDT Toggle 1 Relay, 24V SPDT Bosch 1 8 54438

Diode

9 206-00001-00 8 10 67114-013 Strain Relief 1NPT 62/ 75 1 11 67114-008 Connector, Strain Relief I_ 12 67114-009 Strain Relief 3/4"NPT .62/.75 2 13 67124-003 Connector, Locknut 1"

I 3 14 67124-002 Locknut Connector .75 15 67123-003 Seal, Connector Electrical 1" .1 3 16 67123-002 Seal, Connector Electrical 3/4" 3 17 BOW23022 Ring Tongue -18 67837-006 Tie,Nylon-6"Black 8 -19 B OW31430 Washer, Flat #10 ID 1 20 B OW31129 Screw, Slotted Rnd. #8-32UNF x .375 1 1 21 B OW31232 Nut, Hex Keps #8-32 UNF 4 -22 B OW31124 Screw, Slotted Rnd. #16-32UNF x 50 23 B OW31231 Nut, Keps #6-32UNF 4 24 B OW31428 .Washer, Flat #6 4 25 67295-024 Cable, 8 cond 16 AWG Type SO 8LF 26 67295-023 Cable, 10 Cond 16 AWG Type SO 8 3LF 67295-004 Cable, 16Ga /12C - XL 8 3LF 27 67295-024 Cable, 8 Cond 16 AWG Type SO 6LF 28 34552-016 Terminal Stip 2 29 67940 Holder, Fuse 1 30 67939-015 Fuse, 15A 1/4" x 1 1/4 AGC-15 1 Wire, 12Ga White 4LF -31 58251 -32 58292

1.LF Wire, 16Ga White Disconnect, Sta-Kon Female 33 66720-001 6 34 BOW23087 Terminal, Female Push-On 16-18 2 35 67960-006 Ring Terminal, 16Ga #10 Stud 2 36 BOW23024 Ring Terminal, 16Ga 1/4" Stud 1 37 BOW23025 Ring Terminal, 16Ga 5 /16 Stud 1 38 BOW18578 Terminal, Piggyback Push-On 1 1 39 BOW23087-2 Terminal, Female Push-On 40 BOW23028 Terminal, 8 Stud 16/14Ga Spade 41 BOW23028 Terminal, 8 Stud 16/14Ga Spade - XL 43 41 67961-006 Terminal, 8 Stud 12/10Ga Spade 10

MANUAL 92377-003 March 1998 Revised1/99

FIGURE 6. 1 : Box Assembly -Lower Control

I OPERATING INSTRUCTIONS .TO OPERATE FROM GROUND. TURN SWITCH TO -"LOWER" POSITION_ • IN AN EMERGENCY, PUSH RED BOTTCN. TO OPERATE, BUTTON MUST BE PULLED OUT •PO1-1 TOGGLE :SWITCH TO MOVE PLATFORM. • TuRN SWITCH TO -UPPER" POSITION, \..11-9OPERATE FROM PLATFORM.

hi

PLATFORM RAISE

DOW PPER OFF LO ER

MANUAL 92377-003 March 1998 Revised1/99

FIGURE 6 .1 : Box Assembly - Lower Control V1433XL Serial Numb ers X11597076 Above -

V1833XL SerialNumbersX21598001 Above -

ITEM PART NUMBER DESCRIPTION

QTY

Ref. 55853 Box Assembly - Lower Control V14/1833-03 Ref.

Ref. 55853-XL Box Assembly - Lower Control V14/1833XL-03 Ref. 1 55752 Box, V1433 Lower Control 1 -2 55893 Decal, V1433 Lower Control Electrical Tags 1 3 51913 Operator-Push Pull 1 4 51914 Contact Block NC w/Base 1 5 52671 Operator, 3 Position Rotation Key ZB2-BG3 .1 6 52029 Contact, 2N0 w/Base 1 7 50075 Switch, SPDT Toggle 1 8 54438 Relay, 24V SPDT Bosch 1 -9 206-00001-00 Diode 8 10 67114-014 Strain Relief 1NPT 62/ 75 1.

11 67114-008 Connector, Strain Relief 2 12 67114-009 Strain Relief 3/4"NPT .621.75 .1 13 67124-003 Connector, Locknut 1"

1 14 67124-002 Locknut Connector .75 3 15 67123-003 Seal, Connector Electrical 1" 1 16 67123-002 Seal, Connector Electrical 3/4 " 3 -17 BOW23022 Ring Tongue 3 -18 67837-006 Tie, Nylon-6"Black 8 -19 B OW31430 Washer, Flat #10 ID 1 20 B OW31129 Screw, Slotted Rnd. #8-32UNF x .375 1 21 B OW31232 Nut, Hex Keps #8-32 T.

1 -22 B OW31125 Screw, Slotted Rnd. #6-32UNF x 5/8 4 23 BOW31231 Nut, Keps #6-32UNF 24 67295-024 Cable, 8 cond 16 AWG Type SO 8LF 25 67295-023 Cable, 10 Cond 16 AWG Type SO 8.3LF 67295-004 Cable, 16Ga /12C - XL 8.3LF 26 67295-024 Cable, 8 Cond 16 AWG Type SO 7'LF 27 34552-016 Terminal Strip 2.

28 67940 Holder, Fuse 1.

29 67939-015 Fuse, 15A 1/4" x 1 1/4 AGC-15 1 -30 58251 Wire, 12Ga White 4LF -31 58292 Wire, 16Ga White ILF 32 66720-001 Disconnect, Sta-Kon Female 6 33 BOW23087 Terminal, Female Push-On 16-18 2 34 67960-006 Ring Terminal, 16Ga #10 Stud 2 35 BOW23024 Ring Terminal, 16Ga 1/4" Stud 1 36 BOW23025 Ring Terminal, 16Ga 5/16" Stud 1 37 BOW18578 Terminal, Piggyback Push-On 1 38 BOW23028 Terminal, 8 Stud 16/14Ga Spade 41 BOW23028 Terminal, 8 Stud 16/14Ga Spade - XL 43 39 67961-006 Terminal, 8 Stud 12/10Ga Spade 10

MANUAL 92377-003 March 1998 Revised1/99

• I

5D 12 GA

5D 12 GA

I 00 3 PL

10C 10

y-7110A

SPARE

50 11

8C

SPARE

(."

7

11A

ISOLATE

89 [r-

12

2 PL

3 14

6

15

V'UPPER"

16

8A

4 I

=LOWER J ,

D

I 0 ol

50

RICHT SIDE LEFT SIDE

TO MOTOR CONTACTOR

TO ARMS/ PLATFORM

TO TEl ON CHASSIS

TO HYD VALVES

BOTTOM

4 PL

NOTES: 1. THIS SHEET SHOWS "STANDARD" WIRING ONLY. FOR ANY AND ALL OPTIONS, SEE SHEET 4, 2. ALL WIRING TO BE 16GA, EXCEPT CIRCUITS 3, 5 &5D, AS MARKED. 3. LOCATE ITEM 2, "EL TAGS", BETWEEN TERMINAL BOARDS.

UNLESS OTHERYASE NOTED: TOLERANCES: DECIMALS FRACTIONS 1/10 .5 t .1 ANGLES A t• .XX ± .03 .XXX 0 .010 suRrAct ',Nish+ "V PROJECN. OF \BEM © C:1

COVER

ALL DIMENSIONS ARE iN INCHES LIR.

LIR.

APPR,

DRAM

12/23/96

RAK

CHECKED

DATE

APPR.

APPROAD

D.C.N. NO,

DATE

10153 D.R.N. NO.

A.HITTLE

12/20/96

RAK

i 2/23/9 5

DIVISION OF TIME MFO. CO. 8300 iMPERiAL DRIVE WACO. TEXAS 78712

DWG, V14/18 LWR EL BOX ASSY SUE

DRAWN:, NO.

SCALE 1/2

55853 1,4E7 2 OF 4

REV.

E

FIGURE 6. 1 : Box Assembly -Lower Control V1433X1, Serial Numbers X11597076-Above e V1833XL SerialNumbersX21598001-Above

ITEM PART NUMBER DESCRIPTION

QTY

Box Assembly - Lower Control V14/1833-03 Ref. Ref. 55853 Ref. 55853-XL Box Assembly - Lower Control V14/1833XL-03 Ref. Box, V1433 Lower Control 1 1 55752 Decal, V1433 Lower Control Electrical Tags 1 2 55893 3 51913 Operator-Push Pull 1 Contact Block NC w/Base 4 51914 1 5 52671 Operator, 3 Position Rotation Key ZB2-BG3 .1 6 52029 Contact, 2N0 w/Base 1 Switch, SPDT Toggle 1 7 50075 Relay, 24V SPDT Bosch 8 54438 1

Diode

9 206-00001-00 8 10 67114-014 Strain Relief 1NPT 62/ 75 1 11 67114-008 Connector, Strain Relief 1 12 67114-009 Strain Relief 3/4"NPT .62/75 2 13 67124-003 Connector, Locknut 1" 1 3 14 67124-002 Locknut Connector .75 15 67123-003 Seal, Connector Electrical 1" 1 3 16 67123-002 Seal, Connector Electrical 3/4" 17 BOW23022 Ring Tongue

3 8 -18 67837-006 Tie,Nylon-6"Black -19 BOW31430 Washer, Flat #10 ID 1 20 B OW31129 Screw, Slotted Rnd. #8-32UNF x .375 .1 Nut, Hex Keps #8-32 UNF 21 BOW31232 1 -22 BOW31125 Screw, Slotted Rnd. #6-32UNF x 5/8 ..4 Nut, Keps #6-32UNF 23 BOW31231 4 .8LF 24 67295-024 Cable,8 cond 16 AWG Type SO 25 67295-023 Cable, 10 cond 16 AWG Type SO 8 3LF 67295-004 Cable,16Ga /12C-XL 8 3LF 26 67295-024 Cable, 8 cond 16 AWG Type SO

7'LF 27 34552-016 Terminal Strip 2 Holder, Fuse 28 67940 1

29 67939-015 Fuse, 15A 1/4" x 1 1/4" AGC-15 1 -30 58251 Wire, 12GA White

4LF -31 58292 Wire, 16GA White 1LF 32 66720-001 Disconnect, Sta-Kon Female 6 2 33 BOW23087 Terminal, Female Push-On 16-18 34 67960-006 Ring Terminal, 16GA #10 Stud 2 35 BOW23024 Ring Terminal, 16GA 1/4" Stud 1 36 BOW23025 Ring Terminal, 16GA 5/16" Stud 1 37 BOW18578 Terminal, Piggyback Push-On 1 38 BOW23028 Terminal, 8 Stud 16/14GA Spade 41 BOW23028 Terminal, 8 Stud 16/14GA Spade-XL 43 10 39 67961-006 Terminal, 8 Stud 12/10GA Spade

MANUAL 92377-003 March 1998 Revised1/99

TABLE 1

3 10 I OD 9 11A

BLU ORN

FUNCTION GROUND STROBE LIGHT OPTION

BLK RI-IT WHT /BLI< GRN RED RED /BLK

"FAST" TO LIMIT SWITCH FROM LS TO INHIBIT FAST LOWER PLATFORM "CREEP" TO LIMIT SWITCH FROM LS TO CREEP VALVE SEE NOTE 2 ON SHEET 4

--N

0

0

CABLE FOR - XL - MODELS TO HYD VALVE ASSY SEE TABLE 2 24" INSIDE BOX

Imi.uop Jamoq - XI gums sv xog : I

II COLOR

6 PL SPARE RED BLK 12" 18" INSIDE BOX

10" INSIDE BOX

0

0 Pb

TO TERMINAL BOARD ON CHASSIS SEE TABLE 1

SEE TABLE 3

64" CABLE SHEATH

#3 ORN 10" 63" CABLE SHEATH

TO HID VALVE ASSY SEE TABLE 2

STD CABLE TO MOTOR CONTACTOR

6 PL

6

9".10 1/7 ORN/BLK 8"

PL

#10A 52" CABLE SHEATH

TABLE 3 = CABLE TO If COLOR GRN 2 BLU 3 RED 4 BLU /BLK

Ek, 70

RP-

k‘i

5 RE[)/BLK 6 ORN 7 ORN/BLK WI-I T WH T/BLK 10 BLK BLK /WHT

'0

"XL" MODELS FUNCTION If 10A FAST UP 13 PROP DR 6 2 RD

GROUND LEFT FORWARD DOWN SPARE POSITRAC

TABLE 2 COLOR BLK PR-IT RED GRN ORN BLU WH T /BLK

RED /BL K

12 CRN /BLK 7 ORN /BLK RIGHT 4 REVERSE BLU/BLK 1I A CREEP EiLK /VvH7

STANDARD FUNCTION If FAST 10A UP 11A CREEP SPARE LEFT 6 FORWARD 2 DOWN RD RE VERSE 4 POSITRAC 12 7 RI GHT

(REF) SIGN AL CONTACTOR

(REF) GROUND CON T ACTOR

(5'

(REF ) + 24VDC POWER CONTACTOR (REF) 67964— 002 5' SLOPE SENSOR /BLIP

CONTROL BOX ON PLATFORM FUNCTION GROUND, OR SPARE, IF NO OPTIONS DRIVE FORWARD + 24VDC POWER TO PLATFORM DRIVE REVERSE BATTERY CONDITION INDICATOR OPTION STEER LEFT

12 GRN /BLK

STEER RIGHT RAISE PLATFORM LOWER PLATFORM FAST DRIVE SPEED CREEP DRIVE SPEED POSI TRACTI ON

13 RED/WHT 14 GRN /WHT 15 BLU/W1-IT 16 BLK /RED

PROPORTIONAL DRIVE OPTION SLOPE ALARM OPTION INDICATE LOW VOLT OPTION OVERIDE LOW VOLT INTERRUPT OPTION

UNLES, OTHERYSISE NOTE 0:

(REF) 67964— 002 (REF) — 5' SLOPE SENSOR/WET 67964— 002 5• SLOPE SENSOR/RED

TOLE RANCE. MAC:11.s 3 1/16 ANOU S 3 SURFACE ram*. '0/ PROJEC11. CF Va

DWG, V14/18 LWR EL BOX ASSY

ALL DIME N.X1S ARE IN INC•HES L TR. -

D.C.N. NO.

111153

DATE 12 /23/W5 DATE

Ai-PR.

(IRA.

A. HI TILE

1 2/2OP

R AK

12/23/.

RAP CHECKED APRA, APPROVEDD

DNS'. OF TIME MF O. CO. 8300 IMPERIAL DRNE WACO. TE XAti 767, 2

DECIMALS x .1 .X X X 3 .010 T1 E

NO

REV.

(PORNO N.

B SCALE 1/2

E

55853 SMEE T 3

OF 4

FIGURE 6.1: Box Assembly Lower Control V1433XL Serial Numb ers X11597076-Above -

V1833XL SerialNumbersX21598001-Above

ITEM PART NUMBER DESCRIPTION

QTY

Box Assembly - Lower Control V14/1833-03 Ref. Ref. 55853 Ref. 55853-XL Box Assembly - Lower Control V14/1833XL-03 Ref. Box, V1433 Lower Control 1 55752 1 Decal, V1433 Lower Control Electrical Tags 1 2 55893 Operator-Push Pull 3 51913 1 Contact Block NC w/Base 4 51914 1 1 Operator, 3 Position Rotation Key ZB2-BG3 5 52671 Contact, 2NO.w/Base 6 52029 1 Switch, SPDT Toggle 1 7 50075 .Relay, 24V SPDT Bosch 8 54438 I. 9 206-00001-00 Diode 8 10 67114-014 Strain Relief 1NPT 62/ 75 1 1.

11 67114-008 Connector, Strain Relief 2 12 67114-009 Strain Relief 3/4"NPT .621.75 13 67124-003 Connector, Locknut 1" 1 3 14 67124-002 Locknut Connector .75 1 15 67123-003 Seal, Connector Electrical 1" 16 67123-002 Seal, Connector Electrical 3/4" 3 -17 B OW.23022 Ring Tongue

a -18 67837-006 Tie,Nylon-6"Black 8 -19 BOW31430 Washer, Flat #10 ID 1 20 BOW31129 Screw, Slotted Rnd. #8-32UNF x .375 1 Hex Keps 48-32 UNF

21 BOW31232 Nut, 1 4 -22 BOW31125 Screw, Slotted Rnd. #6-32UNF x 5/8 23 BOW31231 Nut, Keps #6-32UNF Cable, 8 cond 16 AWG Type SO 8LF 24 67295-024 8 3LF 25 67295-023 Cable, 10 cond 16 AWG Type SO 67295-004 Cable, 16GA /12C-XL 8 3LF 26 67295-024 Cable, 8 cond 16 AWG Type SO TLF

Terminal Strip

27 34552-016 2.

Holder, Fuse 28 67940 1.

29 67939-015 Fuse, 15A 1/4" x 1 1/4" AGC-15 1 Wire, 12GA. White 4LF -30 58251 1LF -31 58292 Wire, 16GA White 32 66720-001 Disconnect, Sta-Kon Female 6 2 33 BOW23087 Terminal Female Push-On 16-18 34 67960-006 Ring Terminal, 16GA. 410 Stud 2 1 35 BOW23024 Ring Terminal, 16GA 1/4" Stud 36 BOW23025 Ring Terminal, 16GA 5/16" Stud 1 1 37 BOW18578 Terminal, Piggyback Push-On 41 38 BOW23028 Terminal, 8 Stud 16/14GA. Spade 43 BOW23028 Terminal, 8 Stud 16/14GA Spade-XL 10 39 67961-006 Terminal, 8 Stud 12/10GA> Spade

MANUAL 92377-003 March 1998 Revised 1/99

5D 12 (A

I

SPARE

3 12 GA ,D

12 GA

SEE NOTE 3

5 5B

\_"LIPPER"

REF: BOW23087 5' SLOPE OPTION

"LOWER" SC

J RIGHT SIDE LEFT SIDE

TO MOTOR CONTACTOR

TO ARMS/ PLATFORM

TO TB ON CHASSIS

Z.),

I_ SA 88 IS

I

5D

SEE NOTE 4

VI

E=2

15

1 2 ALARM 0

0

1. THIS SHEET SHOWS ALL OPTIONS, SEE SHEET 2 FOR "STANDARD" WIRING. 2 ALL WIRING TO BE 16 GA, EXCEPT CIRCUITS 3.5 & 5D, AS MARKED,

BOTTOM

(

NOTES:

3. • IF NO ALARM OPTION, OR IF DESCEND ALARM OPTION, THEN CONNECT "RED/BLK" TO "BLANK" TERMINAL, AS SHOWN. IN THIS CASE THE RED/BLK CONDUCTOR IN THE CABLE TO THE TERMINAL E3OARD ON THE CHASSIS, IS A SPARE, DESCEND ALARM IS CONNECTED TO CIRCUIT //9 ON THE TERMINAL BOARD ON THE CHASSIS. • FOR MOTION ALARM OPTION, MOVE "RED/BLK" TO TERMINAL 8C AND ADD TWO DIODES TO TERMINAL 8C AS SHOWN. • FOR TRAVEL ALARM OPTION, JUMPER "BLANK" TO 8D AND MOVE WHT/BLK CONDUCTOR, IN CABLE TO HYD VALVES, FROM 8D TO "BLANK" TERMINAL. 4 IF LOW VOLT OPTION IS USED, THEN REMOVE JUMPER BETWEEN 8A AND 8B,

INTERRUPT 5 RESET 6 GROUND 7 POWER

UNIV. OTHERNIS£ NOTED: TOLERANCES:

DECIMALS .x ± .XX .03 .XXX .010 TiTLE 12t/ PROJECT. a- MW 0

1116

COVER D.C.N. NO.

10103

,ATE

APPR.

ORA.

1 2/23/.

R AK

CNECKD

DATE

APPR.

APPROVED

ki

DtWAON OF VA MFG. 6300 IMPERIAL DRIVE WACO, TEXAS 7672

-

CO.

DWG, V14/18 LWR EL BOX ASSY

GO

ALL DIME WWI,: ARE IN INCHES L TR.

M=`, CUU

A.HITTLE

/20/90

RAK

12/23/90

.2E

SCALE

DRAWN(' NO

1/2

REV.

55853 ' ,Ed

E 4 OF .4

FIGURE 6.1 : Box Assembly - Lower Control V1433XL Serial NumbersX11597076-Above V1833XL SerialNumbersX21598001-Above

ITEM PART NUMBER DESCRIPTION

QTY

Ref. 55853 Box Assembly - Lower Control V14/1833-03 Ref. Ref. 55853-XL Box Assembly - Lower ControlV14/1833 XL-03 Ref. 1 55752 Box, V1433 Lower Control 1 2 55893 Decal, V1433 Lower Control Electrical Tags 1 3 51913 Operator-Push Pull 1 4 51914 Contact Block NC w/Base 1 5 52671 Operator, 3 Position Rotation Key ZB2-BG3 .1 6 52029 Contact, 2NO w/Base 1 7 50075 Switch, SPDT Toggle 1 8 54438 Relay, 24V SPDT Bosch 1 9 206-00001-00 Diode 8 10 67114-014 Strain Relief 1NPT 62/ 75 J. 11 67114-008 Connector, Strain Relief 1 12 67114-009 Strain Relief 3/4"NPT .621.75 2 13 67124-003 Connector, Locknut 1 1 14 67124-002 Locknut Connector .75 3 15 67123-003 Seal, Connector Electrical 1"

1 16 67123-002 Seal, Connector Electrical 3/4" 3 -17 BOW23022 Ring Tongue 3 -18 67837-006 Tie,Nylon-6"Black 8 -19 BOW31430 Washer, Flat #10 ID 1 20 BOW31129 Screw, Slotted Rnd #8-32UNF x 375 1 21 BOW31232 Nut, Hex Keps #8-32 UNF I. -22 BOW31125 Screw, Slotted Rnd. #6-32UNF x 5/8 4 23 BOW31231 Nut, Keps #6-32UNF 4 24 67295-024 Cable, 8 cond 16 AWG Type SO 8LF 25 67295-023 Cable, 10 cond 16 AWG Type SO 8 3LF 67295-004 Cable, 16GA /12C-XL 8 3LF 26 67295-024 Cable, 8 cond 16 AWG Type SO 7'LF 27 34552-016 Terminal Strip 2 28 67940 Holder, Fuse 1 29 67939-015 Fuse,15A 1/4" x 1 1/4" AGC-15 1 -30 58251 Wire, 12GA. White 4LF -31 58292 Wire, 16GA White LLF 32 66720-001 Disconnect, Sta-Kon Female 6 33 BOW23087 Terminal,Female Push-On 16-18 2 34 67960-006 Ring Terminal, 16GA. #10 Stud 2 35 BOW23024 Ring Terminal, 16GA 1/4" Stud 1 36 BOW23025 Ring Termina1,16GA 5/16" Stud 1 37 BOW18578 Terminal, Piggyback Push-On 1 38 BOW23028 Terminal, 8 Stud 16/14GA Spade 41 BOW23028 Terminal, 8 Stud 16/14GA 5/16" Spade-XL 43 39 67961-006 Terminal, 8 Stud 12/1OGA. Spade 10

MANUAL 92377-003 March 1998 Revised 1/99

78

FIGURE 7.1: Armstack Assembly-V1433/V1433 XL

' 13 ) REF SEE NOTE 2

13 ) REF SEE NOTE 2

N

1

13 REF SEE NOTE 2

3023 2 PL

26 251 31

13 REF SEE NOTE 2

K2122) 2 PL z0

MANUAL 92377-003 March 1998 Revised1/99

13 } REF SEE NOTE 2

FIGURE 7 . 1 : Armstack Assembly-Vi 433 N1433 XL ITEM PART NUMBER DESCRIPTION

QTY

Ref. 55581-55581XL Arm Assembly V14331V1433XL 1 55580 Arm Weldment, V1433 Lower Outer 2 55590 Arm Weldment, V1433 Lower Inner 3 55591 Arm Weldment, V1433 LH Outer 4 55618 Arm Weldment, V1433 RH Outer 5 55647 Arm Weldment, V1433 Middle Inner 6 55648 Arm Weldment, V1433 Upper Outer 7 55649 Arm Weldment, V1433 Upper Inner 8 81368-05-40 Bearing, 1.25 ID x 2.5 L x 1/8" W 9 55582-002 Pin, V14/18 6 88"L Arm 10 55582-001 Pin, V14/18 18.25 L Arm

..Ref. 1 1 1 1 1 1 1 14 6 4

11 67281-005 Wrapping, Spiral 3/4" 12 167-00001-00 Collar, 1 V4" Shaft 13 BOW30010 Bolt, Hex 25-20UNC x 2.5L

2 83LF 14

11 14 BOW31431 Washer, Flat .25 ID x .63 OD 19 15 BOW34272 Nut, 25-20UNC Nylon Lock 13 16 02236 Elbow 90° MJ04 M004 1 17 55538 Cylinder, V1433 2.5 x 30.75 Lift 1 55539 Cylinder, V1433XL 2.5 x 30.75 Lift 1 18 55582-003 Pin, V14/18 6 25"L Arm 2 19 BOW32606 Clamp, Wire Loom 1" Dia 8 20 BOW9977 0-Ring, 375 ID x 500 OD 1 21 BOW30000 Bolt, Hex 25-20UNC x .50 2 22 BOW31401 Washer, Flat .25 ID x .63 OD 2 23 BOW30035 Bolt, Hex 31-18UNC x 2 50 2 24 BOW30012 Bolt, 25-20UNC x 3 00 Gr5 Hex 1 25 55083 Manifold Assembly, Lift Cylinder 1 26 55715 Bracket, V1433 Lowering Cable 1 27 54798 Coupling Nut, 10-32UNF 1 28 55848-014 Harness, V1433 Main Control 1 56130-014 Harness, V1433XL Main Control 1 29 81368-05-14 Gar-Max 1.25 x 1.50 OD x .88L 4 30 BOW31432 Washer, .31 ID x .68 OD 8 31 02857 Elbow 90° MJ04 M006 1 -32 55581-DWG Dwg, V1433/XL Armstack Installation 1 33 67295-017 Cable, 12Ga./3C 1433XL 42LF.

- Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

r

8 PL

REF PADS & PIN ARE IN FINAL ASSY

'4'

"

4 PL

:

4 PL

Allrafr/

r

int

8 PL

000

az:Kw:Ksi.w, Efo.

r 'Mr A

SEE NOTE #1

SECTION C—C 4 PL PL

• 00

2 PL 0 2 FL 0

Areer

2 FL

0

If 2 FL 0

I

•

un

1.....11.1.0"

SEE NOTE iy 1

SECTION B—B

woo

4 PL

RIGHT SIDE VIEW

,111116

4 PL

REF-PADS & PIN ARE IN FINAL ASSY REF-PIN IS IN FINAL ASSY REF - CYLINDER

II/ 111.;

!"-

.5.

4 PL

4 FL

15 11=1V

Ig.h.V1W1,1

SEE NOTE #1

SECTION A—A 2 PL

4 FL 2 PL

SECTION D—D

2 FL

40

,4

.0a7"',Z■ci\<,

FIGURE 7.1: Armstack Assembly-Vi433/V1433 XL

REF-BRG BLOCK IS IN PLTFRM ASSY -PIN IS IN FINAL ASSY

FIGURE7.1:ArmstackAssembly-V1433N1433XL ITEM PART NUMBER DESCRIPTION

QTY

Ref. 55581 Arm Assembly V1433/V1433XL Ref. 1 55580 Arm Weldment, V1433 Lower Outer 1 2 55590 Arm Weldment, V1433 Lower Inner 1 3 55591 Arm Weldment, V1433 LH Outer 1 4 55618 Arm Weldment, V1433 RH Outer 1 5 55647 Arm Weldment, V1433 Middle Inner 1 6 55648 Arm Weldment, V1433 Upper Outer 1 7 55649 Arm Weldment, V1433 Upper Inner 1 8 81368-05-40 Bearing, 1.25 ID x 2.5 L x 1/8" W 14 9 55582-002 Pin, V14/18 6.88'L Arm

6 10 55582-001 Pin, V14/18 18 25" L Arm 4 11 67281-005 Wrapping, Spiral 3/4" 2 83LF 12 167-00001-00 Collar, 1 1/4" Shaft 14 13 BOW30010 Bolt, Hex 25-20UNC x 2.5L 12 14 BOW31431 Washer, Flat .25 ID x .63 OD 19 15 BOW34272 Nut, 25-20UNC Nylon Lock 13 16 02236 Elbow 90° MJ04 M004 I. 17 55538 Cylinder, V1433 2.5 x 30.75 Lift 1 55539 Cylinder, V1433XL 2.5 x 30.75 Lift 1 18 55582-003 Pin, V14/18 6 25"L Arm 2 19 BOW32606 Clamp, Wire Loom 1" Dia

8 20 BOW9977 0-Ring, .375 ID x .500 OD 1 21 BOW30000 Bolt, Hex 25-20UNC x 50 2 22 BOW31401 Washer, Flat .25 ID x .63 OD 2 23 BOW30035 Bolt, Hex 31-18UNC x 2 50 2 24 BOW30012 Bolt, 25-20UNC x 3 00 Gr5 Hex 1 25 55083 Manifold Assembly, Lift Cylinder 1 26 55715 Bracket, V1433 Lowering Cable 1 27 54798 Coupling Nut, 10-32UNF I. 28 55848-014 Harness, V1433 Main Control 1 56130-014 Harness, V1433XL Main Control 1 29 81368-05-14 Bearing, 1 25 ID x 875 L x 1/8"W 4 30 BOW31432 Washer, .31 ID x .68 OD 8 31 02857 1 Elbow 90° MJ04 M006 -32 55581-DWG Dwg, V1433/XL Armstack Installation 1 33 67295-017 Cable, l2Ga./3C 1433XL 42LF. - Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

FIGURE 7.2: Armstack Assembly-V1833/V1833XL

-

_

---------'

.-----'-<-_ ___ CC) -„ REF SEE NOTE 2 ------- ___----->-----__ __--- __-----__---- ----_ _----- .---- _------

-------

_ -_ REF SEE NOTE 2

14 REF SEE NOTE 2

REF SEE NOTE 2

23'

2 PL

'

27 REF SEE NOTE

2

32 1 '14 REF SEE NOTE 2

PL

REF SEE NOTE 2

MANUAL 92377-003 March 1998 Revised1/99

FIGURE 7.2: Armstack Assembly-V1833/V1833 XL ITEM PART NUMBER DESCRIPTION Ref. 55659-55659XL Arm Assembly V1833N1833XL 1 55580 Arm Weldment, V1433 Lower Outer 2 55590 Arm Weldment, V1433 Lower Inner 3 55591 Arm Weldment, V1433 LH Outer 4 55618 Arm Weldment, V1433 RH Outer 5 55647 Arm Weldment, V1433 Middle Inner 6 55682-002 Arm Weldment, VI833 RH Outer 7 55682-001 Arm Weldment, V1833 LH Outer 8 55660 Arm Weldment, V1833 Upper Inner 9 55662 Arm Weldment, V1833 Upper Outer 10 55661 Arm Weldment, V1833 Upper Inner 11 81368-05-40 Bearing, 1.25 ID x 2.5 L x 1/8" W 12 55582-001 Pin, V14/18 18 25"Lg Arm 13 55582-002 Pin, V14/18 6 88"Lg Arm 14 BOW30010 Bolt, Hex 25-20UNC x 2.5 L 15 BOW31431 Washer, Flat .25 ID x .63 OD 16 BOW34272 Nut, 25-20UNC Nylon Lock 17 02236 Elbow 90° MJ04 M004 18 55848-018 Harness Assembly, Main Cable 56130-018 Harness Assembly, XL Main Cable 19 BOW30012 Bolt, Hex 25-20UNC x 3.00 20 BOW32606 Clamp, Wire Loom 1" Dia 21 BOW9977 0-Ring, .375 ID x .500 OD 22 BOW30000 Bolt, Hex 25-20UNC x .50 23 B OW31401 Washer, Flat 31 ID x 68 OD 24 BOW30035 Bolt, Hex 31-18UNC x 2.50 25 02857 Elbow, 90° MJ04 M006 26 55083 Manifold Assembly, Lift Cylinder 27 55715 Bracket, V1433 Lowering Cable 28 54798 Coupling Nut, 10-32UNF 29 67281-005 Wrapping, 3/4" Black/Spiral 30 81368-05-14 Bearing, 1.25 ID x 875 L x 1.50 OD 31 167-00001-00 Collar, R# 66388 1.25" Shaft 32 55536 Cylinder, V1833XL 3 x 30.75 Lift 55540 Cylinder, V1833 3 x 30 75 Lift 33 55582-003 Pin, 6 25"Lg Ann 34 55659-DWG Dwg, Armstack Installation 35 67295-017 Cable, 3 Conductor 12Ga XL

- Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

QTY Ref. 1 1 1 1 1 1 1 1 1 1 20 7 6 14 20 20 1.

1 1 1 10 1 2 2 2 1 1 1 1 2 83LF 4 20 1 1 2.

35LF

REF-BRC, BLOCK IS IN PLIRM ASSY -PIN IS IN FINAL ASSY

•

0 0

6 PL 0 "PLAIN"

PL

Iro r/

7.11,2 I

A FL

"XL"

f

low

6 PL

Arz.vmv, 445.21.

SECTION D-D 3 FL

"XL" ONLY

0

0 0

PL

4 FL

4 PL 0

8 FL 4 PL

•

2 PL

LEFT FARSIDE

I

111113

'1,11,V4 SIO

I P IP 4, P PA WI,

SECTION 0-0 4 FL

iNik 1I I '

000

2 FL IIMINILVI.

.*

2 PL

RIGHT NEARSIDE

77,

■■■■; v./

:7-,..1C-Nrs:

e

V.,1 Piir/ ,

II

2 PL

4

11111.1

'I K1Ial■ • mar

SECTION B-B

4 FL REF-CYLINDER

4 FL

REF-PADS & PIN ARE IN FINAL ASSY REF-PIN IS IN FINAL ASSY 4 FL C)

RIGHT SIDE VIEW

000

at

4 FL ., an \MEL

IF

wow SECTION A-A 2 PL

SECTION E-E

2 PL

liii

.2:Armstack Assembly-Vi833/V1833 XL

REF PADS A PIN ARE IN FINAL ASSY

3PL

FIGURE 7.2 : Armstack Assembly-V1833/V183 3)a, ITEM PART NUMBER DESCRIPTION

QTY

Ref. 55659-55659XL Arm Assembly V1833N1833XL Ref. 1 55580 Arm Weldment, V1433 Lower Outer 1 2 55590 Arm Weldment, V1433 Lower Inner 1 3 55591 Arm Weldment, V1433 LH Outer.

1 4 55618 Arm Weldment, V1433 RH Outer 1 5 55647 Arm Weldment, V1433 Middle Inner 1 6 55682-002 Arm Weldment, V1833 RH Outer 1 7 55682-001 Arm Weldment, V1833 LH Outer 1 8 55660 Arm Weldment, V1833 Upper Inner 1 9 55662 Arm Weldment, V1833 Upper Outer 1 10 55661 Arm Weldment, V1833 Upper Inner 1 11 81368-05-40 Bearing, 1.25 ID x 2.5 L x 1/8" W 20 12 55582-001 Pin, V14/18 18 25"Lg Arm 7 13 55582-002 Pin, V14/18 6 88"Lg Arm 6 14 BOW30010 Bolt, Hex 25-20UNC x 2.5 L 14 15 BOW31431 Washer, Flat .25 ID x .63 OD 20 16 BOW34272 Nut, 25-20UNC Nylon Lock 20 17 02236 Elbow 90° MJ04 M004 1.

18 55848-018 Harness Assembly, Main Cable ' 1 55849-018 Harness Assembly, XL Main Cable 1 19 BOW30012 Bolt, Hex 25-20UNC x 3 00 1 20 BOW32606 Clamp, Wire Loom 1" Dia 10 21 BOW9977 0-Ring, .375 ID x 500 OD 1 22 BOW30000 Bolt, Hex 25-20UNC x .50 2 23 BOW31401 Washer, Flat 31 ID x .68 OD 2 24 BOW30035 Bolt, Hex 31-18UNC x 2 50 2 25 02857 Elbow, 90° MJ04 M006 1 26 55083 .Manifold Assembly, Lift Cylinder 1 27 55715 Bracket, V1433 Lowering Cable 1 28 54798 Coupling Nut, 10-32UNF 1 29 67281-005 Wrapping, 3/4" Black/Spiral 2 83LF 30 81368-05-14 Bearing, 1.25 ID x .875 L x 1.50 OD 4 31 167-00001-00 Collar, R# 66388 1.25" Shaft 20 32 55536 Cylinder, V1833XL 3 x 30 75 Lift 1 55540 Cylinder, V1833 3 x 30 75 Lift 1 33 55582-003 Pin, 6 25"Lg Arm 2.

34 55659-DWG Dwg, Armstack Installation 35 67295-017 Cable, 3 Conductor 12Ga XL 35LF - Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

FIGURE7.3:ArmstackLiftCylinderAssembly-V1433

CAVITY FOR PARKER FV101S VALVE CARTRIDGE REF. CONDOR #55221 REF FOUR BUSHING 34145

ITEM PART NUMBER DESCRIPTION

Ref. 55538 Armstack Lift Cylinder Assembly 55538-100 Seal Kit

Castle Nut Cast Iron Ring

Piston (Steel) Wear ring

Jacket Assembly

Piston Rod

Gland Nut 55221 Flow Control Valve, Lift Cylinder - Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

QTY

Ref.

FIGURE7.4:AnnstackLiftCylinderAssembly-V1433xi,

CAVITY FOR PARKER FV1015 VALVE CARTRIDGE REF. CONDOR #55221 \REF FOUR BUSHING 34145

it

ITEM PART NUMBER DESCRIPTION Ref. 55539 .. ..Armstack Lift Cylinder Assembly 55539-100 Seal Kit

Castle Nut

Cast Iron Ring

Piston (Steel) Wear ring

Jacket Assembly Piston Rod Gland Nut

55221 Flow Control Valve, Lift Cylinder

....

- Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

QTY Ref.

FIGURE7.5:ArmstackLiftCylinderAssembly-V1833XL

CAVITY FOR PARKER FV101S VALVE CARTRIDGE REF. CONDOR #55221 \REF FOUR BUSHING 34145

ITEM PART NUMBER DESCRIPTION Ref. 55536 Armstack Lift Cylinder Assembly 55536-100 Seal Kit

Castle Nut

Cast Iron Ring

Piston (Steel) Wear ring

Jacket Assembly

Piston Rod

Gland Nut 55221 Flow Control Valve, Lift Cylinder

- Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

QTY Ref.

FIGURE 7.6: Armstack Lift Cylinder Ass emb ly-V1833

CAVITY FOR PARKER FV101S VALVE CARTRIDGE REF. CONDOR #55221 REF FOUR BUSHING 34145

ITEM PART NUMBER DESCRIPTION Ref. 55540 Armstack Lift Cylinder Assembly 55540-100 Seal Kit

Castle Nut Cast Iron Ring

Piston (Steel)

Wear ring

Jacket Assembly

Piston Rod

Gland Nut 55221 Flow Control Valve, Lift Cylinder

- Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

QTY Ref.

FIGURE 7.7: Manifold Assembly ITEM PART NUMBER DESCRIPTION

Ref. 55083 Manifold Assembly -1 54596-001 Manifold, Lift Cylinder -2 54635-001 Valve, 2W NC SPCL Cartridge -3 00417 .Plug M004 No Drawing At This Time - Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

QTY

Ref. 1.

1 1

FIGURE 7.8 : Harness Assembly

CIRCUIT 2 3 4

COLOR BLU RED BLU/BLK

FUNCTION DRIVE FORWARD + 24VDC POWER DRIVE REVERSE

6

ORN

STEER LEFT

7 8

ORN/ELK WHT

STEER RIGHT RAISE PLATFORM

9

WHT/BLK

LOWER PLATFORM

10 11

ELK BLK/WHT GRN/ELK

FAST DRIVE SPEED CREEP DRIVE SPEED POSITRTACTION

RED/ELK GRN

SPARE SPARE

12

(REF)

REF CABLE SHEATH SHOWN BEFORE ASSY

ITEM PART NUMBER DESCRIPTION

Ref. 55848-018 Harness Assembly 1 67295-004 Cable, 16GA/12C 2 67114-009 Strain Relief 3/4NPT 69/.75 3 67124-002 Locknut, 3/4 NPT Conduit 4 67123-002 Seal, Connector Elect. 3/4" 5 67961-004 SpadeTerminal, 10 Stud 16/14GA 6 67960-006 RingTerminal, 10 Stud 16/14GA - Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

QTY

Ref. 26LF 1 1 1 4 6

FIGURE 7. 9 : Harness Assembly

CIRCUIT 1 2 3 4 5

COLOR

FUNCTION

ORN BLU

GROUND, OR, SPARE, IF NO OPTIONS DRIVE FORWARD + 24VDC POWER

RED BLU/BLK RED/BLK ORN

BATTERY CONDITION INDICATOR OPTION STEER LEFT STEER RICHT

8

ORN/BLK WHT

RAISE PLATFORM

9

WHT/BLK

LOWER PLATFORM

10 11

BLK BLK/WHT

FAST DRIVE SPEED CREEP DRIVE SPEED

12

GRN/BLK

POSITRACTION VALVE

7

(

REF)

L00 0000 00 1

6

3/8 STRIPPED 12 PL

DRIVE REVERSE

BELOW LISTED OPTIONS REQUIRE 16CA/16C CABLE 13

RED/WHT

14

GRN/WHT

15 16

BLU/WHT

PORPORTIONAL DRIVE OPTION SLOPE ALARM OPTION INDICATE LOW VOLT OPTION

BLK/RED

OVERRIDE LOW VOLT OPTION

REF CABLE SHEATH SHOWN BEFORE ASSY

NOTES: 1. CONNECTOR PIN NUMBER IS SAME AS CIRCUIT NUMBER.

- 2 3/4 12 PL INDIVIDUAL CONDUCTORS

2. CIRCUITS 13-16 ARE SHOWN FOR REFERENCE ONLY.

ITEM PART NUMBER DESCRIPTION

QTY

Ref. 56130-18XL Harness Assembly XL 1 67295-003 Cable, 16GA/12C (55849-014) 2 54910-105 Strain Relief, ST-21 3 54910-103 Hood, S/Bolt 1 x 21 T/E 4 54910-101 Plug, Screw Term #1-16

Ref. 41LF

- Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

1 1 1

FIGURE :7.10Hamess DWG ITEM PART NUMBER DESCRIPTION

QTY

Ref. 55848-014 Harness DWG 1 67295-004 Cable, 16GA/12C 2 67114-009 Strain Relief 3/4NPT .691.75 3 67124-002 Locknut-3/4 NPT Conduit 4 67123-002 Seal, Connector, Electric 3/4" 5 67961-004 SpadeTerminal 10 Stud 16/14GA 6 67960-006 Ring Tenninal 10 Stud 16/14GA

Ref 1 1 1 4 6

- Indicates Items Not Shown

CIRCUIT 2

COLOR

FUNCTION DRIVE FORWARD + 24VDC ROWER DRIVE REVERSE

4

BLU RED BLU/BLK

6

ORN

STEER LEFT

7

ORN /BLK

3

8

WHT

STEER RIGHT RAISE PLATFORM

9

WHT/BLK

LOWER PLATFORM

10 11 12

BLK

FAST DRIVE SPEED

BLK /WHT ORN/BLK

CREEP DRIVE SPEED POSITRTACTION

RED/BLK

SPARE

GRN

SPARE

7

,REF,

'2 REF CABLE SHEATH SHOWN BEFORE ASSY

MANUAL 92377-003 March 1998 Revised 1/99

FIGURE : 7.1 1 Harness DWG ITEM PART NUMBER DESCRIPTION

Ref. 56130-1430L Harness DWG 1 67295-003 Cable, 16(1A/16(:

2 54910-105 Strain Relief, ST-21 3 54910-103 Hood, S/Bolt 1 x 21 TIE 4 54910-101 Plug, Screw Terminal 41 16 -

QTY

Ref. 3 1 I 1

- Indicates Items Not Shown

CIRCUIT 1 2 3 4

COLOR ORN BLU RED BLU/BLK

GROUND, OR, SPARE, IF NO OPTIONS DRIVE FORWARD + 24VDC POWER

5 6

RED/BLK ORN

BATTERY CONDITION INDICATOR OPTION STEER LEFT

7

ORN /BLK WHT WHT/BLK

STEER RIGHT

8 9 10 11

FUNCTION

BLK BLK /WH T

CREEP DRIVE SPEED POSI TRACTION VALVE

14

PORPORTIONAL DRIVE SLOPE ALARM

15 16

BLU /WHT BLK /RED

OVERRIDE LOW VOLT

13

(4

RAISE PLATFORM LOWER PLATFORM FAST DRIVE SPEED

CRN /BLK RED/WHT GRN/WHT

12

3/8 STRIPPED 12 PL

DRIVE REVERSE

INDICATE LOW VOLT REF CABLE SHEATH SHOWN BEFORE ASSY

MANUAL 92377-003 March 1998 Revised1/99

- 2 3/4 16 PL INDIVIDUAL CONDUCTORS

This Page intentionally leftb lank

MANUAL 92377-003 March 1998 Revised1/99

FIGURE 8.1: Platform Installation-V14/1833

dill 11

.,

( Side View)

MANUAL 92377-003 March 1998 Revised1/99

FIGURE 8.1 : Platform Installation-V14/1833 ITEM PART NUMBER DESCRIPTION

Platform Installation V14/1833 Ref. 55767 1 55757 .Platform Weldment Block, Arm/Platform Brg 2 55578 3 55766 Guardrail Weldment, Front 4 55765 Guardrail Weldment, Entry Guardrail, Side 5 55764 6 164-00013-00 Chain, 2/0 Chain Snap 7 50286 S-Hook

8 BOW2548 9 BOW30038 Bolt, Hex 31-18UNC x 3 25 10 BOW34273 Nut, Hex .31-18UNC 11 BOW31326 Washer, Lock .31 ID 12 BOW39009 Bolt, Hex 25-20UNC x 2.50 13 BOW34272 Nut, Hex Nylon Lock 25-20UNC 14 BOW36701 Washer, Flat .25 ID 15 BOW39012 Bolt, Hex 25-20UNC x 3 0 7

- Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

QTY

Ref. 1 2 1.

1 2 2 1OLF 1 1 4 4 8 4 12 24 8

.

FIGURE 8.2: Platform Installation-V14/1833XL

/---VM

\ill0z)

3)

3 PLI23124132J ( 9 PL 21 )

ATTACH CHAIN ON RIGHT SIDE

26130 ) SIDE I. \—/\-

4)..÷A.F SIDE 16 PL

213'23,124) 2 PL 117 J18 )

21) 2 PL 211 4 PL

7----\7-----N ;22124 ) 2 PL ----„/------N ..,./\ i 21.124 4 PL f ; 21 4 PL (718 21)8 PL

24)23I2 PL

;24 's 2 PL

0

( 21) 4 PL •••/-* 24 J 31) 2 PL 29I3Oi8 PL 2 ; 30129 ) 4 PL 25 i8 PL

I13i14J20i4 PL 151 2 PL NEAR SIDE ( 28 ) z FL FAR SIDE

MANUAL 92377-003 March 1998 Revised1/99

, (25127 j30) 4 PL

16;

FIGURE 8.2: Platform Installation-V14/1 83 3)a, ITEM PART NUMBER DESCRIPTION

QTY

Ref. 55646 .Platform Installation V14/1833XL 1 55644 .Platform Weldment 2 55578 Block, V14/18 Arm/Platform BRG 3 55636-001 Toeboard Weldmenti, LH 4 55636-002 Toeboard Weldment, RH 5 55645 Handrail, Side 6 55639 Gate, Lift-up Entry 7 55471 Plunger, Latch 8 55243 Spring, Deck Latch Split Ring, Zinc Plated 9 55031 10 164-00013-00 Chain

Chain Snap 11 50286 12 BOW2548 S-Hook 13 54682 Mount Weldment, Ext. Deck Roller

14 54689 Roller, Ext. Deck 15 BOW36718-HD Washer, 3/4" SAE Flat 16 55630 Deck Weldment, V14/1833 XL Ext. 17 55563 Bracket Weldment, Lock Mount 18 55241 Latch Assembly, Deck 62-11UNC Mount 55245 Latch Body, Deck 62-11UNC Mount 55243 Spring, Deck Latch 55242 Plunger 55031 Split Ring 19 55625 Handrail Weldment, XL 20 BOW36702-HD Washer, .313 813"OD x .344"ID x .10 21 BOW36701 Washer, 1/4 Flat 22 BOW39008 Bolt, 1/4-20 x 2.00 Gr 8 HD Hex 23 BOW39002 Bolt, 1/4-20 x 3/4 Gr 8 Hex HD 24 BOW34272 Nut, 25-20UNC Nylon Lock 25 B OW331432 Washer, 31"ID Flat

26 BOW34602 Bolt, 31-18UNC x 1 25 27 BOW30036 Bolt, 31-18UNC x 3 00 Hex 28 BOW36708 Washer, .75 Flat 29 BOW39029 Bolt, 5/16-18UNC x 1 Gr 8 Hex HD 30 BOW34273 Nut, 5/16-18UNC Hex Lock 31 BOW39014 Bolt, 1/4-20 x 3 50 Gr 8 HD Hex 32 65099-14 Clamp, .875 Dia. •Steel Cush Loop 33 55207 Plug, Dome

Ref. 1 2 1 1 2 1 2.

2.

2 2 6LF 1 1 4 4 2 1 1 1 1 1 1 L. 1 8 29 2 9 13 28 18 4 2.

8 28 2 3 2.

- Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised 1/99

.

FIGURE 8.3 : Upper Control B ox Assembly

6 PL 2 FL

CD 3 PL

I N SI DE MEW OF OPEN C a VER

6!

SEE NOTE 2 UP

FAZ -SLOW

DOWN

CNN ISOLATE:

C E EP )

INSIDE VIEW OF BC FILO II OF BO X

•0

2 PL 2 PL

• •

REF

SEE NOTE 4

FE RE F

5EE NOTE 1

MANUAL 92377-003 March 1998 Revised 1/99

FIGURE8.3 : Upper ControlBoxAssembly V1433XL Serial NumbersX11597050-X11597065 V1833XL SeriaANumbersX21567134,X21597001-X21597283

ITEM PART NUMBER DESCRIPTION

Upper Control Box Assembly V14/1833-01 Ref. 55850 1 55787 Box, Upper Control 2 67123-001 Seal, Connector Electrical "2" 3 67124-001 Locknut - 1/2"NPT Conduit

4 67114-003 Strain Relief 1/2"NPT .371.5 5 BOW34575 Bolt, Carriage 25-20UNC x .75 6 B OW31431 Washer Flat .28 ID x .63 OD 7 BOW36780 Nut, Hex Lock 25-20UNC 8 67758 Toggle Switch-67760 Switch (Ref P/N 67760) 9 50075 10 51913 Operator, Red P-Pull ZB2-BT4 11 51914 Base + 1NC Contact ZB2-BZ102 12 66751 .Foot Switch w/Grd. + Cable 13 67837-006 Tie, Nylon - 6" Black 14 58300 Wire, 16Ga. - Black 15 67961-006 Terminal, 8 Stud 12/10Ga Spade 16 BOW23028 Terminal, 8 16/14Ga. Spade (R#67961) .

31 67123-002 Seal, Connector, Electrical 3 /4 " 32 67124-002 Locknut - 3/4"NPT Conduit 33 67114-009 Seal, Connector, Electrical 3/4" - Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

QTY

Ref. 1 1 1 1 2 2 2 1 3 1 1 1 5.

1LF 2 6

Ref. Ref. Ref.

FIGURE 8.4: Upper Control Box Assembly

REF REF

CURTIS EIA9T°TZRY NOICATOR

REF

4 PL REF

EMERGENCY STOP

(

FORWARD [ STEER]

CREEP \ REVERSE / DRIVE SPEED

MANUAL 92377-003 March 1998 Revised1/99

FIGURE 8.4: Upper Control BoxAssembly V1433XL Serial Numbers X11597050-X11597065 V1833XLSeriaANumbersX21567134,X21597001-X21597283

QTY

ITEM PART NUMBER DESCRIPTION

Upper Control Box Assembly V14/1833XL-01 Ref. Ref. 55851 Box, Upper Control 1 1 55855 Controller, BMS4 WRG5 + Lever 1 2 54589 3 51913 Operator-Push Pull 1 Contact Block NC 1 4 51914 Operator Selector 5 52670 r 1 Contact Block NO-NC 6 34464 1 2 7 55012 .Insert, Control Box Plastic Contact Block 1 NO 8 52672 1 Operator Green Pushbutton 9 69146 1 Operator, Blk/Blk Dual Switch 10 54913 1 Contact Block 2 NO w/Base 11 52029 12 54910-104 Mounting Base, AG Base 1 1 13 54910-102 Recep Screw Terminal 41-16 S. 14 67837-006 Tie, Nylon - 6" Black 415 BOW31125 Screw, Slotted Pan #06-32UNF x 62 4 16 BOW31231 Nut, Hex Keps #06-32 Wire, 16Ga Black 8LF 17 58300 31 A620-2633 Battery Condition Indicator (Option) 32 33 A353-2633 Slope Alarm (Option) 34 35 A626-2633 Low Voltage Alarm/Interrupt (Option) 36 37 A304-2633 Signal Horn (Option) - Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

Ref. Ref. Ref. Ref.

FIGURE8 .4 :UpperControl B oxAssemblyV14/ 1833 XL

OPTIONAL SLOPE ALARM

LID (FLIPPED OPEN)

LEFT SIDE

OPTIONAL BATTERY INDICATOR OPTIONAL LOW VOLTAGE OVERRIDE SWITCH

1 0 0 9 -)

3A

7

N

3A

20

4

Lei

do

o d 1

ON

3 4 _12

u

*".

SPARE

3A

5 0 014 d 5 CCWO'

-1-30 d 6

TROLLER

61 RD:

-

TB 4

SEE NOTE 1

2 STOP 3 ^

SEE NOTE 1

3

Li tit 19J

16

OPTIONAL SIGNAL HORN SWITCH

^

3B

Ea

H ON

3B

NE,,

DRIVE SPEED

A

3C

VIEW OF INSIDE OF BOX UNLESS OTHERWISE NO TED: TOLERANCES:

NO TES: 1. CONNECT CIRCUIT 3 AS REQUIRED BY OPTIONS. 2. CIRCUITS 1, 5, 13, 14, 15, & 16 ARE FOR OPTIONS. 3. SPARE CIRCUIT 12 IS USED FOR OPTIONAL PROPORTIONAL DRIVE.

DECIMALS R-14.

A F RNACUr t V ' 6 .)XX V0.3 . XXX . .010 TITLE SURFACE FINISH Uti PROJECT. 0, VIEWS © C:r1

ALL ...sioNs LT,

D.C. N. NO.

—

10153

LTR.

T.R.N. NO.

DATE

APPR.

CHECKED PAID

ARPR,

ARE IN INCHES

DRAWN J. CARMICAL

APPROVED

10/24/95

DIVISION OF 11 M MFG. E CP, 3,,,,,.. ,, 8300 IMPERIAL DRIVE WACO, TE XAS 76712

BOX ASSY, V XL UPPER EL

SUE DRAWING No.

B 55851 SCALE 1/2

1 SHEET 2 OF 2

REV.

FIGURE 8.4: Upper ControlBoxAssembly V1433XL SerialNumbersX11597050-X11597065 V1833XLSeriaANumbersX21567134,X21597001-X21597283

ITEM PART NUMBER DESCRIPTION

QTY

Ref. 55851 Upper Control Box Assembly V14/1833XL-01 Ref. 1 55855 Box, Upper Control 1 Controller, BMS4 WRG5 + Lever 2 54589 1 3 51913 Operator-Push Pull 1 Contact Block NC 4 51914 1 5 52670 Operator Selector 1 6 34464 Contact Block NO-NC 1 7 55012 Insert, Control Box Plastic 2 Contact Block 1 NO 8 52672 1 9 69146 Operator Green Pushbutton 1 10 54913 Operator, Blk/Blk Dual Switch 1 11 52029 Contact Block 2 NO w/Base 1 12 54910-104 Mounting Base, AG Base 1

Screw Terminal #1-16 Recep.

13 54910-102 1 14 67837-006 Tie, Nylon - 6" Black 5.

4 15 BOW31125 Screw, Slotted Pan #06-32UNF x .62 4 16 B OW31231 Nut, Hex Keps #06-32 17 58300 Wire, 16Ga Black FtLF 31 A620-2633 Battery Condition Indicator (Option) 32 33 A353-2633 Slope Alarm (Option) 34 35 A626-2633 Low Voltage Alarm/Interrupt (Option) 36 37 A304-2633 Signal Horn (Option) - Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

Ref. Ref. Ref. Ref.

•

LR

0

2 PL

3 FL

FORWARD

HARNESS FOOT SWITCH

EMERGENCY STEERING STOP REVERSE 0 FAST SLOW CREEP i

1

0

3B

•00 8 WHTj

-

)0(

WH T/BLK } 9

BLH/WHT

,j

Ti

BLK 10 \

DECAL SHOWN FOR REF ONLY 2 PL

I

UP

0

PLATFORM

3B 6

KGRN/BLK 12

La a etx

STEER

I I ON

•

SEE NOTE 3

via B

IN

2

GRN ISOLATE KRE 0 /BLK ISOLATE

DRIVE

3B to- 3B 4 GREEN ISOLATE

RED 3

0 •

3B

rj

3A BLK

6 PL

0 0 0

SEE 36 NOTE 4

NOTE: 1, PRY HINGES FROM BON & DISCARD, 2. TIE WIRES INTO TWO BUNDLES, AS SHOWN. 3. ITEMS 31, 32, 33 ARE PART OF MAIN HARNESS, WHICH IS PART OF ARM INSTALLATION.

CIRCUIT 2 3 4 6

COLOR BLU RED BLU/BLK

FUNCTION DRIVE FORWARD + 24VDC POWER DRIVE REVERSE

ORN

STEER LEFT

7 8 9

ORN/BLK WHT

STEER RIGHT RAISE PLATFORM

WHT/BLK BLK BLK/WHT

LOWER PLATFORM

GRN /BLK RED/BLK

POSITRACTION

10 11

WH

4i)

0

DOWN

0

3B

2 PL

12 2 PL

FAST DRIVE SPEED CREEP DRIVE SPEED

SPARE GRN SPARE HARNESS SHOWN FOR REF ONLY

FIGURE 8.5 : Upper Control Box Assembly-V1433XL-03 S erial Numb ers X11597076 Above V1433XL-02SerialNumbersX11597066-X11597075 V1833XL -03 SerialNumbersX21598001-Above V1833XL-02SerialNumbersX21597162,X21597177-X21597506 -

ITEM PART NUMBER DESCRIPTION

QTY

Ref. 55850 Upper Control Box Assembly V14/1833-02 -03 Ref. 1 55787 Box, Upper Control 1 2 66751 Foot Switch w/Guard & Cable .1 3 67114-003 Strain Relief, 1/2 NPT .371.5 1 4 67123-001 Seal, Connector Elect 1/2" 1 5 67124-001 Locknut, 1/2 NPT Conduit 1.

6 51913 Operator, Red P-Pull 1 7 51914 Base + 1 NC Contact 1 8 52670 Operator, 3 Pos Rot 1 9 34464 Base +1 NO +1 NC Contact 1 10 34384 Contact Block, NC 1 11 50075 Switch R # 67760 3 12 58292 Wire, 16 GA- White 1LF 13 67961-006 Terminal, 8 Stud 12/10GA Spade 2 14 BOW23028 Terminal, 8 Stud 16/14GA Spade 6 15 67837-006 Tie, 6" Black Nylon 5 16 BOW31239 Nut, Hex Keps 31-18UNC 2 17 BOW34575 Bolt, 25-20UNC x 75" Carriage 2 18 BOW31431 Washer, 25"ID x 63"OD Flat 2 19 BOW36780 Nut, 25-20UNC Nylon Lock 2

,

31 67123-002 Seal, Connector Elect 3/4" 32 67124-002 Locknut, 3/4NPT Conduit 33 67114-009 Strain Relief, 3/4NPT .62/.75 - Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

Ref. Ref. Ref.

07

FIGURE 8.6: Upper Control Box Assembly- V1433N1833XL

3) REF

5) REF

2\

7

S

4

(

EMERGENCY STOP

/ FORWARD

FAST SLOW CREEP \ REVERSE / DRIVE SPEED

f 7)

UP

DOWN

NOTES-

1. THIS DWG SUPERCEDES 55317.

MANUAL 92377-003 March 1998 Revised1/99

FIGURE 8.6: Upper Control Box Assemb ly -V1433XL-02 SerialNumbersX11597066-X1.1597075 V1833XL-02 SerialNumb ers X21597162, X21597177-X21597506 V1433XL -03 S erialNumbers X11597076-Above V1833XL-03 SerialNumbersX21598001-Above

ITEM PART NUMBER DESCRIPTION

QTY

Upper Control Box Assembly V14/1833XL 02-03 Ref. Ref. 55851 Box, Mach. Upper Control 1 55855 1

Controller, BMS4 WRG5 + Lever 2 54589 1 Operator Push-Pull 3 51913 1 4 51414 Base + 1 NC Contact 1

Operator, 3 Pos Rot 5 52670 1 6 34464 Base + 1 NO + 1 NC Contact 1 insert, Control Box Plastic 4.91 7 56068 2 8 52672 Base +1 NO Contact 1 1 Operator, Green Push Button 9 69146 Operator, Blk/Blk Dual Switch 10 54913 .1 Base + 2 NO Contacts 1.1 52029 1.

12 54910-104 Mounting Base, AG Base, 1 13 54910-102 Recept. Screw Term. #1-16 1 14 67837-006 Tie, Nylon 6" Black 5

15 BOW31125 Screw, Slot Pan #06-32UNF x .62 4 16 B OW31231 Nut, Hex Keps #6-32 4 Wire, 16 GA Black 17 53800 8.LF Contact Block, NC 18 34384 1 31 A620-2633 Battery Condition Indicator (Opt) 32 A353-2633 Slope Alarm (Opt)

Ref Ref

35 A626-2633 Low Volt Alarm/Interrupt (Opt)

Ref

37 A304-2633 Signal Horn (Opt)

Ref

- Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

•

14

INSIDE OF OPEN LID

z 0

c,

LEFT INSIDE

rr

OPTIONAL LOW VOLTAGE OVERRIDE SWITCH

•• 21 0

00 9 -I 610 —' 3 11

• 7

3A

5

3A DRIVE /STEER CONTROLLER

SEE

13A \

NOTE 4

3B

4

12 0

2

SEE NOTE 4

o SEE NOTE 1

3B

Lgid

12

DRIVE SPEED

11

12

9

SEE NOTE 5

OPTIONAL SIGNAL HORN SWITCH

VIEW OF INSIDE OF BOX

3A 3A

00K 3C

NOTES:

1. MOUNT ITEM 18 ON TOP OF "NO" CONTACT. 2, CIRCUITS 1, 5, 13, 14, 15, & 16 ARE FOR OPTIONS. 3. CIRCUIT 13 IS USED FOR OPTIONAL PROPORTIONAL DRIVE. 4, CONNECT CIRCUIT 3 AS REQUIRED BY OPTIONS, 5. IF SIGNAL HORN, PLUS ALL OTHER OPTIONS ARE USED, THEN DELETE ITEM 18 AND INSTALL RELAY IN CHASSIS TO ENERGIZE POSITRACTION VALVE.

5 0 013

•

6 0 6_ 1 ,4_

7

0 015

rg

10

Fat

•

i-3-0 0/6

z

rTh

0 0

I NSI DE B O TTOM O F BOX

OPTIONAL BATTERY INDICATOR

FIGURE8 .6 :Upper Control BoxAssembly-V143 3N- 1833 XL,

OPTIONAL SLOPE ALARM

FIGURE 8.6: Upper ControlBox Assembly - V1433XL 02 Serial Numbers X11597066 X11597075 V1833XL -02 SerialNumb ers X21597162, X21597177-X21597506V1433XL-03 SerialNumbers X11597076-Above V1833XL -03 SerialNumbers X21598001-Above -

ITEM PART NUMBER DESCRIPTION

-

QTY

Ref. 55851 Upper Control Box Assembly V14/1833XL-02 -03 Ref. 1 55855 Box, Mach. Upper Control 1 Controller, BMS4 WRG5 + Lever 2 54589 1 3 51913 Operator Push-Pull 1 4 51414 Base + 1 NC Contact 1 5 52670 Operator, 3 Pos Rot 1 6 34464 Base + 1 NO + 1 NC Contact 1 7 56068 Insert, Control Box Plastic 4.9'L 2 8 52672 Base +1 NO Contact 1 9 69146 Operator, Green Push Button 1 10 54913 Operator, Blk/Blk Dual Switch 1 11 52029 Base + 2 NO Contacts L 12 54910-104 Mounting Base, AG Base 1 13 54910-102 Recept. Screw Term. #1-16 1 14 67837-006 Tie, Nylon 6" Black

5 15 BOW31125 Screw, Slot Pan #06-32UNF x .62 4 16 BOW31231 Nut, Hex Keps #6-32 4 17 53800 Wire, 16 GA Black au Contact Block, NC 18 34384 1 31 A620-2633 Battery Condition Indicator (Opt) 32 A353-2633 Slope Alarm (Opt)

Ref Ref

35 A626-2633 Low Volt Alarm/Interrupt (Opt)

Ref

37 A304-2633 Signal Hom (Opt)

Ref

- Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised 1/99

FIGURE 9.1: 110 Volt Extension To Platform

GREEN 3 yl:x5 WHITE

._,X7 6 _,X8,A9_} —LOCATED AT RIGHT REAR

OF PLATFORM—NOT ILLUSTRATED WHITE 0 10H

BLACK

UNDER PLATFORM 10 13) 3 PL

CABLE IS TO BE TIGHT BTWN THESE CLAMPS 14 ) LOCATED ON RIGHT INSIDE OF PLTFRM, 37 1/2 - FROM FRONT.

AT CHASSIS

REF. LEFT FRONT OF CHASSIS BLACK

GREEN SCREW

WHITE

SILVER SCREW

MANUAL 92377-003 March 1998 Revised 1/99

FIGURE 9.1: 110 Volt Extension To Platform-V14/1833 (Option) ITEM PART NUMBER DESCRIPTION

QTY

Ref. 54918 110 Volt Extension To Platform -V1433N1833 (Option) Ref. 110 Volt Extension To Platform -V1433XLN1833XL Ref.

1 2 66357 Receptacle, Ground Fault I. 3 55019 Outlet Box, Platform 1 4 66358 Cover, Weatherproof 1 5 67114-003 Strain Relief 1/2"NPT 37/ 5 1 6 67124-001 Locknut, 1/2"NPT Strain Relief .1 7 67123-001 Seal, Connector Elect. "2" 1 8 BOW31105 10-32 x .75 Slotted Pan Head, Machine Screw 2 9 BOW31233 Nut, Hex Keps #10-32 2 10 BOW32603 Clamp, Wire Loom .50 4 11 52710 .Plug, 110 Volt 1 12 55036-001 Grommet, 1/2" ID 1/4 x 13/16" Dia. Gry 1 13 BOW34272 Nut, Hex Lock 25"-20UNC 4 -14 BOW32582 Clamp 1.

- Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

FIGURE 9.2: Travel Alarm (Option) ITEM PART NUMBER DESCRIPTION

Ref. A301-2633 Travel Alarm - 1 80188-024 Wobbulator and Speaker -2 67295-035 Cable, 16Ga./2 Conductor SJO -3 BOW23027 Terminal 6 Stud 16/14Ga Spade -4 55036-001 Grommet, 1/2"ID 1/4" x 13/16"Dia Grv. - Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

QTY

Ref. L 21T 4 1

FIGURE 9.3 : Motion Alarm (Option) al ITEM PART NUMBER DESCRIPTION

Ref. A309-2633 Motion Alarm -1 80188-024 Wobbulator and Speaker -2 67295-035 Cable, l6Ga./2 Conductor SJO -3 BOW23027 Terminal 6 Stud 16/14Ga Spade -4 55036-001 Grommet, 1/2"ID 1/4" x "/16"Dia Grv. -5 206-00001-00 Diode - Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

QTY

Ref. 1 .2LF 4 1 2

116

FIGURE 9.4: StrobeLight(Option)

REF. RIGHT SIDE VIEW OF PLATFORM_

3 PL

ITEM PART NUMBER DESCRIPTION

Ref. A310-2633 Strobe Light 1 58395 Light Amber Stobe 12-72 VDC 2 BOW31400 Washer, Flat #10 3 BOW31144 Screw, Slot Rnd. #10-32UNF x .50 4 55400 Mount - Strobe Light 14" 5 BOW34001 Bolt, Hex 25-20UNC x 1.00 6 BOW31432 Washer, Flat .31 ID x .68 OD 7 BOW36780 Nut, Hex 25-20UNC Nylon Lock 8 67295-035 Cable, 16Ga /2 Conductor SJO 9 52672 Base + 1 NO Contact ZB2BZ101 10 58259 Wire, 18Ga Black-Bulk

- Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

QTY Ref. 1 3 3 1 2 2 2 5OLF 2 1LF

FIGURE 9.5: Descend Alarm (Option)

ITEM PART NUMBER DESCRIPTION

Ref. A312-2633 Descend Alarm -1 80188-024 Wobbulator and Speaker 24V -2 67295-035 Cable, 16Ga /2 Conductor SJO -3 BOW23027 Terminal 6 Stud 16/14Ga Spade -4 55036-001 Grommet, 1/2"ID 1/4" x 13/16"Dia -5 34542

Jumper

- Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised 1/99

QTY

Ref. .1 2LF 4 1

1

FIGURE 9.6: Slope Alarm (Option) ITEM PART NUMBER DESCRIPTION

Ref. A353-2633 Slope Alarm.

-1 32002 Slope Sensor 2-Axis -2 BOW30002 Bolt, Hex 25-20UNC x .750 -3 BOW31432 Washer, Flat .31 ID x .68 OD -4 67295-024 Cable, 8 Conductor 16AWG Type SO -5 BOW23003 Terminal Ring #67960 22-18 #10 Stud -6 34644 Alarm -7 58259 Wire, 18Ga Black-Bulk - Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised 1/99

QTY

Ref. 1 2 2 7LF 2 1 2LF

FIGURE9.7:HourMeter(XL-Option

REFERENCE MOTOR CON TACTOR

ITEM PART NUMBER DESCRIPTION

Ref. A619-2633 Hour Meter - 1 80027 Meter, Hour 4/40V DC -2 67840-001 Bracket, Gauge Mounting -3 BOW30003 Bolt, Hex 25-20UNC x .875 -4 BOW31401 Washer, Flat .25 ID x .63 OD -5 BOW36780 Nut, Hex 25-20UNC Nylon Lock -6 67295-035 Cable, 16Ga /2 Conductor SJO -7 BOW23087 Coupler - R#67963 16-14 Female -8 67960-006 Terminal Ring - 16-14 #10 Stud -9 67837004 Tie, Nylon-4" Black

- Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

QTY

Ref. 1 1 2 4 2 6LF 2 2 4

FIGURE 9. 8: Battery Condition Indicator (XL-Option) ITEM PART NUMBER DESCRIPTION

Ref. A620-2633 Battery Conditon Indicator -1 37716 Meter, 24V Battery -2 37993 Meter Guard -3 58300 Wire, 16Ga -Black -4 67963-001 Coupler - 22-18 Male

- Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised1/99

QTY

Ref. 1 1 2LF 2

FIGURE 9.9: Low-Voltage Warning Interrupt (XL-Option) ITEM PART NUMBER DESCRIPTION Ref. A626-2633 Low-Voltage Warning Interrupt - 1 54169 Low Voltage Interrupt 24V -2 54967-104 Operator, Blue Illum Pushbutton -3 55902 .Base + NO/NC Contact w/24V Bulb -4 58259 Wire, 18Ga Black-Bulk -5 54935 Decal - Low Volt Warning/Override -6 BOW31141 Screw, Slotted Rnd. #10-24 x 2.00 -7 BOW31288 Nut, Hex #10-32 -8 BOW31430 Washer, Flat #10 ID - Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised 1/99

QTY Ref. 1 1 1 6LF 1 2 2 4

FIGURE 9. 10: Larger B atteries IPOS (XL Option) -

ITEM PART NUMBER DESCRIPTION

QTY

Ref. A629-2633 Larger Batteries IPOS -1 50046 Battery - 6 Volt -2 52627 Battery - 6V Trojan T125-WT -3 54836 Angle - Option Battery Tie-Down -4 55505 Angle, Battery Tie-Down 22"

Ref. 4 -4 2 -2

- Indicates Items Not Shown

MANUAL 92377-003 March 1998 Revised 1/99

2 REVISIONS

DRAWING ON CAD, DO NOT MANUALLY UPDATE REV I DESCRIPTION I DATE I APPROVED - ORIGINAL RELEASE 1 CHANGED BLOCK THK. 2 FIXED PART NUMBER

SAE-4 PORT CD,

08/22/97 09/05/97 02/20/98

TAP 1/4"-20 #2B X 0,50" DP (2 PL)

0,719

0 2,500

DRILL 11/32" DIA THRU (2 PL) DRILL 5/16" DIA X 1,63" DP, C'BDRE .499/.504" DIA X •052/,060" DP 0,750 /2/ —0,500 — 1,500 — 2.500 54635-001 HF SV1020J-0-N-24DS 1 1 54596-001 BODY -olo,p-RING 1 00417 SAE-4 FLUSH PLUG 1 PART NO

MATL.

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Aluminum, 6061-T6, 2.5 X 2.5 X 2

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FINISH

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NOTES, UNLESS OTHERWISE SPECIFIED:

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964aNAVOOSWOCIINIC,

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624 Hoggord, Suite 707 Plano TX, 75074

MANI FOLD

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UNLESS OTHERWISE SPECIFIED

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08/97

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DATE

4 3 2 1

MFG

NEXT ASSY USED ON APPLICATION THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO FLUID MOTION SALES INC. USE OR DISCLOSURE WITHOUT ENGR -MGR THE WRITTEN PERMISSION OF AN OFFICER OF FLUID DOC-CIR MOTION IS EXPRESSLY FORBIDDEN.

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TIME CONDOR Corporation

SELF-PROPELLED ELEVATING WORK PLATFORM

MODEL V1433XL, V1433 MODEL V1833XL, V1833 VENDOR SECTION

tC)

SHIPPING ADDRESS

MAILING ADDRESS

TIME CONDOR Corpoation

TIME CONDOR Corporation

8300 IMPERIAL DRIVE WACO, TEXAS 76712 (254) 420-5200

P.O. Box 21447 WACO, TEXAS 76702-1447 (254) 420-5200 MANUAL 92377 March 1998

CONDOR® MODEL V1433/XL, V1833/XL VENDOR SECTION TABLE OF CONTENTS

CONTROLLER CHARGER

OEM CONTROLS LESTER ELECTRICAL

OPEN CIRCUIT TRANSFORMER TEST 2000 SERIES MOTOR

CHAR-LYNN

wiKt. GMARI GAUt -TEUTFIE R

REVISIONS

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20 AWG 6 1/2

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MICROWIICH tYP. 2 PLACES

P.B FOR LEVER

(AUX)

(LEFT)

(REV)

(RIGHT' )

3

2

1-6-51

3 (FWD) *`•\,N, STAMP

(24V) r 0 1-

- STAMP

3 PULE T.B BB/66 TYP. 2 PLACES

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DISENGAGED

08-32 (.138) UK X 1/2" LG SCREW - SEE NOTE 11

NOTES! I. DO NOT CVO/TIGHTEN SCAN. LEVER SHOULD MOVE D C FFEELY flHD SOOTILY.

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01404

. ** TOTAL PAGE. 02 **

MU* 104 1 00

OWNERS MANUAL

24 Volt Fully Automatic Battery Charger Model 17970 Specifications: AC Supply

DC Output

Battery Specifications

Use only on 24 volt, 12 cell.

24 Volts 120 Volts

series connected wet lead 25 Amps Tapering 8 Amps

acid systems. 180-305 to 8 amps 60 Hertz

ampere-hour (20 hr. rate) Single-Phase

clt&itJ—,\AI— El ectrical---÷ 625 West A St. Lincoln, NE 68522 USA

F01532 A

SAVE THESE IMPORTANT INSTRUCTIONS READ AND FAMILIARIZE YOURSELF WITH THIS ENTIRE MANUAL BEFORE INSTALLING OR OPERATING THE CHARGER. FOLLOW ALL INSTRUCTIONS ON THE BATTERY CHARGER, AND BATTERY POWERED EQUIPMENT. THIS MANUAL CONTAINS IMPORTANT SAFETY AND OPERATING INSTRUCTIONS FOR THIS BATTERY CHARGER. LOOK FOR THIS SYMBOL TO POINT OUT SAFETY PRECAUTIONS. IT MEANS BECOME ALERT - YOUR SAFETY IS INVOLVED. IF YOU DO NOT FOLLOW THESE SAFETY INSTRUCTION, PERSONAL INJURY OR PROPERTY DAMAGE CAN OCCUR. SAVE THESE IMPORTANT INSTRUCTIONS.

IMPORTANT SAFETY INSTRUCTIONS

to ensure superior battery performance and life. A patented electronic circuit turns the charger on and off automatically.

When the battery has reached its maximum state of charge. the circuitry will turn the charger off.

1. SAVE THESE INSTRUCTIONS This manual contains important safety and operating instructions for battery charger Model 17970.

2. Before using battery charger, read all instructions and cautionary markings on (1) battery charger, (2) battery, and (3) product using battery.

A CAUTION: TO REDUCE RISK OF INJURY, CHARGE ONLY LIQUID ELECTROLYTE (WET) LEAD ACID RECHARGEABLE BATTERIES. OTHER TYPES OF BATTERIES MAY BURST CAUSING PERSONAL INJURY AND DAMAGE.

RECEIVING AND INSTALLATION When the charger is received, check for possible in transit damage. If any damage is found, it should be reported as a claim to the carrier.

Proper installation of the charger is important in order to achieve good charger performance and to prevent damage to the charger and batteries. The charger should be located in a clean, cool, dry, and well ventilated area. To permit free air flow for convection cooling, allow three inches minimum between the charger and any wall and six inches between the charger and other equipment. Position the charger on a foundation of stone, brick, concrete or grounded metal.

DANGER: TO REDUCE THE RISK OF FIRE, DO NOT USE THE CHARGER NEAR FLAMMABLE MATERIALS OR VAPORS.

3. Do not expose charger to rain or snow.

4. Use of an attachment not recommended or sold by the battery charger manufacturer may result in a risk of fire, electric shock, or injury to persons.

5. To reduce risk of damage to electric plug and cord, pull by plug rather than cord when disconnecting charger.

6. Make sure cord is located so that it will not be stepped on, tripped over, or otherwise subjected to damage or stress.

7. An extension cord should not be used unless absolutely necessary. Use of improper extension cord could result in a risk of fire and electric shock. If extension cord must be used, make sure: a. Pins on plug of extension cord are the same number, size, and shape as those of plug on charger b. Extension cord is properly wired and in good electrical condition. c. Wire size is large enough for ac ampere rating of charger.

8. Do not operate charger with damaged cord or plug - replace it immediately.

9. Do not operate charger if it has received a sharp blow. been dropped. or otherwise damaged in any way; take it to a qualified service center.

10. Do not disassemble charger; take it to a qualified service center when service or repair is required. Incorrect reassembly may result in a risk of electric shock or fire.

11. To reduce risk of electric shock, unplug charger from a live outlet or disconnect AC power to the outlet before attempting any maintenance or cleaning. Turning off controls will not reduce this risk.

A

AC INPUT AND GROUNDING INSTRUCTIONS

A Allaik

CAUTION: TO REDUCE RISK OF ELECTRIC SHOCK OR FIRE, DISCONNECT POWER TO RECEPTACLE BEFORE INSTALLING OR REMOVING UNIT.

This battery charger must be connected to a 120 Vac. 60 hertz. 1 phase AC power source which is properly installed and grounded in accordance with the National Electrical Code (U.S.) and all local codes and ordinances.

Charger should be GROUNDING INSTRUCTIONS grounded to reduce risk of electric shock. Charger is equipped with an electric cord having an equipment-grounding conductor. The installed plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances.

-

A

DANGER: NEVER ALTER AC CORD OR PLUG IF IT WILL NOT FIT OUTLET. HAVE A PROPER OUTLET INSTALLED BY A QUALIFIED ELECTRICIAN. IMPROPER CONNECTION CAN RESULT IN A RISK OF AN ELECTRIC SHOCK. -A- -a-

INTRODUCTION

-c-

COVER OF —,,,,1/44.4N.1 ADAPTER

GROUNOED

This battery charger is a self-regulating charger with a minimum of moving parts, designed for long, trouble free service. Built-in line voltage compensation produces a consistent output when the AC supply voltage varies by as much a 10% from nominal.

Convection cooling maximizes the reliability and minimizes any maintenance costs. ONLY LIQUID ELECTROLYTE (WET) LEAD ACID BATTERIES should be recharged with this charger

OUTLEr 80X (7'."

GROUNDING-I BLADE GROUNDED OUTLET

GROUNDING MEANS

CONNECTED TO COVER OF GROUNDED OUTLET BOX

NOTE: Use of an adapter shown in figures B and C is not permitted in Canada.

-2-

4. Monitor the ammeter for correct charge current. The initial charge current should range between approximately 25 amps. If the batteries have not been discharges, or the AC supply voltage is lower than 120 volts. the initial charge rate may be less. If the batteri( have been excessively discharged, or AC supply voltage is higher than 120 volts. the initial charge rate

This battery charger is for use on a nominai 120 volt circuit and has a arounaina plug, wnich looks like the aaapter iilustratea in figure A. A temporary aaapter, which looks like the adapter illustrated in figures B and C. may be used to connect this piug to a two-pole receptacle as shown in figure B if a properly grounded outlet is not available. The temporary adapter should be used only until a properly grounded outlet can be installed by a qualified electrician.

DANGER: BEFORE USING ADAPTER - AS ILLUSTRATED. BE CERTAIN THE CENTER SCREW OF OUTLET PANEL PLATE IS GROUNDED. The green-colored rigid ear or lug extending from adapter must

may be more than 25 amps.

5. Charge current will gradually taper to approximately 8 amps depending on the age and condition of the batteries. Charger turns off automatically and the "CHARGE COMPLETE" light will glow when battery is fully charged. Charge time varies with battery size and depth of discharge. Allow 12-14 hours for normal charging. Severely discharged batteries may require more time to be properly charged and equalized.

6. After the charger has turned off, disconnect the DC output plug from the battery (if required) and the AC supply cord from outlet.

A

be connected to a properly grounded outlet. If necessary, replace original outlet cover plate screw with a longer screw that will secure adapter ear or lug to outlet cover plate and make ground connection to grounded outlet.

EXTENSION CORD REQUIREMENTS Always use a three conductor No. 14 AWG (1.5mm) heavy duty cord with ground, properly wired, in good electrical condition and keep it as short as possible. Make sure the pins on the plug of the extension cord are the same number, size and shape as the AC plug of the battery charger. The use of an improper extension cord could result in a risk of fire or electric shock. Locate all cores so they will not be stepped on, tripped over or otherwise subjected to damage or stress.

MAINTENANCE INSTRUCTIONS The battery charger requires minimal maintenance. It should be kept clean and all connections are to be tightly secures.

In the event of intermittent operation, examine and tighten. if necessary, all connections. BE SURE THE CHASSIS IS SECURELY GROUNDED. If any problems cannot be resolved consult a qualified service center.

Observe the following battery maintenance procedures to obtain good performance and maximum cycle life.

1. Always observe the following personal safety precautions when working with lead acid batteries: a. Someone should be within range of your voice or close enough to come to your aid when you work near a battery. b. Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing or eyes. c. Wear complete eye protection and clothing protection. Avoid touching eyes while working near battery. d. if battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters eye. immediately flood eye with running cold water for at least ten minutes and get medical attention. e. NEVER smoke or allow a spark or flame in the vicinity of batteries. f. Be extra cautious to reduce risk of dropping a metal tool onto battery. It might spark or short-circuit battery or other electrical part that may cause explosion. g. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a lead acid battery. A lead acid battery can produce a short-circuit current high enough to weld a ring or the like to metal, causing a severe burn. h. NEVER charge a frozen battery.

DANGER: TO REDUCE RISK OF ELECTRIC SHOCK, ALWAYS DISCONNECT THE AC SUPPLY CORD FROM ITS OUTLET AND THE DC OUTPUT CORD FROM THE BATTERY BEFORE ATTEMPTING ANY MAINTENANrc (CHANGING FUSES, ETC.) OR CLEANING OF THE B

DC OUTPUT This battery charger is designed to produce a 24 volt dc output with an initial charge current of 25 amps. ONLY 24 VOLT, 12 CELL, SERIES CONNECTED, 180 TO 305 AMP-HOUR, LIQUID-ELECTROLYTE (WET) LEAD-ACID BATTERIES SHOULD BE USED. The charge current will decrease gradually to about 8 amps as the battery reaches full charge and will remain there until the charger turns off. As the battery ages the charge current may no longer decrease to the 8 amp finish current. Liquid electrolyte batteries will normally be charged to 2.5 volts per cell.

OPERATING INSTRUCTIONS 1. Connect AC supply cord to a properly grounded 120 volt, 60 hertz, single phase outlet.

2. Connect the DC output plug to batteries (if required). The black wire must be connected to battery negative (-), and the red or white wire to battery positive (+). Make sure all connections are clean and tight.

3. The charger will start after a short delay as indicated by the "CHARGING" light, transformer hum and the ammeter movement.

WARNING: LEAD ACID BATTERIES GENERATE GASES A WHICH CAN BE EXPLOSIVE. CHARGE ONLY IN WELL VEN-

TILATED AREAS. DO NOT DISCONNECT CHARGER DC OUTPUT TERMINALS FROM BATTERY WHEN CHARGER IS ON. THE RESULTING ARCING AND BURNING COULD CAUSE THE BATTERY TO EXPLODE. KEEP SPARKS, FLAME, AND SMOKING MATERIALS AWAY FROM BATTERY.

If the charger must be stopped, always disconnect the AC supply cord from its outlet before disconnecting the DC output terminals from the battery.

TERY OR BATTERY CHARGER.

2. New batteries should be given a full charge before their first use because it is difficult to know how long batteries have been stored.

-3-

3. Limit use of new batteries for first five cycles. New batteries are not capable of their rated output until they nave been discharged a number of times.

4. Do not excessively discharge batteries. Excessive discharge can cause polarity reversal of individual cells resulting in complete failure shortly thereafter. Limited use of new batteries will minimize the chance of cell reversal.

5. CHECK THE LEVEL OF THE ELECTROLYTE IN CONVENTIONAL LIQUID ELECTROLYTE LEAD ACID BATTERIES MONTHLY. MAINTAIN THE PROPER ELECTROLYTE LEVEL BY ADDING. DISTILLED OR PURIFIED WATER WHEN NECESSARY. Electrolyte levels lower during discharge and rise during charge. Therefore, it is mandatory that water be added to cells ONLY when they are fully charged - do not overfill. Old batteries require more frequent additions of water than new batteries.

6. Keep tops of batteries clean and dry to prevent excessive self discharge. Keep battery terminals reasonably tight.

c. AC circuit is not live (power outage or circuit breaker blown).

4. CHARGER DOES NOT TURN OFF a. The charger is connected to a battery with an amp-hour.capacity greater than specified. b. The charger is connected to a battery pack with a system voltage higher or lower than specified. c. New batteries (5 cycles or less). cold batteries or over discharged batteries may require an extended charge time to achieve full charge.

5. CHARGER FUSE BLOWS (OR CIRCUIT BREAKER) a. AC fuse blows when wrong AC power supply is used.

6. BUILDING AC LINE CIRCUIT BREAKER OR FUSE BLOWS a. A "weak" fuse or circuit breaker is protecting the circuit. Connect the charger to another outlet on a different circuit. If the charger operates property, have a qualified electrician inspect and test the original circuit. b. The circuit is overloaded. Connect the charger to another outlet on a different circuit.

7. EQUIPMENT RANGE DECREASING a. The electrolyte level in conventional liquid electrolyte lead-acid batteries was allowed to drop below the too of the battery plates. Add distilled water to JUST COVER THE TOPS OF THE PLATES immediately upon discovery and fill to the proper level with distilled water at the completion of the very next charge cycle. Battery capacity lost in this manner is permanent and is not recovered with additional charge cycles. b. Use of the equipment before the batteries have been fully charged and the charger turns off. This shortens battery life and hastens the onset of reduced daily range. Battery capacity lost in this manner is permanent and is not recovered with additional charge cycles.

C. This is the normal wear out process for all types of deep-cycle motive power batteries.

TROUBLE SHOOTING FOR SAFE AND EFFICIENT TROUBLE SHOOTING. READ THIS TROUBLE SHOOTING GUIDE COMPLETELY BEFORE BEGINNING ANY TESTS. .

A

CAUTION: DO NOT OPERATE THE CHARGER IF IT IS DAMAGED OR APPEARS TO BE MALFUNCTIONING. PERSONAL INJURY OR DAMAGE TO THE CHARGER OR BATTERIES MAY RESULT. DO NOT DISASSEMBLE THE CHARGER. TAKE IT TO A QUAUFIED SERVICE AGENT WHEN SERVICE OR REPAIR IS REQUIRED. INCORRECT REASSEMBLY MAY RESULT IN A RISK OF ELECTRIC SHOCK OR FIRE.

To. determine if a charger malfunction exists, eliminate the problems not associated with the charger in the sections below.

If the problem can not be resolved, contact a qualified service center.

1. CHARGER DOES NOT TURN ON a. Battery is not connected to charger. b. Charger is not plugged into a live AC outlet.

WARNING: IF THE AC OR DC PLUG OR RECEPTACLE IS BROKEN, TWISTED, BENT OR LOOSE AND DOES NOT MAKE GOOD ELECTRICAL CONTACT, HAVE IT REPLACED BY QUAUFIED SERVICE PERSONNEL IMMEDIATELY. DO NOT USE THIS CHARGER IN THIS CONDITION AS FIRE OR PERSONAL INJURY CAN RESULT. c. DC fuses blown.

2. CHARGER REMAINS AT HIGH RATE a. The charger is connected to a battery pack with a system voltage lower than specified. b. Battery amp-hour capacity is greater than specified for charger. c. One or more of the batteries in the battery pack has reversed polarity.

3. CHARGER TURNS OFF EARLY a. The DC cord was accidentally disconnected from the battery during charge. b. The battery has been allowed to sulfate. Charge the battery at least once every three days when the equipment is lightly utilized. Once sulfation is allowed to take place it may be partially reduced by returning, temporarily, to daily charging.

-4-

WIRING DIAGRAM

ELECTRONIC TIMER

black red green* TRANSFORMER

tan

DIODE

rea or white

FUSE ASSEMBLY

3

TO BATTERIES

black black I AMMETER

3

black

DIODE

4

green

tan white

120 Vac INPUT

CAPACITOR

*Green wire not used on some models.

PARTS LIST FOR LESTRONIC II CHARGER MODEL 17970 TYPE 24LC25-BET 120 VAC 60 Hz

PART NO. DESCRIPTION 23278S 16105S 16354S 16369S 18320S 02390S 02028S 23282S 087765 04328S

CASE ASSEMBLY TRANSFORMER ASSEMBLY HEATSINK ASSEMBLY, WITH DIODES AMMETER ELECTRONIC TIMER ASSEMBLY CAPACITOR, 6.0 MFD, 660 VAC BUSHING, 7W-2, INSULATOR FOR CORDSET CORDSET, DC, 75", NO PLUG FUSE ASEMBLY AC RECEPTACLE

-5-

Limited Warranty Lester Electrical warrants each new Lester Battery Charger for defects in material and workmanship for a period of two years from the date of manufacture of the complete unit. Repairs can be made at the Lester factory. To do so send the defective unit with transportation charges prepaid to: Lester Electrical 625 West "A" Street Lincoln, NE 68522 U.S.A. Attention: Repair Department

For repairs made at other than the Lester factory, Lester will provide only the replacement parts. Defective parts should be sent with transportation charges prepaid to the Lester factory at the previously mentioned address.

If the unit or parts are found in the reasonable judgment of Lester to be defective in material or workmanship, repair, or replacement will be made by Lester without charge for parts or labor. Repair or replacement will be at the discretion of Lester, with replacements being made using current models or parts performing the equivalent function. Labor charges other than those incurred at the Lester factory are not covered under this warranty. All expenses associated with delivering defective items to the Lester factory and the expense of returning repaired or replaced items from the Lester factory to the owner will be paid for by the owner. All warranty work accomplished at the Lester factory will be completed within a reasonable time after receipt of defective items.

This warranty does not cover any semiconductor parts, such as diodes, which are vulnerable to electrical overloads beyond the control of Lester. Warranty on parts not manufactured by Lester, which include, but are not limited to, timers and ammeters is limited to the period specified in the original manufacturers warranty.

This warranty does not cover any charger that has been subject to misuse, neglect, negligence, or accident. or operated in any way contrary to instructions specified on the charger case and in the owners manual. No claim of breach of warranty shall be cause for cancellation of the contract of sale of any Lester charger. Lester assumes no responsibility for loss of time, inconvenience, or other damage, consequential or otherwise, resulting from a defective charger. All implied warranties (including merchantability) are limited in duration to the two years from date of manufacture warranty period.

Some states do not allow the exclusion or limitation of incidental or consequential damages: or limitations on how long an implied warranty lasts, so the above limitations may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

Lester's obligation under this warranty is strictly and exclusively limited to the repair or replacement of defective items. Lester issues this warranty in good faith and with full confidence in the workmanship and quality of Lester products.

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OPEN CIRCUIT TRANSFORMER TEST Failure of the transformer can be the result of natural aging, premature shorting of adjacent coil turns or overheating damage. The most common cause of transformer overheating and premature burn-out is the result of misuse, connecting the charger to a battery system of lower. voltage than specified on the charger. Darkening of all the transformer secondary coil windings is an indication of possible overheating damage.

! DANGER HIGH VOLTAGE; With the charger operating, the charger capacitor voltage can be as high as 660 Volts AC. Use extreme caution when working near the capacitor terminals.

To test transformers used in chargers of different output voltage than 76 Volt as covered in manual, Form 00910, the transformer coil AC voltages are Charger Nameplate Voltage VDC V,

Number of No Load Open Circuit Lead-Acid Transformer Secondary Coil Battery Cells AC Test Voltages

Resonant Resonant in Series

Capacitor Capacitor

Disconnected Connected

V = = V t X 217 V I al V, X 2 50 a

12 6 27 to 73

17 to 27

to 66

3b to 44

36 13 33 to 97

55 LO t 6 •

48 24 110 to 170

77 to 97

24 12 Z4

Use the equations to calculate approximate test voltages for other systems.

The readings are approximate and transformer failure is indicated • when measured voltages are significantly lower than those calculated in the table. DC voltages measured at the charging leads are about 1/2 the transformer test voltage amounts.

Transformer secondary voltage measurements made with the resonant capacitor connected can occasionally result in noticeably higher readings than expected. No-load transformer instabilities and peculiar wave shapes can increase these voltage readings. This is particularly true when using digital meters, as several models get confused with other than pure sine wave AC or pure ripple-free DC.

PROPER CARE OF MOTIVE POWER BATTERIES

Motive power oattenes are suciectec to severe deep cycle duty on a daily basis. Aithoucn :nese batteries are designed to withstana sucn duty the following precautions must be observed to cctain coca performance and maximum cycie life.

5.

a CAUTION: Always wear protective eye shields and clothing when working with batteries.

Batteries contain acids which can cause bodily harm. Do not put wrenches or other metal objects across the battery terminal or battery top. Arcing or explosion of the battery can result.

1. When installing new batteries be sure the polarity of each battery and overall battery pack is correct. Due to the electricai characteristics of this charger it is possible to improperiy hook uo the batteries and not blow the fuse wnen cnarging. Battery ana/or charger damage can result.

2. New batteries should be given a .full charge before their first use because it is difficult to know how long the batteries have been stored.

3. Limit the use of new batteries for the first 20 cycles.

New batteries anc older batteries that have been in storage are not cacable of their rated outcut until they have been discnargec anc chargec a numcer of times.

4. Sulfation results when batteries in storage are not maintained in a charged active state. Internal self discharge can bring about the start of this condition in as little as three days in warm temperatures. Batteries

6.

7.

8.

9.

ailowea to sit unmaintainec in storage self discharge. sulfate to various degrees and lose caoacitv.

Repeated charging will generally result in the recovery of most of the °artery's capacity, thougn some permanent loss can be expected.

DO NOT EXCESSIVELY DISCHARGE THE EATTEFIES. Excessive discharge can cause polarity reversai of individual cells resulting in complete failure shortly thereafter. Heavily discharging (Over 60%) new batteries before they have been broken in (approximately 20 cycles) can cause permanent cell damage. resulting in reduces energy capacity and shortened life.

Maintain the prover electrolyte level by adding water when necessary. Never allow the electrolyte level to fall below the top of the battery plates. Electrolyte levels fall during discharge and rise during charge.

Therefore. to prevent the overflow of electrolyte when charging, it is mancatory that water be added to cells AFTER they have been fully charged. DO NOT OVERFILL Old batteries recuire more frequent auditions of water than do new batteries.

When the temperature falls below 65 degrees F, the batteries should be placed on charge as soon after use as possible. Cold batteries require more time to fully recharge.

The tops of the batteries and battery hold-downs must be kept clean anc on at all times to prevent excessive self discharge anc flow of current cetween the battery posts ana frame.

Follow all operating instructions. cautions. and warnings as specified in this manual. on the charger. and in your vehicle owner's manual.

TROUBLE SHOOTING GUIDE TO BE ABLE TO USE THE TROUBLE SHOOTING GUIDE SAFELY AND EFFECTIVELY IT IS IMPORTANT TO READ THIS GUIDE COMPLETELY BEFORE BEGINNING ANY TESTS.

A

CAUTION: REPAIRS BY QUALIFIED PERSONNEL a DANGER: HIGH VOLTAGE — With the charger on. the internal charger capacitor voltage is ONLY. NOTE: Modifying this charger for approximately 650 volts. use other than that for which it was intended, repairs by persons not quali fied, or not using original equipment a CAUTION: ALWAYS UNPLUG THE ELECTRICAL

replacement parts will void the warranty CORDS FROM THE AC OUTLET AND and Lester liability.

THE BATTERIES BEFORE ATTEMPTING

A CAUTION: DO NOT DISASSEMBLE THE CHARGER.

ANY REPAIRS TO THE CHARGER. TAKE IT TO A QUALIFIED SERVICEMAN A WARNING: Do not operate the charger if it is malWHEN SERVICE OR REPAIR IS functioning. Personal injury or property REQUIRED. Incorrect assembly may damage could result. result in a risk of electric shock or fire.

The Lestronic II battery charger is a reliable. automatic charger designed for long, trouble-free service. If a malfunction should develop, identify the symptom and follow the associated test procedures.

SECTION

MALFUNCTION SYMPTOM

CHARGER DOES NOT TURN ON A. Relay does not Close. No Transformer Hum and Ammeter Does Not Register.

B. Relay Closes But No Transformer Hum and Ammeter Does Not Register.

C. Relay Closes and Transformer Hums But Ammeter Does Not Register.

D. Eectronic Timer Kit Replacement

Instructions.

2 CHARGER FUSE BLOWS A. Single Fuse Link Blows B. Both Fuse Links Blow

SECTION

3

AMMETER READS 30 AMPS FOR MORE THAN 30 MINUTES

4 CHARGER OUTPUT IS LOW 5 CHARGER TURN OFF MALFUNCTIONS A. Charger Turns Off Too Soon.

B. Charger Does Not Turn Off. C. Charger Runs Too Long But Does Turn Off.

6 AC LINE FUSE OR CIRCUIT BREAKER BLOWS

7 TRANSFORMER SHORT OR BURN-OUT

SECTION 1 — CHARGE DOES NOT TURN ON :n normal ocerat:cr, :re orarcer 2C output c:.-,nnectcr must ce conrec:=-, o :ne catteries tfl orcer to turn the cnarcer ce!av of 2 :o seconcs is crevices to allow adec2:e time to ma<e a secure connection oefore the care r :7s Dn. After this time ceiay the power relay cioses 3 3 r, should be heara.

When ;re e v ocwer is suppiled to the transformer or:ma:7 cc::. f ocerating oroceriy the transformer snouic :7'1/4..7.. aro tr. E..mmeter srcuic indicate the charce rate. if e c7-aro.r :cec oroperly refer to Part A. Eior C for specific :est orccedures.

PART A— RELAY DOES NOT CLOSE. NO TRANS-.

FORMER HUM AND'ANIMETER DOES NOT REGISTER. Check to be sure the power suociy cord is securely connected to a :lye outiet. Check the DC output connector and the battery connector for damage. dirt or corrosion that would prevent a ;coo eiectricai connection.

a WARNING: If the plug or receptacle is broken,

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

Then oisconnec: tne power suppiy cord from its outlet.

With the DC output connector still connected to the battery connector. measure the voitace at the battery connector using a suitapie DC voltmeter as snown in Figure 1.

The Electronic Timer Kit may be bypassed in orcer to verify that a malfunction exists. First cisconnect the cnarger cewer supply c:s•rc from its outlet and the DC output connector from the battery connector. Place a jumper wire oetween terminals #1 and '43 to bypass Me Electronic Timer Kit as snown in Figure 2 and Figures ,: and 7.

The oower succiy core is now connected directly to the primary transformer cod ana the transformer should hum when the power sucoiy cord is connected to a live outlet.

The cnarger oceration may be checked by first connecting the DC output connector to the battery connector, anc then connecting the power supply cora to an outlet If normal charging current is indicated on the ammeter the Electronic Timer Kit is defective and must be replaced.

a CAUTION: DO NOT charge batteries with the Elec-

tronic Timer Kit bypassed. The charger will remain on as long as the power supply cord is connected to an outlet.

Severe overcharging and eventual damage to batteries will result.

If the transformer does not hum and the ammeter still does not register witty the Electronic Timer Kit bypassed. a continuity check of the charger AC circuit is necessary.

Disconnect me power suopty cord from its outlet aria the DC output connector from the battery connector anc. with a suttacie continuity tester. cnecx Me circuit across the power sucoiv cord prongs as snown in Figure 2.

With the Electronic Timer Kit bypassed. the CIRCUIT SHOULD SE COMPLETE. If the circuit is not complete. indivicuaily check the continuity of the power supply cord. primary transformer coil and all connections.

PART 8 — RELAY CLOSES BUT NO TRANSFORMER HUM AND AMMETER DOES NOT REGISTER Check to be sure the power supply cord is securely connected to a live AC outlet. When three-prong to two prong acapters are usea. they tend to work loose resulting in a poor connection. Check the AC line fuse or circuit breaker and. if possible. measure the AC line voitage at the outlet to be sure AC power is present. if necessary connect a functioning charger, utility light. or other electrical appliance to the outlet to verify the presence of AC cower.

FIGURE 1 Battery DC Voltage Test The voltage reacing should be the same as the battery terminal voltage anc must be between 24 and 50 volts DC in orcer to c:cse the relay. If the DC voltage is within the above limits. remove the charger cover and verify that the charger is properly wired and you read the same voltage (24 to 50 Vdc: inside the cnarger where the white and black wires of The DC core attach. (Fig. 4 and wiring diagram Fig. 3.; If the battery DC voltage measured inside the charger ls new below the above limits or not present. the DC plug or ccrcset has an internal break and must be replacea. If the cnarger is wired correctly and a satisfactory battery DC voltage is measured inside the charger, a malfunction in the Electronic Timer Kit has probably occurrea. Cue to its complexity. do not attempt to make field repairs to any part of the Electronic Timer Kit. If a malfunction - exists. simciv remove-the entire Electronic Timer Kit anc reoiace it with a new one. Refer to Part D—"Electronic Timer Kit Replacement—for correct procedure.

If AC power is present. disconnect the power sum ,/ cord from its outlet and the DC cutout connector from the battery connector. Bypass the Electronic Timer Kit as described in Section 1, Part A, and with a suitable continuity tester check the circuit across the power supoiy cord prongs as shown in Figure 2. With the Electronic

T.

FIGURE 2 Charger AC Circuit Continuity Test (Transformer removed for clarity)

zonnectcs•r. aria cnecx the charger fuse. If a fuse link is ziown. refer to Section 2 — "Charger Fuse Blows • for furtner tests. if the fuse cnecks gooa, use a iow voltage continuity :ester to pertorm the following tests:

Timmer Kit bvcassea. the CIRCUIT SHCULt SE CCM? LETEE. if tne circuit is comciete. re!.r to :re wiring gram in Figure a. anc cnecx :re re:ay wiring arc all connections. If the circuit is not ccmlete. cnecx tne wirIna of :re power supply ccrc. transformer primary coil leaas ana the Eiectronic Timer Kit. If the cnarger is wirea correctly, inciyicually cneck :re continuity of the power supply cord. transformer primary anc relay.

1. Connect the tester leads to the cnarger DC output connector as snown in Figure 3. ana note the reacing. Reverse the tester leads and check the output connector again. The circuit should be complete In only one airection. If the circuit does not conduct in ether avec:ion anc the fuse is gooa, individually check the continuity of the OC output cora. ammeter. diodes. ana all connections. If the circuit conducts in both directions. a "short" exists in the charger OC circuit. First cneck the OC output cord for a "short" between the two wires. It is more likely that one or both diodes have "shorted." Refer to Section 2 — "Charger Fuse Blows' for continuity test of diodes.

PART C — RELAY CLOSES AND TRANSFORMER HUMS BUT AMMETER OCES NOT REGISTER If the relay cioses ana the transformer hums. the• cnarcer AC circuit ana Eiectronic Timer Kit are functioning prcoeriy. If the • ammeter aces not recister. a fault in the cnarcer DC circuit exists anc a continuity cnecx must Pe periormea. Disconnect the power supply cora from its outlet ana the CC output connector from the battery

2. If the charger DC circuit test is good. a check of the capacitor is necessary. Disconnect the power supply cord from its outlet ana the DC output connector from the battery connector. Then disconnect both transformer coil leads from the capacitor terminals. Use care when disconnecting the capacitor leads so the wires ao not break. Using an ohmmeter. set the scale to R X 10K ohms and test the capacitor as follows:

GOOD CAPACITOR—When the ohmmeter lea=

are connected to the capacitor terminals. the meter needle jumps to mid-scale and rapidly moves to hign resistance (=c).

FIGURE 3 Charger DC C.xltinuity Test

°TT CAPACITOR COIL (SECONDARY COIL UNDERNEATH1

PRIMARY COIL

i 1 11111111' III:I )

•

ift'rerr ri

BLACK WIRE OF OC CCRO

I;

HEAT SINK ASSEMBLY

‘4.‘ ;.—• •

RED WIRE . FROM ELECTRONIC . • TIMER KIT 4 -1,,,--• •

BLACK WIRE FROM ELECTRONIC TIMER KIT

■

WHITE WIRE

OE OC CORD

Feat

WIRE FROM ELECTRICAL — TIMER KIT • DIODE TERMINAL

FIGURE 4 Electronic Timer.Kit Wiring

OPEN CAPAC:TOR--when me onmmeter leads

are connected to the capacitor termtnais. the meter neecle does not move and stays at nign resistance (?c).

A bulge in the too of the capacitor may be visible if the caoacitor has failed "Coen. SHORTED CAPAC:TOR--when the ohmmeter leads are connected to the capacitor terminals, the meter neecle jumps immediately to zero onms and remains there.

If the capacitor is "Open" or "Shorted" . t must be reolacac.

a CAUTION: Use only a 6 Mfd. 660 volt AC rated

capacitor for replacement (Part No. 02390S). The use of a different value capacitor may result in improper charging, capacitor failure. transformer burnout, and/or battery damage.

3. If the charger DC circuit and capacitor check good. a test of the transformer is necessary. Refer to Section — "Transformer Short or Burn-Out" for test procedures.

PART D

—

ELECTRONIC TIMER KIT REPLACEMENT

The. Electronic Timer Kit should always be replaced as a complete assembiy. The tools recuired are a Phillips

heac screwdriver, 3/8" and 11/32" wrenches. and pliers. No soldering is required. To replace the kit follow the step-by-step procedures listen below.

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

2. Disconnect the green, black, and red wires of the Electronic Timer Kit as shown in Figure 4. Then remove the black and white leads of the power supply cord and both primary transformer coil leads from the Electronic Timer Kit terminal tabs. The Kit can be removed by removing the three mounting screws on the charger front panel. Save ail hardware for reassemoly.

3. Install the replacement Electronic Timer Kit by reversing the disassembly procedures described in Step 2.

When reconnecting the wires to the Electronic Timer Kit terminal tabs support the terminal board to prevent damage to the electronic circuit board. Connect

either transformer primary lead to terminal #2, arc the remaining primary teaci to terminal #3.

Connect :ne ()lack :eac of the power suooiy cord to terminal 41 on the Electronic Timer Kit and the wnite :eac cf me power sucoly cord to terminal #2.

Connect trte red wire of the Electronic Timer Kit along with the wnite leac of the DC cora to the Heat Sink Assernoty. Connect the black wire of the Electronic Timer it along Wan the black leac of the DC cord to the ammeter post. Do not allow the ammeter post to

turn wnen tigntentng the nut. Reconnect the green wire of the Electronic Timer Kit along with the transformer seconoary !ead to the diode lead terminal.

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

4. Replace the charger cover and check the Electronic Timer Kit for proper operation as follows: a. With the DC cutout connector disconnected from the battery connector, insert the power suocly cord into an outlet. The relay on the Electronic

Timer Kit shouic not close. A DC voltmeter cnnecteci across the DC output connector should incicate zero volts. b. Disconnect the Power supply cord from its outlet anti connect the DC output connector to the cattery connector. The reiay on the Electronic Timer Kit should close with an audible "click" after a two to five second delay. c. If the Electronic Timer Kit does not operate as (a) and (b) above. refer to the wiring diagram in Figure 8 and check to be sure the charger is wired correctly. If the Electronic Timer Kit operates properly, the charger is ready for use. Always monitor the first charge cycle to verify that the charger is turning off properly.

SECTION 2 — CHARGER FUSE BLOWS The charger fuse assemoiy consists of a dual element fuse link under a transparent cover mounted on the charger front panel. Each fuse element is electrically connected in series with a rectifier diode to provide protection for the transformer

in the event of a diode failure. Visually inpsect and electrically test the fuse to determine if one or both fuse links are blown

and refer to Part A or Part B for test procedures. LOCATE AND CORRECT CAUSE OF TROUBLE BEFORE REPLACING BLOWN FUSE. DO NOT attempt to repair the fuse link

as inadecuate protection will result PART A — SINGLE FUSE LINK BLOWS This conoition is normally caused by a short circuit failure of one diode. The fuse link will blow when the charger DC output connector is connected to the battery connector, regardless of whether the power supply cord is connected to an outlet To check the diodes, disconnect the power supply cord from its outlet and the DC output connector from the battery connector, and then disconnect one transformer secondary coil lead from the diode terminal. Using a low voltage continuity tester. connect one tester lead to the diode mounting plate and the other tester lead to a diode terminal as shown in

Figure 5.

FIGURE 5 Diode Continuity Test

Note the reading and then reverse the tester leads and check each diode again. If a diode conducts current in both directions, it is "shorted" and the complete Heat Sink Assembly with Diodes (Part No. 09653S) must be replaced.

On rare occasions a single fuse in may melt due to excessive neat. This can ce causec by a ioose internal fuse connection. Check all three ruse connections inside, the charger to be sure they are ciean anc tignt. The proper torcue on the fuse connector nuts is 20 IncnPounas (23 Cm-Kg).

PART B

—

BOTH FUSE LINKS BLOW

This is normally causea by a reverse polarity connection between me °cnarger DC cutout connector anc the battery connector. Check the patter/ pack anc cattery connector to be sure they are wired in me correct polarity. If possible check the voltage and oolarity at the battery connector with a CC voltmeter. Also. check the cnarger DC cutout connector for the correct polarity. The white wire snoula be connected to the positive (+) contact. anc the black wire to me negative (--) contact. if a reverse polarity connection is mace between the charger anc batteries. both fuse links will blow regardless of wnether the power supply cora is connected to an outlet.

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

SECTION 3 — AMMETER READS 30 AMPS FOR MORE THAN 30 MINUTES

This high output condition is caused by misuse. connecting the charger to an incorrect battery system which is lower than 36 volts. A common error is to install one or more of the 6 volt batteries in a 36 volt battery pack reverse polarity. Using a

suitacie DC voltmeter test to be sure all batteries in a battery pack are correctly wired. and also test the battery pack voltage at the charging connector. After charging for 30 minutes at this excessive rate the measured on charge voltage should rise to 34 to 38 volts DC for a 36 volt system. Voltage measurements, while charging, lower than this indicate an incorrect or failed battery pack that must be corrected before using the charger.

a CAUTION: DO NOT connect the charger to battery packs which are not 36 volt systems. This misuse will cause overheating and transformer bum-out will result.

SECTION 4 — CHARGER OUTPUT IS LOW

The most probable cause of low output is a single fuse link blowing as the result of a short circuit failure of one diode. Refer to Section 2 — "Charger Fuse Blows" for trouble-shooting procedures. On rare occasions a short

circuit failure of the transformer coils may cause the output to be low. Refer to Section 7 — -Transformer Short or Burn-Out" for test procedures.

a CAUTION: Do not use the charger if the output is

low. Batteries will not reach full charge, thereby increasing the possibility of a harmful deep discharge during their next use.

SECTION 5 — CHARGER TURN OFF MALFUNCTIONS

The Electronic Timer Kit turns the charger off as well as on. Proper charge time is determined by many factors. but the main elements are: (1) Battery size. (2) Depth of battery discharge. and (3) Finish charge rate. Large severely discharged batteries require more time to reach full charge than do smaller lightly discharged batteries.

The charge rate. as indicated by current flow in amperes

on the panel meter, is controlled by the batteries rising voltage during charge. The higher the on cnarge voltage

will rise. the lower the finisn charge rate wiil be before the Electronic Timer terminates cnarging.

The following timer malfunctions are occasionally due to factors other than the charger's performance. To help isolate the problem it is often necessary to use the charger on a different set of batteries and the original set of batteries on another charger.

PART A — CHARGER TURNS OFF TOO SOON

Check to ce sure the cower sum* core is securely connected to a live outlet. if the power supply outlet is live proceed with the next step.

To determine if the charger did shut off too soon. disconnect and reconnect me charger D.C. output connector.

This will restart the charger. Observe cnarger output on the ammeter.

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

2. The ammeter needle jumps smartly to between 20 anc 25 amps. but does not taper below 14 amps within 15

minutes. If the batteries have been . properly maintainea anc chargec regularly, this generally indicates that the batteries were not fully cnargec. If possibie. use a hydrometer to check the specific gravity of several battery cells. If the specific gravity readings are

more than 30 points (.030) lower than normal full charge readings, the electronic timer has malfunctioned and the complete Electronic Timer Kit must be replaced. Refer to Section 1, Part 0—"Electronic Timer Kit Replacement." for correct procedure.

If the batteries have not been used or charged regulady, they may be sulfated and will not produce their full capacity. Repeated cycles (at least 5) of a light discharge followed by a full charge will generally result in the recovery of most of the battery's capacity.

Do not interpret this reduced bartery capacity as being caused by the charger turning off too soon. The charger is working properly if, after several charge cycles. the battery capacity increases to near normal.

Sulfation occurs most often when the batteries have been stored without weekly charging. New batteries may also be sulfated due to extended shipment or

storage time prior to sale.

As batteries age, individual cells may weaken causing a reduction in battery capacity. This condition normally results in a finish charge rate higher than 10 amps and less time is required to fully charge the batteries. Do not interpret this shorter charging time and reduced battery capacity as being caused by the charger turning off too soon. The battery is aging naturally and the charger is working properly. When the batteries will no longer perform as required they should be replaced.

PART B — CHARGER DOES NOT TURN OFF New batteries with all good cells should rise to at least 2.5 volts per cell. This will allow the finish charge rate to taper below 8 amperes. As batteries age individual cells may weaken and these cells may not reach 2.5 volts.

This will result in finish charge rates greater than 8 amperes. and less time will be required for the batteries to reach full charge. At a finish charge rate of 8 amperes or less the charge time should not exceed 18 hours. At a finish charge rate greater than 8 amperes the charge time should not exceed 14 hours.

allow to charge normally. After the charge rate has tapered to its lowest ooint..measure the battery terminal voitage using a D.C. voltmeter capaPle of reading in increments of .001 volts. Continue charging and check the batter voitage reading every hour. if the battery voltage increases less than .012 volts. or if the battery volt age decreases between successive hourly readings, tt. charger should turn off. If the cnarger does not turn off. the Electronic Timer nas malfunctioned and the complete Electronic Timer Kit must be reotaced.

If the cnarger remains on longer man the specified maximum time, cneck to see if the cnarger turns on immediately wnen the D.C. output cora is connected without the normal two to five second delay. If the charger turns on instantly without the two to five second delay the Electronic Timer Kit has probably failed. This type of malfunction generally results in the cnarger not turning off and the complete Electronic Timer Kit must be replaced.

Refer to Section 1, Part 0 — "Electronic Timer Kit Replacements' for correct procedures.

If the cnarger remains on longer than the maximum time specified and the two to five second delay is present, verify that the green wire from the Electronic Timer Kit and the secondary transformer 'coil lead are securely connected to the diode lead as snown in Figure 4. The cnarger will NOT turn off if the green wire is loose or disconnected. If the green wire is securely connected. the Electronic Timer has malfunctioned ana the complete Electronic Timer Kit must be repiaced.

PART C — CHARGER RUNS TOO LONG BUT DOES TURN OFF In the event of A.C. power interruption when the charger is on. the charger will automatically restart when A.C. power is restored. This power outage can make the apparent charge time seem longer than the actual charge time. To check for A.C. power interruptions plug an electric clock into the same outlet to which the A.C. cord -is connected. Charge normally and note any time difference between the test clock time and the actual time.

If a precision digital type D.C. voltmeter is available. a test to verify that the Electronic Timer has malfunctioned can be made. Connect the charger to the batteries and

ELECTRONIC IlvER KIT

115 VAC

teur

—1– :ApAarca CAPACITC14 COIL

FIGURE 6

Transformer Coil Voltage Test (without capacitor)

FIGURE 7 Transformer Coil Voltage Test (with capacitor)

ELECTRONC TIAER KIT

QED GREEN TRANSFORMER

TAN

'NWT. TO DC RUG AND BATTERIES

FUSE ASSEMBLY dlACX, AC tipur GROUNDED

9LACK AMmETER

a TAM

CAPACITOR

FIGURE 8 Charger Wiring Diagram

MEASURE BATTERY DC VOLTAGE AT THESE POINTS INSiDE CHARGER

SECTION 6 — AC LINE FUSE OR CIRCUIT BREAKER BLOWS

If this occurs wnen the charger ocwer supply cora ;s connec:ea to an outlet. without the OC output connector. connectea to the oattery connector. tne charger power suociy cora may be snorted. Disconnect the cower supoly cora from its outlet ana the DC cutout connector from the oattery connector. then check to be sure the Eiectronic Timer Kit is NOT bypassed. With a suitanie continuity tester check the circuit across the power supply cora :Prongs as snown in Figure 2. THE 'CIRCUIT SHOULD NOT SE COMPLETE. If the circuit is compiete. check the relay contacts to ,Pe sure they are open ana have not weiaecl cosec. If the relay contacts are ocen. the power supply cord is snorted ana must oe reotacea. if the power supply cord checks good the transformer coils may be snorted. Refer to Section 7 — - Transformer Short or Burn-Out" for test proceaures.

SECTION 7

—

TRANSFORMER SHORT OR BURN OUT

Failure of the transformer can be the resuit of natural acing, premature snorting of adjacent coil turns or overneating carnage. The most common cause of transformer overheating ana premature burn-out is the resuit of misuse. connecting the cnarger to a battery system of lower voltage than specified on the cnarger. (See Section 3) Darkening of all the transformer seconaary winainas is an inaication of possioie overneat;na carnage. A low or complete lac.< of output would be coservea on the ammeter. however the transformer may hum or the AC line fuse or circuit breaker may blow when the charger is turner on. To test the transformer. aisconnect the power suoply cora from its outlet ana the DC cutout connector from the battery connector. Then aisconnect the transformer secondary coil leads #1 and #4 from the diode terminais and disconnect the transformer capacitor coil lea= from the capacitor terminals. Use care when disconnecting the capacitor lead so the wires do not break.

DANGER—HIGH VOLTAGE: With the charger operating, the charger capacitor voltage is approximately 650 volts AC. Use extreme

caution wnen working near the capacitor

terminals. .

In orcer to acply AC cower directly to the transformer primary coil the Eiectronic Timer Kit must oe cypassec.

Refer to Section 1. Part A for bypass Procedures. With the Eiectronic Timer Kit bypassea ana taking care for personai safety. connect the cower suopiy cord to an outlet. If the AC line fuse or circuit breaker blows. me

transformer is snorter internally aria must be replaced. :f this does not occur. cnecx the transformer seconaary and cacac:tor coil voltages as snown in Figure 6. using a suitable AC voltmeter. if the measures voltages are supstantially lower than those snown. the transformer is snorter internally ana must be replaced.

If the transformer secondary coil voltage and capacitor coil voltage cneck good. disconnect the power supply cord from its outlet. Check the capacitor to be sure its rating is 6 Mfd, 660 volts AC. and then carefully reconnect the capacitor coil leaps to the capacitor terminals. Then. taking care for personal safety, reconnect the power supply cord to an outlet and measure the transformer seconaary voltage again. The correct voltage reading is snown in Figure 7. If the transformer secondary voltage reading is the same as measured with the capacitor disconnectea. from Figure 6. the cacao:tor may oe open. the capacitor coil may be open or the caoacitor coil terminals may not be making proper electrical contact. Refer to Section 1. Part C. Item 2 for capacitor test proceaures. if the voltage readings are correct. both the transformer anc capacitor are good. refer to Section 1, Part C. Item 1 for

further tests of the DC circuit If it should become necessary to replace a terminal on one of the transformer leads. the new terminal must be crimped AND soldered. NOTE. Some transformer leads may be aluminum wire and a solder must be used on these wires that is intended for use on aluminum.. such as Alcoa ,1807 solder with Alcoa #69 flux. If these materials are not available locally, contact the Lester factory.

NO. 7-124

Eaton Hydraulics Division

ac Pa° Lr nITorTmaTon

R

2000 Series Char-Lynn® Motors

008

2

Valve Housing

Balancing Ring

Shaft Face Seai Bearing and Shaft Ass'y

Back-up Washer

Splined Drive

Seal

Valve

Outer Face Seal

Seal

Wear Plate Seal

Key Bearing Housing

Geroler

Valve Plate

Inner Face Seal

Shaft Seal

Seal

Plug

Spring

Exclusion Seal

Valve Drive

Case Drain Plug Seal

Tools required for disassembly and reassembly.

Torque wrench 500 lb-in[57Nm] capacity

12-16[300-450] * breaker bar 9/16 socket Small screwdriver 6-8x1/4[150-200x6,5] blade 3/16 alien wrench Press *Unless indicated otherwise, measurements are given in inches[mm] . **Shaft seal installation tool **Bullet for 1 diameter shafts

The following tools are not necessary for disassembly and reassembly, but are extremely helpful.

Alignment studs (2) 8[200]

7 1[25]

7---Approx.1/2[131

U111111101

0 =1 5/16[8].1

Tie Bolt

Pin

3/8[9,5] Dia. Steel Rod

3/8-24 UNF -\

Grind Fiat Spots on Each Side "Available--by special order © Copyright 1985 Eaton Corporation

3 Disassembly Cleanliness is extremely important when repairing a hydraulic motor. Work in a clean area. Before disconnecting the lines, clean the port area of the motor thoroughly. Use a wire brush to remove foreign material and debris from around the exterior joints of the motor. Check the shaft and keysiot, remove all nicks, burrs or sharp edges that might damage the bearing housing seals when installing the shaft and bearing assembly. Before starting the disassembly procedures, drain the oil from inside the motor.

2

Remove 4 bolts from motor.

Figure 3

3 Lift valve housing straight up. If done carefully the pins, springs, balance ring assembly, and valve will remain on the valve plate.

Figure 1

<5

Place the motor in a vise with the output shaft down. Clamp across the mounting flange of the motor not the housing. Excessive clamping pressure will cause distortion. When clamping, use some protective device on the vise, such as special soft jaws, pieces of hard rubber or board.

Although not all drawings show the motor in a vise, we recommend that you keep the motor in the vise during disassembly and reassembly.

Follow the clamping procedures explained throughout the manual.

Seal

Seal

)

Case Drain Plug

Figure 4

4 Carefully remove 3{76] diameter seal from valve housing.

5 Remove case drain plug—with seal, from valve housing.

6 Remove 2 pins and 2 springs from balance ring assembly, see Fig. 5.

Figure 2

Disassembly Outer Face Seal

15 Remove tne 3[76] diameter seal from wear plate, see Fig. 7.

Bearing Housing

Seal

Wear Plate

Inner Face Seal Valve Balance Ring Figure 5

Shaft Face Seal

7 Remove balance ring assembly.

Figure 8

8 Remove inner and outer face seals from balance ring,.

16 Remove the wear plate.

17 Remove the shaft face seal from the wear plate.

9 Remove the valve.

Valve Plate

Valve Drive

18 Remove the 3{76] diameter seal from bearing housing.

Bearing Housing

Shaft & Bearing Assembly

Seal Figure 6 10 Remove the valve plate.

Figure 9

11 Remove the 3[76] diameter seal from valve plate.

19 You may need a press to remove shaft and bearing assembly from bearing housing. (Key must be removed before removing shaft.)

12 Remove the valve drive.

Seal

Shaft Seal

Bearing

Housing Exclusion Seal Back-up Washer

Figure 10 Drive Geroler Figure 7 13 Remove the Geroler. Be sure to retain the rollers in the outer ring if they are loose.

14

Remove the drive.

Use a small screwdriver to remove shaft seal, back-up washer and exclusion seal from bearing housing, see Fig. 10. Do not damage bore of housing.

20

Note: Individual parts of shaft and bearing assembly are not sold separately. Replace as a unit.

Check all mating surfaces. Replace any parts that have scratches or burrs that could cause leakage.

Clean all metal parts in clean solvent. Blow ary with air. Do not wipe dry with cloth or paper towel because lint or other matter can get in the hydraulic system and cause damage. Do not use a coarse grit or try to file or grind these parts. Check around the keyway and chamfered area of the shaft for burrs, nicks or sharp edges that can damage the seals when•reassembling the bearing housing.

Note: Lubricate all seals (prior to installation) with petroleum jelly such as Vaseline. Use new seals when reassembling this motor. Refer to parts list (6-129) for proper seal kit number.

21 Use a press to install exclusion seal in outer bore of bearing housing. Lip of seal must face outward. See Fig. 11. If a press is not available use a plastic or rubber hammer, being careful not to damage or cock seal in the bore.

Shaft Face Shaft Seal

Shaft Face Seal

26 Alignment studs can be very helpful in reassembly of the motor. See special tool listing page 2. If you use studs. install 2 studs diagonally opposed the bearing housing.

Install the shaft face seal in the wear plate as shown in Fig. 11. Do not distort seal.

27

28 Install the wear plate, see Fig. 11.

29 Apply a light film of petroleum jelly to the 3[76] diameter seal and install seal in the wear plate.

30

Install the drive into the output shaft.

31 Align the notch on the outside of the Geroler with the notch on the wear plate. Install the Geroler against the wear plate. Be sure to retain the rollers in the outer ring if they are loose.

32

Install the valve drive in the Geroler.

Note: Installation at this time involves 3 steps in the timing of the motor. Timing determines the direction of rotation of the output shaft. Timing parts inch,: 1. Geroler 2. Valve Drive

Back-up Washer

Exclusion Seal

5 Reassembly

Shaft & Searing Ass'y

3. Valve Plate 4. Valve

Geroler Valve Pate Valve Drive

Valve

Valve Clockwise

Drive

\1/2 tooth max. to Engage Spline

Place back-up washer into seal bore. Place shaft seal onto installation tool and press seal into seal bore of the housing.

22

23

Clamp housing in vise, see Fig. 1.

Place protective bullet (see note below) over shaft. Apply petroleum jelly to inside diameter of dust and shaft seal. You may need a press to install shaft and bearing assembly. Do not distort shaft seal. Damage to this seal will cause leakage.

24

Rotate

Largest Open Pocket

Alignment Ref. Only

Anyone of 6 Ports open to Outside of Valve

Figure 12 Timing Alignment 7/# 1—Locate the largest open pocket in the Geroler and mark it on the outside edge of the Geroler.

Timing Step Note: Bullet for 1" shafts, available-by special order. Use tape over other shafts to prevent cutting the seals.

25 Apply petroleum jelly to the 3{76] diameter seal. Install seal into the bearing housing.

33 Apply a light film of petroleum jelly to the 3{761 diameter seal. Install seal in groove of valve plate.

Reassembly 34 Align the notch on the outside of the valve plate with the notch on the Geroier as shown in Fig. 12.

Timing Step ## 2— Locate the slot opening in the valve plate which is in line with the largest open pocket of the Geroler.

Timing Step 3— Locate anyone of the side openings of the valve and align this opening with the open slot of the valve plate that is in line with the largest open pocket of the Geroler. I nstall the valve by rotating it clockwise until the spline teeth engage (1/2 spline tooth max. ). This will provide the proper rotation when pressurized as shown in Fig. 13.

Important: Install face seals in the positions shown in Fig. 15. or the motor will not operate properly.

Do not force or bend the face seals. Any damage to these seals will affect the operation of the motor.

Balance Ring Figure 15

38 Align pin notches in balance ring with pins in bore of valve housing. Install balance ring assembly in valve housing.

Clockwise Rotation Balance Ring

Counter Clockwise Rotation

Valve Housing Figure 13 Figure 16 Valve Housing

Alignment Studs Valve Plate

Figure 14 Figure 17

I nstall 2 springs and 2 pins in the holes located 35 in the bore of the valve housing, as shown in Fig. 14.

36 Apply a light film of petroleum jelly to the 3[76] diameter seal. Install seal in the valve

I nsert your finger through port of valve 39 housing. Apply pressure to side of balance ring as shown in Fig. 16. Hold ring in position until valve housing is in place against valve plate. See Fig. 17.

housing.

37 Apply petroleum jelly to inner and outer face seals. I nstall seals on balance ring as shown in Fig. 15.

Note: After installing the valve housing on the valve plate check for proper placement. Push down on the valve housing. You should get a slight spring action.

Reassembly 40 Install the tie bolts. If you use alignment studs. install 2 bolts opposite the studs. Finger tighten bolts. Remove the alignment studs and replace wi -L the 2 remaining bolts. Torque all 4 bolts alternately to 450 lb-in[50Nmj. Tie Bolts

41 Install seal on case drain plug then install in valve housing. Torque to 50 lb-in [6Nmi .

Case Drain Plug with Seal Figure 18

Wheel Motor On wheel motors, a different bearing housing is used, see Fig. 19. Other than this the parts are the same as the standard motor and the same disassembly and reassembly procedures apply.

Bearing Shaft Shaft &

Housing Seal Bearing Ass'y

Castle Nut

Back-up Washer Exclusion Seal

Seal

Shaft Face Seal

Figure 19

Bearingiess Motor

Flange

Seal

This motor is the same as the standard motor without the shaft/bearing assembly, and bearing housing.

The mounting flange replaces the bearina housing, see Fig. 20. Follow same disassembly and reassembly procedures as rear section of standard motor.

Figure 20