CONDOR Scissor Lift V2033XL V2033 Operator's & Parts Manual - PDF DOWNLOAD

SELF-PROPELLED ELEVATING WORK PLAlFORM

MODEL V2033XL, V2033 Serial Number X21599064, X21599073, X21599077 & X31597070 & Above

OPERATOR'S, MAIN'IENANCE, AND PARTS' MANUAL

SHIPPING ADDRESS

MAILING ADDRESS

TIME CONDOR

TIME CONDOR

8300 IMPERIAL DRIVE VVAco,TEXAS76712 (254)420-5200

P.O. Box 21447 VVAco,TEXAS76702-1447 (254)420-5200

.

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

SELF-PROPELLED ELEVATING WORK PLATFORM

MODEL V2033XL, V2033 Serial Number X21599064, X21599073, X21599077 & X31597070 & Above

OPERATOR'S MANUAL

SHIPPING ADDRESS

MAILING ADDRESS

TIME CONDOR

TIME CONDOR

8300 IMPERIAL DRIVE VVAco,TEXAS76712 (254)420-5200

P.O. Box 21447 VVAco,TEXAS76702-1447 (254)420-5200

MANUAL

SIN

92383 May 1999 X21599064, X2 I 599073, X21599077 & X31597070 & Above

i 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 ofthe 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®.

It is YOUR RESPONSmn..ITY 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 RESPONSmILITY to consider all of the personnel when making decisions regarding the intended use of this CONDOR®.

It is also YOUR RESPONSmILITY to understand and obey all federal, state, and local regulations regarding the operation and use of aerial work platforms. A copy of the ANSIISIA 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 ofthe 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 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

ii

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: (817) 420-5200 Telephone (817) 420-5299 Voice Mail (800) 443-5803 FAX

2.

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

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

3.

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

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

4.

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

8300 IMPERIAL DRIVE. P.O. Box21447, WACO. TEXAS 76702-1447 817-420-5200, 817-666-4544 FAX 0

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

iii TABLE OF CONTENTS

INTRODUCTION •••••••••••.•••••••.•..•••...•••••••••••••••••.••••••.••••.•••••••••••••••••••• _•.•.•.••.••••••••••••••.•••.••••.••••...•.•••••••••••• i SERVICE INFORMATION .............................................................................................................••.•••••• ii TABLE OF CONTENTS ......................................................................................................................... iii

I.

PREPARAnON, INSPECTION, AND MAINTENANCE ............................................................... 1 A. B. C. D. E. F.

Overall Machine Condition ....................................................................................................... 1 Lower Control Station ............................................................................................................... 1 Emergency Lowering ................................................................................................................ 1 Platform and Upper Control Station .......................................................................................... 2 Hydraulic System ...................................................................................................................... 2 Batteries .................................................................................................................................... 2

II. MACmNE OPERATION ••.•••.••••••••••••••.••.•••••.••.••••••.••.••••.••.••.•.••••.....••.•••••••••• _••••••••••••••.••..•....•.••.• _.. 2 A. B. C. D. E. F. G.

RatedWork Load ...................................................................................................................... 2 Lower Controls .......................................................................................................................... 2 Upper Controls .......................................................................................................................... 3 Emergency Lowering ................................................................................................................ 3 Lift-up Entry Gate ..................................................................................................................... 3 Deck Extension ......................................................................................................................... 5 Removable Upper Control Box ................................................................................................. 5

Ill. MOVING FROM JOB-SITE TO JOB-SITE .................................................................................... 5 A. B. C. D. E.

Loading and Unloading ............................................................................................................. 5 Ramp Method ............................................................................................................................ 5 Forklift Loading and Unloading Method .................................................................................. 5 Transporting .............................................................................................................................. 6 Freewheel Operation ................................................................................................................. 6

IV. STORAGE •...•.••..•••..•......•.......•...•....•.•...••.•.•..•.•••••.••.•••.....•..•..•........•..•.•....••..•.....••.•......•.•••••...••.••••..••.• 6 APPENDIX: DECALS ILLUSTRATION ................................................................................................ 8 ANSIISIA A92.6 - 1990 MANUAL OF RESPONSIBILITIES

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

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

I.

PREPARATION, INSPECTION, AND MAINTENANCE

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®.

STEERING:

D

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

BRAKES:

D

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

DECALS:

KNOW TIDS CONDOR® AND ITS CAPABILITIES. REPORT ANY UNUSUAL OPERATION,SUCHASERRATICSWAYOR MOTION OF THE ARMS OR PLATFORM.

D

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 MACmNE CONDITION MISSING, BROKEN, OR DAMAGED PARTS:

D

Check cylinder mounting pins, pivot pins, pin retainers, bearing pads, bolts, and nuts.

STRUCTURAL:

D

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

B. LOWER CONTROLS

D

TIRES AND WHEELS:

D

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).

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

C. EMERGENCY LOWERING

D

Check emergency lowering function by pulling red T -handle.

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 &X31597070 & Above

•

•

D. PLATFORM AND UPPER CONTROL STATION

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

D

D D D

D

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

Check for missing bolts & nuts - Replace before operating.

D

Keep vent caps tightly in place.

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

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

ll. 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.

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 ifrequired. Ensure that the breather cap is clean and in place on the tank.

Check for hydraulic leaks at all fittings and valves.

D Check all hydraulic hoses and tubes for damage and kinks.

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

D

D

Check that extension deck is locked in place.

E. HYDRAULIC SYSTEM

D

D Keep battery tops clean and dry.

Check Electrolyte level daily in each cell.

Ifnecessary, add clear, odorless, mineral free water to bring the level to 112" 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 CONDOR® MUST BE OPERATED ON FIRM, LEVEL GROUND ONLY. A. RATEDWORKLOAD The platform will support a combined weight equal to the unit's rated work load-including personnel, tools, and equipment-throughout the working envelope ofthe 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 750 Ibs. (340 kg) including two occupants.

B. LOWER CONTROLS 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 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

2. To store ann stand, raise platfonn so that ann stand can be rotated until it rests on the stop provided on the scissor anns.

Select desired drive speed with the "highllowl creep" switch. (A limit switch automatically cuts drive speed to "creep"as the platfonn is raised.)

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

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.)

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

Tum switch to "upper" position, to operate from platfonn.

C. UPPER CONTROLS Tum "controls" switch, on lower control panel, to "upper" position to operate from platfonn.

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 platfonn, both red buttons, on lower and upper controls, must be pulled out.

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

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

To improve drive traction, depress and hold "positraction" switch. (This will automatically cut-out high drive speed.)

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

Gently pull to lower the platfonn. 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.

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

•

LOWER CONTROLS

r-____________

REDEMERGENCY_____ STOP BUTTON

~~~~~ RAISEILOWER BUTTONS

OPERATING - _ _ _+-_-1INSTRUCTIONS

CONTROLSTATION------~~~--~~--_rrr~ SELECTOR SWITCH CONTROL CIRCUIT BREAKER

UPPER CONTROLS RIGHT/LEFT STEER ROCKER SWITCH POSITRACTION SWITCH

DRIVE CONTROL HANDLE

REDEMERGENCY ____--+-~~~~~~ STOP BUTTON RAISEILOWER BUTTONS

HIGHILOW/CREEP DRIVE SPEED SELECTOR SWITCH

POWER BUTTON

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

F. DECK EXTENSION

B. RAMPMETHOD

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 untillockpin 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!

G. 'REMOVABLE' UPPER CONTROL BOX 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®.

ill. MOVING FROM JOB-SITE TO JOB-SITE

The ramp should be set, not steeper than this CONDOR®'s rated gradeability, which for Model V20331XL is 14° or 25%, or a rise of30 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.

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

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 2633

WEIGBT(#) 3,300Ibs.

WEIGBT(KG) 1496 kg

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

(SEEm.A.) 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 92383 May 1999 SIN X21599064, X21599073, X21599077 &X31597070 & Above

•

•

D. TRANSPORTING This CONDOR® can be easily transported between job-sites ifthe 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 90 0 and 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.

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

CAUTION Never park the CONDOR® with platform raised.

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

NOTES

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

•

APPENDIX: DECALS ILLUSTRATION

PARTIAL SECTION A APPLIES TO ALL MODELS

12

000 o 0 0 0 0 0 0 o 0 0 0 0 0 o 0 0 0 0 o 000 0 0 o 0 0 0 0 000 0 0 0 o 0 0 0 0 000 0 0 0

o

ARMSTAND

o

0

0

0

0

REF

000 0 0 0 0 0 0 0 0 0 0 0 0 000 0 0 0 0 0 0 0 0 0 000 0

0

0

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

APPENDIX: DECALS ILLUSTRATION

QTY

ITEM

PART NUMBER

Ref *1

20 *21

55982XL .......................... Decal Installation .......................................•........................................... Ref. 55890 ................................ Decal V Upper Operator Instructions V2033 ..................................... 1 55889 ................................ Decal V XL Upper Operator Intructions V2033 XL ......................... 1 55894 ................................ Decal, V General <:aution ........................................................................ 1 54652-003 ........................ Decal, GuardrailI<ltain <:aution ............................................................ 1 55963-800 ........................ Decal, 800 Rated Load .................•........................................................... 2 55963-750 ........................ Decal, 750 Rated Load ...•......................................................................... 1 55944 ............................•... Decal, 250RWl. On Ext. XL .................................................................. 1 55480-002 ........................ Decal, Lower Op Instruction .................................................................. 1 55480-00 1 ...........•....•....... Decal, Lower <:::Ontrols ....................................................................•........ 1 56303 ................................ Decal, lIse Annstarnd <:aution ............................................................... 1 54984-005 ........................ Decal, Rear Btttnper .................................................................................. 1 66973 ................................ Decal, Elect.l1azard Keep aear ............................................................ 2 55871-001 .............•.......... Decal, V Upper Electrical Box Top ...................................................... 1 55856-001 ........................ Decal, V XL Upper <:::Ontrol Box .......................................................... 1 55871-002 ........................ Decal, V Upper Electrical Box Front .................................................... 1 55856-002 ........................ Decal, V XL Upper Electrecal Box Front ............................................ 1 54984-007 ........................ Decal, Hydraulic Fluid .............................................................................. 1 55940-023 ........................ Decal, o)NDOR 3.45 x 23 .................................................................. 2 55984 ................................ Decal, V2033XL ........................................................................................ 2 55941-017 ........................ Decal, <:::Ondor "Bird" ............................................................................... 2 53259 ................................ Tape, Non-Skid 6" BIack .............................................................. 1.50lF 66921 ................................ <:::oating, Non-Skid Jet Black ........................................................025GL 55982-DWG ................... Dwg. V 2033/XL Decal Installation ..................................................... 1 54984-006 ........................ Decal, 110V Extention To Platform V2033XL ................................. 1 56302 ................................ Decal, Gushing Danger V2033XL ........................................................ 1

31

51340 ................................ Nanteplate Scissors Indentification .................................................... Ref.

* *

55982-102 ........................ Decal Kit, V2033XL Essential ............................................................ Ref. 55982-101 ........................ Decal Kit, V2033 Essential ................................................................ Ref.

*2 *3 *4 *5 *6 *7 *8 >K)

*10 *11

*12 *13 14 15 16 17 18 19

DESCRIPTION

- Indicates Items Not Shown *Indicates Included In Essential Decals

?,REF

,

~

r r

2 1/4 MARGIN NO NON-SLIP COATING

PLANVIEW OF MODEL V2033

PARTIAL REAR VIEW OF MODELS V2033

•

APPENDIX: DECALS ILLUSTRATION

OPERATING INSTRUCTIONS

1

• 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.

2

551190

I&CAUr~ONI • DO NOT OPERATE THIS CONDO~ UNTIL YOU HAVE BEEN PROPERLY TRAINED AND HAVE COMPLETEL Y READ AND UNDERSTOOD THE OPERA TOR'S MANUAL LOCATED ON THIS CONDOR~ • THIS CONDOR· IS NOT ELECTRICALLY INSULA TED. SEE OPERA TOR'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 SECTION 6 OF THE ANSI 92.6 STANDARD. • DO NOT USE THE CONDOR", IF IT IS MALFUNCTIONING OR DAMAGED IN ANY WAY, OR IF THE WIND BLOWS OVER 15 MPH. • RAISE PLA TFORM ONLY WHEN CONDOR·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 OPERA TOR'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.

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

APPENDIX: DECALS ILLUSTRATION

3

I~CAU1~ONI GUARDRAILS AND SAFETY CHAINS MUST BE SECURED AND USED AT ALL TIMES 5<4652-0Q.l

5

RA TED WORK LOAD ON DECK EXTENSION 250 LBS 55944

OPERATING INSTRUCTIONS 6

• 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.

55480-002

21

8

I~ Cfo\lrr~ON I USE THIS ARMSTAND DURING MAINTENANCE 56303

CRUSHING HAZARD

KEEP CLEAR

56302

10

ELECTROCUTION HAZARD DEATH OR SERIOUS INJURY WILL RESULT FROM CONTACT WITH THIS MACHINE IF IT SHOULD BECOME ELECTRICALLY CHARGED.

KEEP CLEAR

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

SELF-PROPELLED ELEVATING WORK PLATFORM

MODEL V2033XL, V2033 Serial Number X21599064, X21599073, X21599077 & X31597070 & Above

MAINTENANCE MANUAL

SHIPPING ADDRESS

MAILING ADDRESS

TIME CONDOR

TIME CONDOR

8300 IMPERIAL DRIVE VVAco,TEXAS76712 (254)420-5200

P.O. Box 21447 VVAco,TEXAS76702-1447 (254)420-5200

MANUAL

SIN

92383 May 1999 X21599064, X21599073, X21599077 & X31597070 & Above

i

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

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

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

It is YOUR RESPONSmILITY to follow procedures while operating the CONDOR®. The manufac-

turer of this CONDOR® cannot control the wide range ofapplications that may be used in carrying out a variety of jobs. Therefore, it is THE USER'S RESPONSmILITY to consider all personnel when making decisions regarding the CONDOR®'s intended use.

It is also YOUR RESPONSmILITY to understand and obey all federal, state, and local regulations

regarding the operation and use of aerial work platforms. A copy of the ANSIISIA Manual of Responsibilities is attached for your use: ANSIISIA A92.5-1992 is provided for Boom-Supported Elevating Work Platforms, and ANSIISIA A92.6-1990 is provided for Self-Propelled Elevating Work Platforms.

Time Manufacturing-Condor Division 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 MANUFACTURING-CONDOR DIVISION

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

NOTE:

Please refer to the Condor Division section ofthe Operation, Maintenance, & Parts Manual for information pertaining to your CONDOR®.

ii

CONDOR® SERVICE INFORMATION

1. If you need assistance or have any service or maintenance questions, Condor Division service and parts personnel are always available by phone or fax. The telephone numbers are: (817) 420-5200 Telephone (817) 420-5299 Voice Mail (800) 443-5803 FAX

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

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

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

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

4. Condor Division 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.

CONDOR DIVISION

-8300 iMPBRIALDRlVE, P.O. Box21447, WACO, TBXAS 76702-1447· 817-420-5200, 817-666-4544 FAX

iii

Condor® Self-Propelled Booms and Scissors WARRANTY Time Manufacturing (Condor Division) warrants to the purchaser that each new aerial work platform made

by Condor Division is free from defects in material and workmanship arising undernormal use and servicein the case of major weldments, (chassis, turret, and booms), for a period of five (5) years after the original shipment ofthe aerial work platform from Condor Division'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 Condor Division's plant, whichever comes first.

The obligation and liability under this Warranty is expressly limited to repairing or, at Condor Division's option, replacing free of charge at its factory in Waco, Texas or at an authorized repair facility designated

by Condor Division, the defective part. In no event shall Condor Division 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 Condor Division, 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 Condor Division's factory for inspection. This Warranty applies to replacement parts provided under the terms of this Warranty only for the remainder of the Warranty period applicable to the original purchase.

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

No agent, employee, distributor, dealer, or other representative of Condor Division 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 Condor Division and should not be relied upon as limited warranties of Condor Division, and no attempt, effort, or promise to repair equipment by Condor Division 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 Condor Division. This Warranty covers only new and unused aerial work platforms manufactured by Condor Division. Products or parts manufactured by others are covered only by such warranties as are extended to the purchaser by Condor Division'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 76702·1447-817-666-4545,817-666-4544 FAX Fonn No.S13-3M-392

Effective Date 911190 Printed in U.SA

Effective January 1, 1993 WARRANTY PROGRAM Warranty is a function of a manufacturing company to back up the product it manufactures. It is a guarantee against defects in design and workmanship ofcomponents utilized in the product, and is offered for a fixed period of time following the purchase of the product by a customer.

Condor Division Warranty states, in general, that Condor Division 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 Condor Division. 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 Condor Division, whichever comes first. In the case of major weldments (chassis, turret, and booms), the Warranty Period is five (5) years following shipment from Condor Division.

2.

The Truck-Mounted CONDOR® Warranty Period is one (1) year from shipment ofthe CONDOR® from Calavar'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 Condor Division, whichever comes first, unless the part is furnished to correct a defective part on the original shipment still under Warranty.

4.

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

5.

During the Warranty Period, in addition to covering the parts replaced under Warranty, 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 ManufacturingCondor Division'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 Condor Division, whether it will be the dealer or the end user, to complete this form and return it to Condor Division'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 Condor Division 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 Condor Division.

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, ifthey are found to be defective, contact can be made with the manufacturer's local dealer.

2.

Hvdraulic 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 Condor Division by its suppliers.

4.

Freight and Charges: The warranty does not include any transportation, other charges, or the cost ofinstallation 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, Condor Division 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 Condor Divison 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 Condor Division for your stock and will utilize it for this replacement.

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

2.

c.

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

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

d.

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

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

Provide as much information as possible to enable Condor Division to thoroughly evaluate the claim and process it in the shortest amount oftime possible.

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

3.

E.

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

RETURN AUTHORIZATION 1.

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

2.

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

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

3.

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

4.

All parts claimed under Warrrantywill be required to be shipped back to Condor Division FREIGHT PREPAID. No freight collect shipments will be accepted.

CONDOR® Model V2033XL, V2033

MAINTENANCE MANUAL TABLE OF CONTENTS

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

Table ofContents ....................................................................................................................... 1 Specifications ............................................................................................................................. 3 RecommendedToolList ............................................................................................................. 4 Serial Number Location .............................................................................................................. 5 HydraulicSystemDescription ..................................................................................................... 7 Pressure Adjustment Procedures ............................................................................................... 11 ElectricalSystemDescription .................................................................................................... 15 MachineOptionsDescription .................................................................................................... 19 BatteryService ......................................................................................................................... 23 PreventiveMaintenance ............................................................................................................ 31 Hydraulic Fluid Specifications ................................................................................................... 41 BatteryChargerTroubleshootingGuide ..................................................................................... 43 BoltTorqueChart .................................................................................................................... 53

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

NOTES

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

SPECIFICATIONS SPECIFICATIONS

V2033~

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 Power System Battery Capacity Number of Batteries Battery Voltage Battery Charger WheelBase Tires

26 ft.

20 ft.

39.5" 93" 33" 79" 50" 92.5" x 30" 7501bs.

3,3610Ibs. 24 volt DC 235 amp hour 4 6 volt 25 amp 75" 16 x 5 (Solid Rib) 24" .75/1.5/3 mph 25%114° 35/30 sec

Inside Turning Radius Drive Speed Gradeability LiftlLower Time OPTIONS

*

* * * *

*

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

*

* * *

MotionIMovement Alarm Descend Alarm 5° Slope Alarm Low Volt WarninglInterrupt Battery Protection System

The CONDOR® Model V2033/XL is designed and built to conform to Condor Div. 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 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

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

1 each I each 1 each 1 each 1 each leach 1 each 1 each 1 each 1 each 1 each 1 each 1 each 1 each 1 each 1 each 1 each 1 each 1 pair 1 pair 1 pair 1 pair 2 pair

Volt/Ohm Test Meter Hydraulic Flow Meter, 0-10 GPM Hydraulic Flow Meter, 0-50 GPM Hydraulic Quad Meter Pressure Gauge Battery Hydrometer Battery Load Tester 112" Drive Torque Wrench, 0-250 ftIlbs Pry Bar Strap Type Filter Wrench Grease Gun Hammer, 24 oz.

Vice Grip Pliers Combination Wrench Set, 114" to 1-112" 3/8" Drive Socket Set, 114" to 3/4" 112" Drive Socket Set, 3/8" to 1-112" Hex Key (allen wrench) Set, up to 112" 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 ofthe 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 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

Serial Number Location •

1

2

TheCONDOR® Model Y2033/XLSerial Number is stamped in two locations on the machine.

1.

2.

The first place to find the serial number is on the data plate affixed to the chassis, at the rear between fork lift pockets.

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

kingpin.

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

This Page Intentionally Left Blank

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

HYDRAULIC SYSTEM DESCRIPTION The following is a detailed description ofthe hydraulic system used on the CONDOR® model V20331XL 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 V2033/XL consists primarily of a single manifold assembly, used to control all the hydraulic functions through the use ofhydraulic 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 ofthe open-center valve type, meaning that the hydraulic fluid circulates back to the tank when the pump is running and no functions are being operated. Al1lift 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 ofthe 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 ofthe 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. The use of a tank strainer and shut-off valve (ball valve) for the tank has been discontinued. Although the tank configurations differ between models, the attaching components are identical.

Filler Cap

Ball Valve

FIG. I

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 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

PUMPIMOTOR The pump and motor assembly is located in the right side of the belly pan, between the tank and the fixed axle (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 .194 cubic inch per revolution, which equals to 2.7 GPM of hydraulic flow at 3600 rpm. One section ofthe 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.

HYDRAULIC TANK

PUMP/MOTOR CONTACTOR

FIG. 2

MAIN VALVE ASSEMBLY Located in the left side of the belly pan between the batteries and battery charger is the main valve assembly which performs all of the hydraulic functions ofthe machine (See FIG. 3).

This assembly includes three directional control valves and a variety ofcartridge valves to achieve the operation ofthe cylinders and motors for the machine functions. These individual functions are described in detail below.

Ground Controls

Batteries

Main Valve Assembly

Battery Charger

FIG. 3

MACHINE FUNCTIONS The hydraulic functions of the CONDOR® model V2033/XL includes: forward and reverse drive with three selectable speeds at limited height, spring appliedlhydraulicallyreleased 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 tum 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 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

--

~

__________________

~4D

Drive Directional Control Valve

1..----.

Flow Divider/Combiner

FIG. 4.

Creep Speed Solenoid Valve

Creep Speed Needle Valve

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 11.9 cubic inch per revolution displacement and are located on the steer axle. When the positraction button is depressed at the upper control box, the 4-way normally open positraction valve closes, blocking the flow of fluid through it, but forcing the fluid through the flow divider/combiner to enhance tire traction.

The deceleration valve is utilized to cushion the braking action of the 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 of the machine.

The V2033/XL has a creep speed which is either automatically activated at platform 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 travel speed of 80-100 sec/88 feet, on firm, level ground; (Ref.. 75/.6 mph), (see note #2 on schematic at end ofhydraulic section).

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

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 oflift 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

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).

Steer Cylinder

FIG. 6

LIFT FUNCTION Lifting ofthe platform is accomplished by energizing the select directional control valve.

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

Coil Located on the cylinder body (See FIG. 7), is the holding valve, which consists of a manifold Cable 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 FIG. 7 manually lowering the platform via aT-handle located at the rear ofthe 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 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

-

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 "G 1" 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 "RVl" 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 "G 1fI 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, "CB 1" and "CB2", are factory set. Ifthey are not functioning properly, they must be replaced; DO NOT ATTEMPT ADJUSTMENT. Lift PressurelDescent 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 "FCl" to obtain a 25-35 second descent from a fully raised position.

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

To aid troubleshooting, some ofthe 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.

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

3.

"CBI" and "CB2" are identical-- DO NOT ADmST!

4.

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

5.

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

"G2" Gauge Port - i t - t - - - - (Reads Steer/Lift!

High Drive Pressure) "G1" Gauge Port (Reads Drive Only Pressure)

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

"RV5" Secondary Lift Relief Creep Speed Adjustment "RV1" Relief For Drive Only ("G1" Gauge Port)

·SEQ" (Sequence) Valve Controls High Drive Shifting

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

FIG. 8

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

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MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

ELECTRICAL SYSTEM DESCRIPTION

•

The following is a detailed description of the electrical system used on the CONDOR® model V20331XL 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 V20331XL 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 V20331XL. All of the options contained in this description are electrical only, and do not affect the hydraulic performance of the machine.

BATTERIES ThemodelV2033/XLscissoruses four, 6 volt DC batteries, each having a235 amp hour capacity.

There are two batteries on each side ofthe 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 47.

BATTERY CHARGER The battery charger has a 25 amp @ 24 volt DC nominal rating, and operates offofaIlS 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 left side of the belly pan, between the main valve assembly and the fixed axle (See FIG. 9). More detailed information ofthe charger can be found in the Battery Charger Troubleshooting Guide beginning on page 67.

Main Manifold

Ground Controls

Assembly

CIRCUIT BREAKERIFUSE 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 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

PUMP MOTOR The CONDOR® model V2033XL utilizes a pump motor which is a 24 volt DC unit, rated 6hp@3600rpm. SincethemodelV2033XL utilizes a gravity lowering system, the motor does not run while the lowering function is activated.

Pump/Motor Contactor

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 cable to the upper controls. At the lower controls are switches (see FIG. 11), to provide operation Control Selector Switch ----tf.-+--I~=-1 J of the lift function only; drive is not available from this control box. The lower control box _ I 15 Amp Circuit Breaker/Fuse --!lIH--@ contains an emergency stop button which must be ___________ ...1 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.

I I

I I

UPPER CONTROL FUNCTIONS The upper control box, located at the right hand forward comer ofthe 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 ofthe box, or ease ofrepair to the controls. Some ofthe 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 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

UPPER CONTROL FUNCTIONS (cont'd)

Positraction Button (black)

Lift Controls

r

Cut-Away View of Slip-Fit Insert

Drive Controller w/Steer Rocker Switch

Power Button (green)

Cable Harness Plug

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 ofthe rocker switch) functions. This lever, however, does not affect the lift controls. Movement ofthe drive handle 13 0 in either direction will tum 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 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

NOTES

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 &X31597070 &Ahove

•

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 of2 joules, a power output of3 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.

SOSLOPE ALARM (OPTION) This option sounds an alarm when the V20331XL is 5° or more outoflevel. A5°omni-directional sensor is mounted in the belly pan to sense a 5° out-of-Ievel condition. In this situation, a fast pulselloud 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 ofan analog 10-LED bar display, the indicator provides a visual reference for reading propedycharged 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).

SlopeAlann

Battery Condition Indicator

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

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

LOW VOLTAGE BATTERY PROTECTION SYSTEM (OPTION) This option prevents operation when the batteries are in a low voltage condition. It beLow Volt Override Pushbutton ignal Hom (w/Amber Indicator Lamp) comes energized whenever the control selector 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 motor contactor from being activated once the battery voltage reaches 12.S% undervoltage, or Slope E~9- 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 ofthe upper control box (See FIG. 14), which energizes terminalS ofthe module.

However, the override will only allow three repeated by-pass cycles of2 minutes 30 seconds each. The LVI module will reset when the battery voltage reaches approximately 2S.S 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.

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 orreverse 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" ofthe 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 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

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MANUAL 92383 May 1999 SIN X21S99064, X21S99073, X21S99077 & )(31597070 & Above

BATTERY SERVICE BATTERY SERVICING TOOLS Use proper tools when perfonning battery service to prevent damage to battery, cables, tenninals 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 predetennined 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 tenninals or the container. An excellent carrier forplastic cased batteries is a clamp ("ice tong") type carrier with rubber pads which grip the SIDE WALLS ofthe container just below the lip ofthe 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 ofthe 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 defonned or loose tenninal 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 tenninal 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 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

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 ofthe cable clamps. Connect the cables to the terminal posts (ground cable last). Coat the terminal connections with a spray corrosion inhibitor or high temperature grease.

The second item in routine servicing of conventional batteries is to check the electrolyte level in all cells. Ifnecessary, add clear, odorless, mineral free water to bring the liquid level to the level indicator in all cells. If the battery does not have a level indicator, bring the level to 112" (l3mro) 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 ofadjacent 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. Ifbelow the tops of the plates in any cells, fill all cells with water to just above the tops ofthe 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. Iftherange (highest-lowest) is 50 points (0.050sp. gr.) or greater or the lowest is less than 1.225 sp.gr., charge the batteryatthe 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

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

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

The average state ofcharge ofthe cells in a battery can be detennined 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. Ifthe cell connectors are accessible for voltage measurements, a range of 0.05 volts between the highest and lowest cells corresponds to a 50 point variation in specific gravity.

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

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 tenninals, make certain tenninals are free of corrosion.

D.

Connect current transducer (if necessary) to appropriate lead.

E.

Apply test load equivalent to 50% of Cranking Perfonnance rating of battery for 15 seconds. If Cranking Perfonnance 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 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

.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% ofthe Cranking Performance rating or 3 times to 20 ampere-hour capacity ofthe 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.

Ifthe 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 ofcharge 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 ofcharge 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 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

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 offall accessories in the equipment.

Check for leakage using one ofthe 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 ohmmeter to the disconnected cable end and to the chassis. A resistance measurement ofunder 100 ohm indicates a load of0.1 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 (l00 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 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

FIGURE: X BATTERY TESTING CHART ST EP1

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

I OBVIOUS DAMAGE I

I NO OBVIOUS DAMAGE I

IREPLACEBATTERVI

I CHECK ELECTROLYTE LEVELJ

I

BELOW TOP OF PLATES IN ONE OR I 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 15-25AMPS. PROCEED TO STEP 2

ST EP2

I HYDROMETER TEST

I

I

I

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

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

I

I I RECHARGE

1DISCHARGE AT 150 AMPS FOR 15 1 SECONDS

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

I

I

CONTINUE TO STEP 3

I

I IREPLACEBATTERVI

I LOAD TEST I

STEP 3

I 1. PLACE THERMOMETER IN CENTER CELL. COVER BATTERV WITH A DAMP CLOTH. 2. CONNECT VOLTMETER AND AMPERE LOAD EQUAL T01/2THECOLDCRANKINGAMPERES AT O°F (-18°C) RATING OF THE BATTERV FOR 15 SECONDS. 3. OBSERVE VOLTAGE AT 15 SECONDS WITH LOAD ON. 4. REFER TO VOLTAGE CHART BELOW.

I

I

I VOLTAGE BELOW CHART VALUE I IREPLACEBATTERVI

I

I VOLTAGE EQUAL TO OR ABOVE CHART VALUE - RETURN TO SERVICE

I

I

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 6Q°F (16°C) 50°F (10°C) 40°F WC) 30°F (_1°C) 20°F (-7"C) 10°F (-12°C) O°F (-18°C) MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

9.6 9.5 9.4 9.3 9.1 8.9 8.7 8.5

•

FIGURE:Y

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.

I I

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I OBVIOUS DAMAGE I

NO OBVIOUS DAMAGE I

I

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

IREPLACEBATTERY!

STEP 2

I FIXEDLOADTESTI

I 1. 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 O°F, -1 SOC).

3. IF TESTER OOES 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.

I

J

I

IBATTERY FAILS LOAD TEST I 1 ! PROCEED TO STEP 3 J STEP 3

I

BATTERY PASSES LOAD TEST I RETURN TO SERVICE. I

IOPEN CIRCUIT VOLTAGE TEST! I 1. ALLOW 10 MINUTES FOR BATTERY VOLTAGE TO STABILIZE AFTER LOAD TEXT. 2. READ OPEN CIRUIT VOLTAGE.

I 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

010 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. MANilA ,\/2383

May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

NOTES

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

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:

1.

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.

Wheel Bearings Lubricant:

Wheel bearing grease.

Time Interval:

Every 500 hours ofoperation 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: Ifdamage is evident, remove the CONDOR® from service until the spindle assembly is replaced, and contact the Condor Div. 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 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

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 ofoperation. 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.

Suction StrainerMOL, MOl, AND MOC:

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

DO NOT MIX 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 112" 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 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

PREVENTIVE MAINTENANCE INSPECTION

•

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

The time interval of 50 hours applies to normal operation under normal conditions. Should the unit be subjected to extensive use or abnormal environmental conditions, the inspections should be made more frequently. Condor Div. 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:

Hydraulic Fluid Leaks:

Decals and Placards:

B.

For protection, wear a faceshield. Inspect for swelling of battery sides, tightness and corrosion of terminals. If corrosion is present, remove cables from the battery (ground cable first). Clean terminals and posts with a wire brush and reconnect to battery (ground cable last). Coat the terminal connections with a spray corrosion inhibiter, or high temperature grease.

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.

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 112" 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 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

C.

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 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

PREVENTIVE MAINTENANCE DAILY INSPECTION MON

ITEM

TUES

WED

THURS

FRI

SAT

SUN

L2::V V V V V V V

I

HOURS

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 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

PREVENTIVE MAINTENANCE INSPECTION SO 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:

Electric Motor and Pump:

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.

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

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

B.

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

Visual Inspection: Lift Cylinder Hoses and Fittings:

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

Electrical Cable:

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

Lift 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:

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.

Limit Switch:

UpperlLower Electrical Junction:

Armstack Bearing Pads (chassis):

C.

Inspect cylinder pins and retaining bolts for security.

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. Ifbinding or chatter is present during movement, lubricate sliding surfaces with antisieze compound.

PLATFORM Visual Inspection:

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

Platform Pivot Shafts and Retaining Bolts:

Inspect security of retaining bolts and pin.

Platform Bearing Pads:

Platform Entrance Lift Gate and Latch Assemblies:

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

Inspect for damage. Ensure that gate slides (operates) freely

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 &X31597070 & Above

•

•

C.

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

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

Electrical Cable:

D.

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

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

E.

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 92383 May 1999 SIN X21599064, X21599073, X21599077 &X31597070 & Above

•

PREVENTIVE MAINTENANCE 50 HOUR INSPECTION MON

ITEM

I

rz / HOURS

CHASSIS

TUES

WED

THURS

FRI

SAT

/ / / / 1//

Visual Inspection Steering Cylinder Steering Connecting Ann 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 UpperlLower Electrical Junction AnnstackBearing Pads (chassis)

PLATFORM Visual Inspection MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

SUN

•

PREVENTIVE MAINTENANCE 50 HOUR INSPECTION (cont'd) MON

ITEM

TUES

WED

TIruRS

FRI

SAT

SUN

ZVVVVVVV

I

HOURS

PLATFORM (cont'd)

Platform Pivot ShaftslRetaining Bolts Platform Bearing Pads Platform Entrance Lift GatelLatches Extension Deck and Latch Assembly Electrical Cable Manual Storage Container MDL, MDI and MDC Models

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

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

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

HYDRAULIC FLUID SPECIFICATIONS FOR CONDOR® AERIAL WORK PLATFORMS

Shell Tellus - T32 Hydraulic Fluid

Viscosity SUS@ lOO°F SUS@2lOoF

155 47

Viscosity Index

154

Flash Point OF

325°

Pour Point OF

-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, M5S 2S4, 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 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

•

NOTES

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

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.

CAUflON REPAIRS BY QUALIFIED PERSONNEL ONLY.

I

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 of2 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.

WAlL~ING Do not operate the charger if it is malfunctioning. Personal injury or property damage could result.

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

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.

\VARNING 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 TIDS 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 ofthe DC cord attach. Ifthe 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. Ifthe chargeris 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 ofthe 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 92383 May 1999 SIN X21599064, X21599073, X21599077 &X31597070 & Above

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.

IfAC 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. Ifthe 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. If the 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. Ifthe 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 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

2. lfthe charger DC circuit test is good, a check ofthe 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:

DANGER mGH 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. lfthe 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 11132" 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 I lead to terminal #3.

MANUAL 92383 May 1999 SIN X21599064. X21599073. X21599077 & X31597070 & Above

Connect the black lead ofthe 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.

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

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 testthe fuse to determine ifone 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 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

PART A - SINGLE FUSE LINK BLOWS This condition is nonnally caused by a short circuit failure ofone 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 transfonner secondary coil lead from the diode tenninal. Using a low voltage continuity tester, connect one tester lead to the diode mounting plate and the other tester lead to a diode tenninal.

Note the reading and then reverse the tester leads and check each diode again. Ifa 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 nonnally 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. Ifa 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 ofboth 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 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

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 ofthe 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 oflow output is a single fuse link blowing as the result of a short circuit failure ofone 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 Bum 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 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

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 ifthe charger did shut ofItoo soon, disconnect and reconnect the charger DC output connector. This will restart the charger. Observe charger output on the ammeter.

1.

The ammeter needle jumps smartly to between 20 and 25 amps and then tapers below 14 amps 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.

2.

The ammeter needle jumps smartly to between 20 and 25 amps, but does not taper below 14 amps 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. Ifthe 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.

Ifthe batteries have not been used or charged regularly, they may be sulfated and will not produce their full capacity. Repeated cycles (at least 5) ofa 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 ofItoo 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 of8 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.

Ifthe charger remains on longer than the specified maximum time, check to see ifthe 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 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 &Ahove

•

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 tum offifthe green wire is loose or disconnected. Ifthe 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 tum off. If the charger does not tum 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 ofAC powerinterruption when thechargeris 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 Ifthis 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. Ifthe 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 oftransformer overheating and premature burnout is the result of misuse, connecting the charger to a battery system oflower 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 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

DANGER mGH 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. lithe 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.

lithe transformer secondary coil voltage and capacitor coil voltage check goo..d, 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 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

APPENDIX A

BOLT TORQUE CHART NOMINAL THREADS

BASIC [sTRESS

TENSILE STRENGTH (1) MIN

MAJOR AREA SQ. IN DIA INCH

PROOF WAD (P) SAE GRADE1J9~11 GRADES GRADE 8 T

4-40 4-41S o-~.l

6-40 8-32 IS-~O

10-24 IU-32 1/4-2U 1I'1-.l1S

:1110-1 IS 51 1b-24

3/1Hb 3/lS-Z4 HII-14

71lb-l.U 1(1.-13 112-20 Wlb-U

9/16-18

.1120 .1120 .1380

.00604 .00661

.1380 .1640 .1640

mOls

.1900 .1900 .2500 .2500 .3125 .3125 .3750 .37SO .4375 .4315 .5000 .5000 .5625

:IllS-II

.562S .6250

5/lHlS

.62S0

3/4-10 3/4-16

.7500 .7SOO

7/8-9 7/8-14

.87SO

.00909

.01400 .01474 .01750 .0200 .03 ISO .03640 .05240 .05800 .077SO .08780 .10630 .11670 .14190 .IS990 .18200 .20300 .22600 .25600 .33400

.8750 1.000 1.000

.37300 .46200 .S0900 .60600 .66300

13/8-12

t.l25O t.I25O 1.2500 1.2500 1.3750 1.3750

.76300 .S56OO .96900 1.0730 t.t5SO 1.31SO

11l2-b 1112-12

1.5000 1.5000

I.40SO 1.S800

l-lS 1-12 11/8-7 1 I/IS-I.l

1114-7 1114-12 I 3/lS-6

p

T

P

120KSI 8SKSI 120KSI 8SKSI 120KSI 8SKSI

1SOKSI 1SOKSI lSOKSI

120KSI

120KSI 8SKSI 120KS! 8SKSI

lSOKS! ISOKSI

120KSI 120KSI

12OKS! 120KSI 120KSI 120KSI 120KSI 120KSI

8SKSI 8SKSI 8SKSI 8SKSI 85KSI 8SKSI

ISOKSI ISOKSI ISOKSI ISOKSI ISOKSI lSOKSI

120KSI 120KSI 120KS! 120KSI 120KSI 120KSI

120KSI 8SKSI 120KSI 8SKSI 120KSI 8SKSI 120KSI 8SKSI

ISOKSI lSOKSI lSOKSI lSOKSI

120KSI 8SKS!

l50KSI

120KSI 120KSI 120KSI 120KSI 120KSI

120KSI 120KSI 120KSI 120KSI

l50KSI l5OKS! l5OKS!

8SKSI 8SKSI

85KSI 8SKS! 120KSI SSKS! 120KSI 85KSI 120KSI 85KSI

l50KSI ISOKSI lSOKSI l50KSI

120KSI 8SKSI 120KSI 8SKSI 120KSI 8SKSI 120KSI 8SKSI 120KSI 8SKSI 10SKSI 74KSI 105KSI 74KSI IOSKSI 74KSI IOSKSI 74KSI IOSKSI 74KSI

l50KSI I50KSI

120KSI 120KSI

CLAMP WAD LBS. 3SO 420 580 640 900 940 1120 1285 2020 2320 3340 3700 4940 5600

6800 7550

120KSI 120KSI 120KSI 120KS!

9050 10700 11600 12950

120KSI 120KSI

14400 16950 21300

120KSI 120KSI

23800 29500 32400

ASSEMBLY TORQUE R-.2ooDRY =.ISOUJB 8LB-IN 9LB-IN 16LB-IN 18LB-IN 3OLB-IN 3ILB-IN 43LB-IN 49LB-IN 8LB-Fr 10LB-Fr 17LB-Fr 19LB-Fr 30LB-Fr 35LB-Fr 5OLB-Fr SSLB-Fr

22LB-IN 23LB-IN 32LB-IN 36LB-IN 7SLB-IN 86LB-IN 13LB-Fr 14LB-Fr 23LB-Fr 2SLB-Fr 3SLB-Fr 4OLB-Fr

920

1260 1320 1580 1800 2860 32SO 4720

ASSEMBLY TOROUE R=.2ooDRY ~-.ISOUJB 12LB-IN 13LB-IN

9LB-IN 10LB-IN

23LB-IN 2SLB-IN 41LB-IN

11LB-IN 19LB-IN

43LB-IN 6OLB-IN 68LB-IN

31LB-IN 32LB-IN 4SLB-IN SILB-IN

12LB-Fr 14LB-Fr

9LB-Fr 10LB-Fr

25LB-Fr

18LB-Fr 20LB-Fr

5220 1000

2SLB-Fr 4SLB-Fr

1900

5OLB-Fr 70LB-Fr

3SLB-Fr 3SLB-Fr S5LB-Fr SOLB-FT 9OLB-Fr

9SS0 10700

6OLB-Fr

14400

SOLB-Fr 1l0LB-Fr 12OLB-Fr

SOLB-FT 9OLB-FT 1I0LB-FT

16400 182SO 203S0

l5OLB-Fr 170LB-Fr 220LB-FT

1I0LB-FT 130LB-FT 170LB-FT

130LB-FT 2ooLB-FT

23000 30100

240LB-FT 3SOLB-Fr

180LB-Fr 280LB-FT

3OOLB-FT 520LB-FT S10LB-Fr 770LB-FT 850LB-FT

220LB-FT 390LB-FT 43OLB-Fr 5SOLB-Fr 63OLB-FT

33600 41600 4S800 S4500 59700

420LB-FT 6OOLB-FT 66OLB-Fr 9OOLB-FT loooLB-FT

32OLB-FT 460LB-FT 5OOLB-FT 680LB-Fr 740LB-FT

8OOLB-FT 880LB-FT 1120LB-Fr 1248LB-FT 1468LB-FT

6OOLB-FT 66OLB-FT 840LB-FT 920LB-FT llooLB-FT

68700 77000 87200

126OLB-FT 1460LB-FT 1640LB-FT

120LB-FT ISOLB-FT lSOLB-FT 260LB-FT

l50KSI l50KSI l50KSI l50KSI l5OKS!

120KSI 120KSI 120KSI 120KSI 120KSI

42300 47500 53800

10SKS! 74KSI 10SKS! 74KS!

l50KSI IS0KS!

120KSI 120KSI

73000 78000

16SOLB-FT 1940LB-FT

IOSKSI 74KSI

lSOKSI

120KSI

87700

22ooLB-FT

S9600 64100

12LB-IN 13LB-IN

WAD LBS. S40 600 820

127SO

I50KSI l50KSI

38600 42300

6LB-IN 7LB-IN

CLAMP

55LB-FT 6SLB-FT

7SLB-Fr 9OLB-FT 110LB-Fr

120KSI 120KSI 120KSI 120KSI

I50KSI

SAEGRADE8

SAE GRADE 5

96600

104000 118400

126500 142200

1280LB-Fr 1440LB-Fr I 82OLB-Fr 2oooLB-Fr 23SOLB-Fr

960LB-FT 108OLB-FT I 36OLB-Fr iSOOLB-FT SOLB-FT

272OLB-FT 316OLB-FT

2040LB-Fr 236OLB-FT

3S60LB-Fr

2660LB-Fr

NOTES: 1. THIS CHART SHOWS RECOMMENDED BOLT TORQUES. 2. TORQUE = R X D X T R = .150 FOR LUB CONDITIONS R = .200 FOR DRY CONDITIONS TO ASSURE CONSISTENCY IN TORQUE, LUBRICATE FASTENERS WITH ENGINE OIL (MAY BE USED OIL) D = NOMINAL DIAMETER IN INCHES T = DESIRED CLAMP LOAD IN POUNDS = 75% PROOFLOAD X STRESS AREA MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

APPENDIXB

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.

THREADS

M4

27.5*

17·

18'"

38.5*

24'"

32.5'"

M5

56.5*

33.5·

37*

78'"

47*

65'"

M6

95*

57.5'"

61'"

132'"

79*

109*

M8

19

12

13

27

16

22

MI0

39

23

25

53

32

44

M12

67

40

44

92

55

76

M14

107

64

69

146

89

122

M16

167

100

108

230

138

190

M20

325

195

211

449

269

370

M24

562

337

386

775

465

640

726

1540

924

1271

.-

M30

1117

670

1210

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

ATTENTION MANUAL OF RESPONSIBILITIES for Dealers, Owners, Users, Operators, Lessors, Lessees and Brokers of ANSIISIA A92.6-2006 Self-Propelled Elevating Work Platforms

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

IMPORTANT You are required by ANSIISIA A92.6-2006 to read and understand YOUR RESPONSIBILITIES before you use or operate this Aerial Platform.

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

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

The USER and OPERATOR MUST MAKE DECISIONS of the Aerial Platform with due OPERATOR AND OTHER COMPLY with your REQUIRED Platform could result in DEATH OR Refer to the manufacturer's platform and The

nalntenaIllce, use and operation' that the SAFETY OF THE decisions. FAILURE TO and operation of the Aerial

nn<•...,~1n...

aerial

Self-Propelled Manual incorporates

Definitions Responsibilities of Dealers Responsibilities of Owners Responsibilities of Users Responsibilities Section 9 Section 10 Section 11 Figure 1

Page 2 Page 4 Page 6 Page 10 Page 13 Page 13 Page 13 Page 14

Single copy list price $4.95 Published by

Scaffold Industry Association, Inc. Post Office Box 20574 Phoenix, AZ 85036-0574 Telephone: (602) 257-1144 / Fax: (602) 257-1166 e-mail: sia@scaffold.org / web: www.scaffold.org Copyright © 2006 by Scaffold Industry Association, Inc. All rights reserved.

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

Printed in the. United States of America

RESPONSIBILITIES MANUAL

Reprint from ANSIISIA A92.6 2006

13. DEFINITIONS

Insulated platform. A platform designed and tested to meet the specific electrical insulation ratings consistent with the manufacturer's identification plate.

Interlock. A control or mechanism that, under specified conditions, automatically allows or prevents the operation of another control or mechanism.

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

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

Maintenance. The act of upkeep such as inspection, lubrication, adjustment and scheduled part(s)

Aerial platform. A mobile device that has an adjustable position platform, supported from ground level by a structure.

Anchorage(s). A secure point of attachment to be used with personal fall protection equipment (PFPE).

Authorized personnel (authorized person).

Personnel approved or assigned to perform a specific type of duty or duties at a specific location or locations at a work site.

Base. The relevant contact points of the aerial platform that form the stability fulcrum (e.g. wheels, casters, outriggers, stabilizers).

Broker. An independent business entity or person that arranges a lease or transfer of ownership of an aerial platform, but does not own the aerial platform. If the entity or person is an employee of the buyer, seller, lessor or lessee of the aerial platform, he shall not be considered a broker.

Chassis. The integral part of the aerial platform that provides mobility and support for the elevating assembly.

Configuration. All positions in which an aerial platfol~ part thereof can be placed within its intended operating Critical component(s). Load supporting elements which or stabilize the platform or aerial platform.

Dealer. A person or entity distributor and who !;;<;1.'<;""11. platforms. custody of the aerial Delivery. Transfer of care, platform from one person or entity to another person or entity.

Directional controls. Controls that initiate functions that movement of the platform or the aerial platform.

Ductile materials. Materials having a mlllllII\un 10% in 2 inches (50.8mm).

Elevating assembly. The platform relative to the aerial Familiarization. Providing the control functions and safety devices for aerial platform(s) to a qualified person or operator who controls the movement of the aerial platform(s) being delivered.

Guardrail system. A vertical barrier primarily intended to protect against personnel falling to lower levels.

Hazardous location. Any location that contains, or has the potential to contain, an explosive or flammable atmosphere as defined in ANSIINFPA 505 - 1996, Powered Industrial Trucks.

Instability. A condition of an aerial platform in which the sum of the moments that tend to overturn the unit exceeds the sum of the moments tending to resist overturning.

A document containing the 3) and the requirements mandated in this the following entities: Dealers (Section 5); Owners 6); Users (Section 7); (Section 8); Lessors (Section 11). makes, builds, or .aximum platform height or the manufacturer. modified. To make a change(s) to an aerial affects the operation, stability, safety factors, rated or safety of the aerial platform in any way.

Most adverse stability condition(s).

The permitted configuration of the aerial platform most likely to cause instability while maintaining stability. Factors to be considered shall include: (1) With zero load to maximum test load.

(2) Up to and including maximum platform height.

(3) All positions and configurations of the platform(s).

(4) All wheel and axle positions.

(5) Forward and backward configurations of the elevating assembly; (6) All other moveable features which affect the stability of the aerial platform.

Multiple rating(s), multiple rated loads. Two or more different rated work loads based on alternative configurations of the aerial platform.

Operation. Performance of functions of an aerial platform within the scope of its specifications and in accordance with the manufacturer's instructions, the user's work rules, and applicable governmental regulations.

1

RESPONSIBILITIES MANUAL

Reprint from ANSIISIA A92.6 2006

Operator. A qualified person who controls the movement of an

Stability/Stable. A condition of an aerial platform in which the

aerial platform.

sum of the moments that tend to overturn the unit is less than or

Outriggers.

equal to the sum of the moments tending to resist overturning.

Devices that increase the stability of the aerial

platform and that are capable of lifting and leveling the aerial

Stabilizers.

platform.

platform but are not capable of lifting or leveling the aerial

Override. To take over aerial platform movement control functions at the upper control station by those at the lower control

platform.

Training. Instruction to enable the trainee to become a qualified

station.

Owner.

person regarding the task to be performed, including knowledge regarding potential hazards.

A person or entity who has possession of an aerial

Devices that increase the stability of the aerial

platform by virtue of proof of purchase.

Unintended motion. Motion of the aerial platform or platform

Passive. Under specified conditions, automatically performed and not requiring any specific action to accomplish.

without activation of any control.

Unrestricted rated workload. The maximum designed carrying

The portion of an aerial platform intended to be

capacity of the aerial platform allowed by the manufacturer in all

Platform.

occupied by personnel with their necessary tools and materials.

Platform height. The vertical distance measured from the floor

User. A

operating configurations.

of the platform to the surface upon which the machine is being

the aerial

or entity who has care, control and custody of This person or entity may also be

supported.

Powered functions. Those which control motion of the platform

the

, a dealer, owner, lessor, lessee, or

or the aerial platform and are caused by hydraulic or pneumatic forces.

Qualified person. One who, by possession of a recognized certificate, or professional standing, or by training, and experience, has ability to solve or resolve work, or the project.

Rated horizontal force.

operating, maintenance, repair and parts

A92.6 2006 aerial platform

force at the top rail which can be specified by the manufacturer.

Rated work load. The designed carrying capacity of the

OF DEALERS.

platform as specified by the manufacturer.

Rebuild/recondition.

The

Basic principles. Sound principles of safety, training,

adjustment of an aerial replacement parts and

inspection, maintenance, application, and operation consistent with all data available regarding the parruneters of intended use

beyond the scope of mamtfmatlC standard) in order to restore, to

and expected environment shall be applied in the training of operators, in maintenance, application, safety provisions and

platform or component specifications.

to

manufactured

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

5.2 Manuals.

Remanufacture. The modification of an aerial platform, either by the original manufacturer or another qualified entity, so that

5.2.1 Machine manual(s). Dealers shall keep and maintain a copy(ies) of the :

the aerial platform will comply with the ANSI Standard in effect on the date the modification is completed.

Repair. The act of restoring to good condition that which has been broken, damaged or worn due to use, abuse or other

(1) (2) (3) (4)

reasons.

Shall. The word "shall" is to be understood as being mandatory.

Should.

The word "should" indicates that the rule is a

Operating manual Maintenance manual Parts manual Repair manual

The operating manual and maintenance manual shall be provided with each rental, lease or sale delivery and shall be stored in the

recommendation, the advisability of which depends on the facts

weather resistant storage compartment on the aerial platform.

Manual(s) are considered an integral part of the aerial platform and are vital to communicate necessary safety information to

in each situation.

2

RESPONSIBILITIES MANUAL

Reprint from ANSIISIA A92.6 2006

owners, users and operators. In addition, repair and parts manuals should be provided with each sale delivery.

(1) identify the weather resistant compartment (for manual storage).

5.2.2 Manual of Responsibilities. The current Manual of Responsibilities for Dealers, Owners, Users, Operators, Lessors, Lessees, and Brokers of Self-Propelled Elevating Work Platfonns shall be provided and stored in the weather resistant storage compartment.

(2) confinn the manuals, as specified by the manufacturer, are on the aerial platfonn.

(3) review control functions

5.3 Pre-delivery preparation. inspected,

serviced

and

(4) review safety devices specific to the model aerial platfonn being delivered.

Aerial platfonns shall be

adjusted

to

the

5.9 Dealer as user. Whenever a dealer directs personnel to operate an aerial platfonn (loading, unloading, inspecting, sales

manufacturer's

requirements prior to each delivery by sale, lease or rental.

demonstrations, or any fonn of use), the dealer shall assume the responsibilities of users as specified in Section 7 of this standard.

All personnel authorized to operate the aerial platfonn shall have

5.4 Maintenance, inspection and repair.

5.4.1 Maintenance. When a dealer accomplishes preventative maintenance on the aerial platfonn, it shall be in accordance with the manufacturer's (remanufacturer's) recommendations, the environment, and severity of use.

been: (1 ) Trained.

5.4.2 Inspection. When the dealer accomplishes frequent and

(3)

(2) Familiarized with the aerial platfonn to be operated.

annual inspections, they shall be accomplished in accordance with the manufacturer's (remanufacturer's) manuals.

of the responsibilities of operators as outlined in this Standard. owners and users. If a dealer is unable to

5.4.3 Repairs. Repairs accomplished to correct LH".lJ.LUl~ and problems shall be in accordance with the mamutat1

or user's question(s} relating to rated capacity, maintenance, repair, inspection, or operation of the

(remanufacturer's) manuals and instructions.

5.5 Maintenance safety precautions. repairs are started on an aerial nlolttn,rm

platfonn, the dealer shall

the proper infonnation if the manufacturer infonnation to the

shall be taken as applicable: (1) Power

plant inoperative;

stopped

rendered

(2) All controls in the "Off'

years:

secured from inadvertent motion by brakes, blocks, or oth means; (3) Elevating assembly and platfonn lowered to

address of the purchaser of each aerial platfonn Records of the predelivery preparation perfonned prior to each delivery.

cribbing to prevent

(3) Records of frequent and annual machine inspections accomplished.

(4) Records of repairs accomplished to correct malfunctions and problems.

(5) Name of the person(s} trained.

(4) Hydraulic oil pressure before loosening or rprt""''''" (2) Safety props or latches prescribed by the manufacturer.

5.6

Replacement parts.

(6) Name of the person(s) providing the training.

When parts or components are

replaced, they shall be identical or equivalent to original aerial

(7) Date of training.

(8) Name of person(s) receiving familiarization with the aerial

platfonn parts or components.

5.7

platfonn upon each delivery unless this individual has been

Training. The dealer shall offer appropriate training to

provided with familiarization on the same model, or one

facilitate owners, users, and operators to comply with requirements set forth in this standard regarding the inspection, maintenance, use, application, and operation of the aerial

having characteristics consistent with the one being delivered, within the prior 90 days.

(9) Name of person(s) providing familiarization with the aerial

platfonn.

5.8 Familiarization on delivery. Upon delivery by sale, lease, rental or any fonn of use, the dealer shall have the responsibility with the person designated by the receiving entity for accepting the aerial platfonn to:

platfonn upon each delivery.

5.11.2 Proof of training. The dealllr should provide trainees who successfully complete training a means to evidence they are trained. The dealer shall provide such proof if requested by the

3

Reprint from ANSIISIA A92.6 2006

RESPONSIBILITIES MANUAL

RESPONSmILITIES OF OWNERS.

trainee. The document evidencing training shall include the following information: (1) Name of trainee (2) Name of entity providing training or retraining.

(3) Name oftrainer(s).

(4) Clear identification that training covered Self-Propelled Elevating Work Platforms.

(5) Date of training.

5.11.3 Record dissemination. Upon request, the dealer shall provide the following information: (1) To the owner of the aerial platform, a copy of frequent or annual inspections performed.

(2) To the owner of the aerial platform, a copy of repairs accomplished.

(3) To a user, proof of training for an operator, including name of trainer and date of training.

(4) To a user, the name of the person(s) receiving familiarization upon delivery of the aerial platform.

5.12 Modifications. Modification, alteration or ""J"au,...a.,,~ of an aerial platform shall be made only with prior permission of the manufacturer.

Should manufacturer no longer exist, a qualified such modifications. All modltllcatl

the a copy(ies) of with each rental, lease,

manufacturer's requirements (Responsibilities of maillutitctur,ers 5.13 Manufacturer's

they are properly stored in the

The dealer shall comply with safety from the manufacturer (remanufacturer).

an integral part of the aerial platform communicate necessary safety information to users and operators, In addition, repair and parts "U.''''''':;H:;U

5.14 Responsibilities upon sale. When the aerial sold, the dealer:

manuals should be provided with each sale delivery.

6.3.2 Manual of Responsibilities. The current Manual of Responsibilities for Dealers, Owners, Users, Operators, Lessors,

(1) Shall, upon delivery, ensure the manuals are conveyed to the (2) Shall, upon delivery, provide Responsibilities for Dealers, Lessors, Lessees and Brokers

Lessees, and Brokers of Self-Propelled Elevating Work Platforms shall be provided and stored in the weather resistant storage compartment.

Work Platforms.

(3) Should, within 60 days of sale, provide repair and parts

6.4 Maintenance, inspection and repair.

6.4.1 Maintenance. The owner of an aerial platform shall arrange that the maintenance specified in this standard is properly performed on a timely basis. The owner shall establish a preventive maintenance program in accordance with the manufacturer's (remanufacturer's) recommendations and taking into account the environment of the work place and severity of use of the aerial platform.

6.4.2 Inspection. The owner shall arrange for frequent and annual inspections to be performed in accordance with the recommendations of the manufacturer (remanufacturer). All malfunctions and problems identified in the inspection shall be corrected before the aerial platform is returned to service.

manuals.

(4) Shall, within 60 days of the sale, notify the manufacturer (remanufacturer) or its successor (if existing) of the sale, providing the full name and address of the purchaser.

(5) Should, if the aerial platform is used, accomplish an annual machine inspection prior to delivery and provide a copy to the purchaser within 60 days of the sale.

(6) Shall, upon delivery, familiarize the person designated by the receiving entity with the aerial platform being acquired.

4

RESPONSIBILITIES MANUAL

Reprint from ANSIISIA A92.6 2006

6.4.3 Repairs. When the aerial platform is damaged or in need of repair, all malfunctions and problems identified shall be corrected before the aerial platform is returned to service.

Aerial platforms shall be 6.5 Predelivery preparation. inspected, serviced, and adjusted in accordance with the manufacturer's (remanufacturer's) requirements prior to each delivery by sale, lease or rental.

6.6 Frequent inspection. The owner of an aerial platform shall ensure that a frequent inspection is performed in accordance with the manufacture's (remanufacturer's) instructions, for the aerial platform: (1) That was purchased used.

This inspection shall be accomplished unless it is determined that the frequent and annual inspections are current; (2) That has been in service for three (3) months or 150 hours, whichever comes first;

manufacturer (remanufacturer) for an annual inspection. The owner shall not place the aerial platform into service until all malfunctions and problems have been corrected.

6.8 Maintenance safety precautions. Before adjustments and repairs are started on an aerial platform, the following precautions shall be taken as applicable: (1) Power plant stopped and starting means rendered inoperative; (2) All controls in the "off position and all operating systems secured from inadvertent motion by brakes, blocks, or other means; (3) Elevating assembly and platform lowered to the full down position, if possible, or otherwise secured by blocking or cribbing to prevent dropping; oil pressure relieved from all hydraulic circuits or removing hydraulic components; or latches installed where applicable as

(3) That has been out of service for a period longer than three months.

The inspection shall be made by a person qualified as a on the specific type of aerial platform or one having design characteristics. The inspection shall be in accordance items specified by the manufacturer for a frequent inspection and shall to the following: (1 ) All functions and their and limits of motion; (2) Lower controls including the for overriding of upper controls (3) All chain and cable mechanisms for adjustment and damaged parts; (4) All emergency and safety devices; (5) Lubrication of all element(s), hydraulic oil, by the manufacturer; and other critical (6) Visual inspection of structural components such as fasteners, pins, shafts and locking devices; (7) Placard, warnings and control markings; (8) Additional items specified by the manufacturer.

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

6.7 Annual inspection. The owner of an aerial platform shall ensure that an annual inspection is performed on the aerial platform no later than thirteen (13) months from the date of the prior annual inspection. The inspection shall be performed by a person(s) qualified as a mechanic on the specific make and model of the aerial platform or one having similar design characteristics.

The inspection shall be in accordance with items specified by the

When parts or components are shall be identical or equivalent to original aerial shall train their of the

.1i:1HUClJli:1IU;C

6.11 of this standard.

Whenever an owner directs or to operate an aerial platform (loading, inspecting or any form of use) the owner shall assume responsibilities of the user as specified in Section 7 of this standard and shall ensure the person has been: (1 ) Trained.

(2) Familiarized with the aerial platform to be operated.

(3) Made aware of the responsibilities of operators as outlined in Section 8 of this Standard.

6.11.2 Assistance to user. Upon request of the user, when an owner leases, rents or provides an aerial platform for any form of beneficial use, the owner at that time shall offer to do training or advise the user where training may reasonably be secured.

6.12 Familiarization upon delivery. Upon delivery for lease, rental or any form of beneficial use, the owner shall have the responsibility with the person designated by the receiving entity for accepting the aerial platform to: (1) Identify the weather resistant compartment (for manual storage).

(2) Confirm that the manuals, as specified by the manufacturer, are on the aerial platform.

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Reprint from ANSIISIA A92.6 2006

RESPONSIBILITIES MANUAL

6.15.3 Record dissemination. Upon request, an owner accomplishing training and/or familiarization shall provide the following: (1) to a user, proof of training for an operator, including name of trainer and date of training; (2) to a user, the name of the person(s) receiving familiarization upon delivery of the aerial platform.

6.16 Modifications. Modification, alteration or remanufacture of an aerial platform shall be made only with prior written permission of the manufacturer (remanufacturer). Should the manufacturer (remanufacturer) no longer exist, a qualified person may approve such modifications. All modifications shall meet the applicable manufacturer's requirements as specified in section 4 (Responsibilities of manufacturers) of this Standard.

6.17 Safety Bulletins. The owner shall bulletins as received from the or the dealer Upon sale of the aerial

(3) Review control functions with the operator or person(s) designated by the user.

(4) Review safety devices specific to the model aerial platform being delivered.

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

6.14 Assistance to users and operators. If an owner is unable to answer a user's or operator's question(s) relating to rated capacity, intended use, maintenance, repair, inspection, or operation of the aerial platform, the owner shall obtain the proper information from the dealer or manufacturer and provide that information to the user or operator.

6.15 Record retention and dissemination.

6.15.1 Record retention. The owner shall date and retain the following records for at least 4 years: (1) Name and address of the purchaser of each aerial by serial number and date of delivery.

(2) Written records of the frequent and annual inspections repairs performed. The record shall found, corrective action the person(s) performing (3) Written records of platform.

(4) (5) (6) (7)

and maintenance current Manual of Users, Lessors, Elevating Work and parts manuals to the new owner. the request of the new owner, offer to do training where training may reasonably be obtained.

accomplished and 'u..."'.. u".~."'" the repairs.

Pre-delivery preparation performed prior to each Name of the person(s) trained.

Name ofperson(s) Name of person(s)

RESPONSIBILITIES OF USERS.

7.1 Basic principles. The information in this standard must be supplemented by good job management, safety control, and the application of sound principles of safety, training, inspection, maintenance, application, and operation, consistent with all data available regarding the parameters of intended use and expected environment. Since the user has direct control over the application and operation of aerial platforms, conformance with good safety practices in this area is the responsibility of the user and the operating personnel, including the operator. Decisions on the use and operation of the aerial platform must always be made with due consideration for the fact that the aerial platform will be carrying personnel whose safety is dependent on those decisions.

7.2 Manuals.

7.2.1 Machine manuals. Users shall keep and maintain a copy(ies) of the operating and maintenance manual(s) in the

on the same model, or one with the one being delivered, (8) Name ofperson(s) providing familiarization upon delivery.

6.15.2 Proof of training. Owners providing training should provide successful trainees a means to evidence their training and shall provide such proof if requested by the trainee. The document evidencing training shall include the following information: (1) Name of trainee (2) Name of entity providing training or retraining.

(3) Name oftrainer(s).

(4) Clear identification that training covered Self Propelled Elevating Work Platforms.

(5) Date of training

6

RESPONSIBILITIES MANUAL weather

resistant

storage

compartment

Reprint from ANSI/SIA A92.6 2006 provided

by

the

(3) Elevating assembly and platform lowered to the full down position, if possible, or otherwise secured by blocking or

manufacturer. The manual(s) is considered an integral part of the aerial platform and is vital to communicate necessary safety

cribbing to prevent dropping;

information to users and operators.

(4) Hydraulic oil pressure relieved from all hydraulic circuits

7.2.2 Manual of Responsibilities.

before loosening or removing hydraulic components;

The current Manual of

Responsibilities for Dealers, Owners, Users, Operators, Lessors,

(5) Safety props or latches installed where applicable as

Lessees, and Brokers of Self-Propelled Elevating Work Platforms

prescribed by the manufacturer (remanufacturer);

shall be provided and stored in the weather resistant storage

(6) Precautions specified by the manufacturer (remanufacturer).

compartment.

7.4 Replacement parts.

7.3 Inspection and maintenance.

Users shall inspect and

When parts or components are

replaced, they shall be identical or equivalent to original aerial

maintain the aerial platform as required to ensure proper

platform parts or components.

operation. The frequency of inspection and maintenance shall be

7.5 Maintenance training. The user shall ensure only qualified

in accordance with the manufacturer's recommendations taking

personnel inspect and maintain the aerial platform in accordance

into account the environment of the work place and the severity

with the manufacturer's (remanufacturer's) recommendations and

of use of the aerial platform. Aerial platforms that are not in

and 7.4 of this standard.

and retraining. Whenever a user directs

proper operating condition shall be immediately removed from service until repaired.

Repairs shall be made by a qualified

individual to operate an aerial platform the user

person and the repairs shall be in conformance with the being assigned to operate the aerial platform.

manufacturer's recommendations.

7.3.1 Frequent inspection. Users of an aerial

with the aerial platform to be operated.

Made aware of rp.~l'1on~jhj as outlined in

PlaUOITI

ensure that frequent inspections Section 6.6 of this standard.

Section 8 of this

(4) Retrained, if

7.3.2 Annual inspection.

observation and

ensure that annual of the trainee's aerial platform

Section 6.7 of this standard.

7.3.3 Prestart inspection.

by the user for at least 4 years.

beginning of each shift, the aerial

before use.

shall be given a visua

personnel to operate an aerial platform. The user

inspection and functional test including but not limited to th

ensure that before use the operator is familiar with the

following: (1)

(2)

The user shall permit only

Operating and emergency controls.

model of the aerial platform to be operated, and specifically:

Safety devices.

(1 ) knows where the weather resistant compartment for manual storage is located.

(2) knows the operating and maintenance manuals supplied by

(3) (4)

Cables and wiring

(5)

Loose or missing parts.

the manufacturer (remanufacturer) are stored in the weather resistant compartment and is familiar with the operating and

(6)

Tires and wheels.

(7)

Placards, warnings, manual(s).

(3) understands all control functions, placards and warnings.

(8)

Outriggers, stabilizers, and other structures.

(4) is aware of and understands all safety devices specific to the

(9)

Guardrail system.

safety manuals.

control markings, and operating

model aerial platform being used.

7.8 Workplace inspection. Before the aerial platform is used

(10) Items specified by the manufacturer.

7.3.4 Maintenance safety precautions.

Before adjustments

and during use, the user shall check the area in which the aerial

and repairs are started on an aerial platform, the following

platform is to be used for possible hazards such as, but not limited

precautions shall be taken as applicable:

to:

(1) Powerplant stopped and starting means rendered inoperative;

(1) Drop-offs or holes, including those concealed by water, ice,

(2) All controls in the "Off' position and all operating systems

mud, etc.

secured from inadvertent motion by brakes, blocks, or other

(2) Slope(s).

(3) Bumps and floor obstructions.

means;

(4) Debris.

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RESPONSIBILITIES MANUAL

Reprint from ANSIISIA A92.6 2006

(5) Overhead obstructions and high voltage conductors.

(6) Hazardous

locations

and

atmospheres

from

(reference

the

aerial

and

energized

electrical

conductors and parts. practices intended to prevent electric shock covered by the

(7) Inadequate surface and support to withstand all load forces by

obstructions

(7) Electrocution hazard. All applicable safety related work

ANSIINFPA 505-1996). imposed

overhead

platform

in

all

Code of Federal Regulations (CFR) 1910.333 shall be

operating

configurations.

defined and explained to the operator by a qualified person.

(8) Wind and weather conditions.

In particular, such person shall direct the operator,

(7) Presence of unauthorized persons.

commensurate with the operator's qualifications, to maintain

(8) Other possible unsafe conditions.

the appropriate minimum approach distance (MAD) from

7.9 Determination of hazardous locations.

energized power lines and parts covered by CFR 1910.333

It shall be the

responsibility of the user to determine the hazard classification of

(c).

(8) Personal protective equipment (PPE).

the intended location of operation. Aerial platforms operated in

The user shall

hazardous locations shall be approved in accordance with, and of

direct the operator to ensure all personnel on the platform

the type required, by ANSIINFPA 505-1996.

wear personal protective equipment (PPE) as required.

7.10

Operator warnings and instructions.

The user shall

direct personnel operating the aerial platform to be in compliance

floor while working thereon. Climbing by

with the provisions set forth in section 8 of this standard. The

midrail or toprail of the aerial platform is

user shall monitor their performance and supervise their work to

of planks, ladders, or any other devices

ensure the use, application and operation of the aerial n1l1lttnrm

for achieving additional height or reach is

in conformance with the provisions set forth in this warn personnel of potential hazards, provide means to

When other

against identified hazards, and explain the potentIa local ordinances or

of not following proper operating

the workplace.

guidelines regarding proper necessarily be limited to the

Warnings

roped off areas, flashing

(1) Fall protection. The

be used as appropriate.

or malfunctions. The user shall direct

provides fall protection.

to immediately report to a supervisor any

required to wear personal fall protection equipment (PFPE),

or malfunction(s) that become evident during operation.

aerial platform manufacturer

The user shall ensure

all problems and

malfunctions are repaired prior to continued use.

anchorage( s).

(12) Reporting potentially hazardous locations. The user shall

(2) Slope and grade. The in any marmer on grades,

direct the operator to immediately report to a supervisor any

those for which the aerial

potentially hazardous location(s) that become evident during operation.

manufacturer (remanufacturer).

(3) Deployment of stability enhancing means.

(13) Hazardous location operation.

Outriggers,

Operation of aerial

stabilizers, extendible axles, oscillating axles or other

platforms not approved and marked for operation in a

stability enhancing means shall be deployed and locked into

hazardous location shall be prohibited.

(14)

place as required by the manufacturer (remanufacturer).

(4) Guardrail system.

Care shall be taken to prevent rope,

the aerial platform.

positioned, and access gates or openings shall be closed per (15)

the manufacturer's (remanufacturer's) instructions.

Capacity limitations.

Rated capacities shall not be

exceeded when loads are transferred to the platform at any

(5) Distribution of load. The load and its distribution on the

height.

platform and any platform extension(s) shall be in (16)

accordance with the manufacturer's (remanufacturer's) rated

Work area. The user shall direct the operator to ensure the area surrounding the aerial platform is clear of personnel

capacity for that specific configuration.

(6) Maintain overhead clearance.

Entanglement.

electric cords, and hoses, etc., from becoming entangled in

Guardrails shall be installed and

and equipment before lowering the platform.

The operator shall be

instructed to ensure that adequate clearance is maintained

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RESPONSIBILITIES MANUAL

Reprint from ANSIISIA A92.6 2006

(17)

Fueling. The engine (if applicable) shall be shut down while fuel tanks are being filled. Fueling shall be done in a well-ventilated area free of flame, sparks, or other hazards that may cause fire or explosion.

(18) Battery charging. Batteries shall only be charged in a well-ventilated area free of flame, sparks, or other hazards that may cause fire or explosion.

(19) Improper platform stabilization. The aerial platform shall not be positioned against another object to steady the platform or improve stability.

(20) Misuse as a crane. The aerial platform shall not be used as a crane.

(21) Unusual operating support conditions. The aerial platform shall not be operated from a position on trucks, trailers, railway cars, floating vessels, scaffolds, or similar equipment unless the application is approved in writing by the manufacturer (remanufacturer) or a qualified person.

(22) Travel speeds. The user shall direct the operator to limit travel speed according to conditions, including the "nTHiitlnn of the support surface, congestion, visibility, slope, of personnel, and other factors leading to hazards which cause collision(s) or result personnel.

(23) Driving requirements. aerial platform, the user shall (a) Maintain a clear view of of travel. (b) Ensure personnel in the worksite area that affected are aware of the movement, cOlnIrmnica and maneuvering the aerial platform

personnel shall be removed from the platform/basket before attempts are made to free the platform using lower controls.

(28) Vacating (or entering) an elevated aerial platform. If permitted by the manufacturer, personnel shall only vacate or enter a raised aerial platform by following the guidelines and instructions provided by the manufacturer (remanufacturer).

(29) Modifications. Modification or alteration of an aerial platform or the fabrication and attaching of frameworks, or the mounting of attachments for holding tools or materials onto the platform or the guardrail system shall only be accomplished with the prior written permission of the manufacturer (remanufacturer). Should the manufacturer (remanufacturer) no longer exist, a qualified person may modifications. All modifications shall meet manufacturer's requirements as specified in of manufacturers) of this operator. If an operator encounters any malfunction of the aerial platform, or any hazard capacity, intended the operator shall request further Any

problem(s)

or

use of the aerial platform. ,uifprilll!l (larger than the platform.) The user ensure that only tools and materials which are evenly distributed and can be safely handled by a person(s) working from the platform are transported.

(33) Rated horizontal force. The user shall direct the operator not to exceed the manufacturer's (remanufacturer's) rated horizontal force.

(34) Bridge cranes. When an aerial platform is to operate within the area of travel of a bridge crane or similar equipment, steps shall be taken to prevent a collision with the aerial platform.

(35) Adequate support requirements. The user shall insure the support surface is adequate for the aerial platform and the load carried.

(36) Leveling the aerial platform. Outriggers and leveling devices supplied by the manufacturer (remanufacturer) shall be utilized to level the aerial platform when provided.

(37) Protecting against unauthorized use. The user shall direct the operator not to use, rent, lease, or provide the aerial platform for any form of beneficial use unless so authorized.

(c) Maintain a safe distance offs, holes, depressions, ensure safe travel. (d) Maintain a safe distance obstacles and energized electrical conductors.

(24) Stunt driving. The user shall inform the operator that stunt driving and horseplay are prohibited.

(25) Securing the aerial platform. The user shall direct the operator to implement means provided to protect against use by an unauthorized person(s).

(26) Altering safety devices. Interlocks or other safety devices shall not be altered or disabled.

(27) Snagged platform. If the platform/basket or supporting assembly becomes caught, snagged, or otherwise prevented from normal motion by adjacent structures or other obstacles such that control reversal does not free the platform, all

9

RESPONSIBILITIES MANUAL 7.11

Reprint from ANSI/SIA A92.6 2006

User as Operator. If a user is also the operator of an

permission of the manufacturer (remanufacturer).

aerial platform, the user shall have the responsibilities of operators specified in Section 8 of this standard as well as responsibilities of users as specified in Section 7 of this standard.

7.12

Should the

manufacturer (remanufacturer) no longer exist, a qualified person may approve such modifications. All modifications shall meet the applicable manufacturer's requirements as specified in section

Shutdown of aerial platform. The user shall authorize

4 (Responsibilities of manufacturers) of this Standard.

and direct the operating personnel to cease operation of the aerial platform in case of any suspected malfunctions of the aerial

7.15

Manufacturer's safety bulletins. The user shall comply

platform, or any hazard or potentially unsafe condition that may

(remanufacturer), dealer or owner.

with safety-related bulletins as received from the manufacturer

be encountered, and to request further information as to safe operation from the owner, dealer, or manufacturer before further operation ofthe aerial platform.

18.

RESPONSIBILITIES OF OPERATORS.

7.13 Record retention and dissemination.

7.13.1 Record retention. The user shall retain the following records for at least 4 years: (1) Names of the operator(s) trained and retrained.

8.1 Basic principles. The information in this standard shall be

(2) Names of operator(s) provided familiarization.

situation. Since the operator is in direct control of

Su}:'pl~:m~:n!~:d

(3) The owner (or the entity designated by the owner) is responsible to ensure frequent and annual inspections are

by good judgment, safety control, and caution in

iWV'll,,.VUJ.Y

of the operator. The operator shall

on the use and operation of the aerial platform

conducted and written records are maintained. The shall include the date of the inspection, any found, the corrective action recommended and 1(1entllIc

consideration for the fact that his or her own safety as platform is dependent as the safety of other

of the person(s) performing the inspection.

(4) platform, the user shall shall include the date accomplished, and 1'(lenUIlcl

manuals are stored in the weather on the aerial platform. The InSlldelred an integral part of the aerial platform and communicate necessary safety information to the

the repair.

7.13.2

Record dissemination

annual inspections, not later than 60

The operator shall be familiar with the manuals and reference them as required.

inspections. the appropriate

8.2.2 Manual of Responsibilities.

owner of the aerial

familiar with the requirements for operators as set forth in Section 8 of the Manual of Responsibilities for dealers, owners, users, operators, lessors, lessees, and brokers of Self-Propelling

(1 ) When the user directs personnel to accomplish

(2)

The current Manual of Elevating Work Platforms.

Responsibilities for Dealers, Owners, Users, Operators, Lessors, Lessees, and Brokers of Self-Propelled Elevating Work Platforms

the owner.

7.13.3

Proof of training.

Users providing training should provide successful trainees a means to evidence their training and shall provide such proof if requested by the trainee.

The operator shall be

shall be provided and stored in the weather resistant storage compartment.

8.3 Prestart inspection. Before use each day or at the beginning of each shift, the aerial platform shall be given a visual inspection and functional test including but not limited to the following: (1) Operating and emergency controls.

(2) Safety devices.

(3) Personal protective devices.

(4) Air, hydraulic, and fuel systems leaks.

(5) Cables and wiring harness.

(6) Loose or missing parts.

(7) Tires and wheels.

(8) Placards, warnings, control markings, and operating manual(s).

The

document evidencing training shall include the following information: (1) Name of trainee.

(2) Name of entity providing training or retraining.

(3) Name oftrainer(s).

(4) Clear identification that training covered Self Propelled Elevating Work Platforms.

(5) Date of training.

7.14 Modifications. Modification, alteration or remanufacture of an aerial platform shall be made only with prior written

10

RESPONSIBILITIES MANUAL

Reprint from ANSIISIA A92.6 2006

(9) Outriggers, stabilizers and other structures.

(10) Guardrail system.

(11)Items specified by the manufacturer (remanufacturer).

8.4 Problems or malfunctions. Any problems or malfunctions that affect the safety of operations shall be repaired prior to the use of the aerial platform.

8.5 Training, retraining, and familiarization.

8.5.1 General training. Only personnel who have received general instructions regarding the inspection, application and operation of aerial platforms, including recognition and avoidance of hazards associated with their operation, shall operate an aerial platform. Such items covered shall include, but not necessarily be limited to, the following issues and requirements: (1) The purpose and use of manuals.

(2) That operating manuals are an integral part of the aerial platform and must be stored properly in the weather resistant compartment when not in use.

(3) A pre-start inspection.

(4) Responsibilities associated with problems or malfunctions affecting the operation of the aerial platform.

(5) Factors affecting stability.

(6) The purpose of placards and decals.

(7) Workplace inspection.

(8) Safety rules and regulations.

(9) Authorization to operate.

(10) Operator warnings and instructions.

(11) Actual operation of the aerial platform. of a qualified person, the . platform for a sufficient proficiency in the actual 8.5.2 Retraining. The OP(:ratlor directed by the user, based evaluation of the operator.

8.5.3 Familiarization. When an operator is directed to an aerial platform he/she is not familiar with, the receive instructions regarding the following items: (1) The location of the weather resistant manual storage).

(2) The purpose and function of (3) Safety devices and operatin~ aerial platform.

8.6 Before operation. Before operator shall: (1) Read and understand the manufacturer's (remanufacturer's) operating instruction(s) and user's safety rules or have them explained.

(2) Understand all labels, warnings and instructions displayed on the aerial platform or have them explained.

(3) Ensure all occupants of the aerial platform wear appropriate personal protection equipment (PPE) for the conditions, including the environment in which the aerial platform will be operated.

8.7 Workplace inspection. Before the aerial platform is used and during use, the operator shall check the area in which the aerial platform is to be used for possible hazards such as, but not limited to:

(1) Drop-offs or holes, including those concealed by water, ice, mud, etc.

(2) (3) (4) (5) (6)

Slope(s).

Bumps and floor obstructions.

Debris.

Overhead obstructions and electrical conductors.

Hazardous locations and atmospheres (reference ANSIINFPA 505-1995).

(7) Inadequate surface and support to withstand all load forces imposed by the aerial platform in all operating configurations.

(8) Wind and weather conditions.

(9) Presence of unauthorized persons.

(10) Other possible unsafe conditions.

8.8 Prior to each elevation. Before each elevation of the platform, the operator shall ensure: '''''V'UL",,,, extendible axles, or other stability

are used as required by the manufacturer. and access gates or openings are m~nmp-r'~ (remanufacturer's) instructions. its distribution on the platform and any extension(s) are in accordance with the (remanufacturer' rated capacity for that specific configuration.

All personnel on the Lll<>.all<'U

to understand the hazard location of operation according to warnings and instructions. The operator shall operation of the aerial platform is in compliance with

(2)

(3)

(4) (5)

(6)

11

Fall protection. The guardrail system of the aerial platform provides fall protection. If occupant(s) of the platform are required to wear personal fall protection equipment (PFPE), occupants shall comply with instructions provided by the aerial platform manufacturer (remanufacturer) regarding anchorage(s).

Slope and grade. The aerial platform shall not be operated in any manner on grades, side slopes or ramps exceeding those for which the aerial platform is rated by the manufacturer (remanufacturer).

Deployment of stability enhancing means. Outriggers, stabilizers, extendible axles, oscillating axles or other stability enhancing means shall be deployed and locked into place as required by the manufacturer (remanufacturer).

Guardrail system.

Guardrails shall be installed and positioned, and access gates or openings shall be closed per the manufacturer's (remanufacturer's) instructions.

Distribution of load. The load and its distribution on the platform and any platform extension(s) shall be in accordance with the manufacturer's rated capacity for that specific configuration.

Maintaining overhead clearance. The operator shall ensure that adequate clearance is maintained from overhead obstructions and energized electrical conductors and parts.

RESPONSIBILITIES MANUAL

Reprint from ANSIISIA A92.6 2006 (21) Unusual operating support conditions.

The aerial platfonn shall not be operated from a position on trucks, trailers, railway cars, floating vessels, scaffolds, or similar equipment unless the application is approved in writing by the manufacturer (remanufacturer) or a qualified person.

(22) Travel speeds. The operator shall limit travel speed according to conditions, including the condition of the support surface, congestion, visibility, slope, location of personnel, and other factors leading to hazards which may cause collision(s) or result in potential injury(ies) to personnel.

(7) Electrocution hazard. The operator shall perfonn only that work for which he or she is qualified, in compliance with all applicable safety related work practices intended to prevent electric shock covered by the Code of Federal Regulations (CFR) 1910.333. The operator's level of competence shall be established only by persons qualified to do so. Operators shall maintain the appropriate minimum approach distance (MAD) from energized power lines and parts covered by CFR 1910.333 (c).

(8) Personal protective equipment (PPE). The operator shall ensure all occupants of the platfonn wear personal protective equipment as required.

(9) Personnel footing. Personnel shall maintain finn footing on the platfonn floor while working thereon. Climbing by occupants on the midrail or toprail of the aerial platfonn is prohibited. The use of planks, ladders, or any other devices on the platfonn for achieving additional height or reach is

(23) Driving requirements. Before and during driving the aerial platfonn, the operator shall: (a) Maintain a clear view of the support surface and route of travel. (b) Ensure personnel in the worksite area that may be affected are aware of the movement, communicating and maneuvering the aerial platfonn as required to against personal injury. a safe distance from obstacles, debris, dropdepressions, ramps, and other hazards to travel.

prohibited~

(10) Precaution for other moving equipment. When other moving equipment and vehicles are present, special precautions shall be taken to comply with local ordinances safety standards established for the workplace. such as, but not limited to, flags, roped off areas, lights, and barricades shall be used as appropriate.

(11) Reporting problems or malfunctions. The operator immediately report to a supervisor malfunction(s) that become operator shall ensure affect the safety of use.

(12) Reporting potentially

hazardous location shall be (14) Entanglement. Care cords, and hoses, etc., platfonn.

(15) Capacity limitations. exceeded when loads are height.

(16) Work area. The operator shall ensure the area surrounding the aerial platfonn is clear of personnel and equipment before lowering the platfonn.

(17) Fueling. The engine (if applicable) shall be shut down while fuel tanks are being filled. Fueling shall be done in a wellventilated area free of flame, sparks, or other hazards that may cause fire or explosion.

(18) Battery charging. Batteries shall only be charged in a wellventilated area free of flame, sparks, or other hazards that may cause fire or explosion.

a safe distance from overhead obstacles and :nelrgt~ed electrical conductors. driving. Stunt driving and horseplay are prohibited.

Securing the aerial The operator shall implement means against use by an unauthorized (26) Altering or other safety devices shall not platformibasket or supporting (27) "nal~gt:u snagged, or otherwise prevented by adjacent structures or other obstacles control reversal does not free the platfonn, all shall be removed from the platformibasket before atte:mpts are made to free the platfonn using lower controls.

Vacating (or entering) an elevated aerial platform. If pennitted by the manufacturer, personnel shall only vacate or enter a raised aerial platfonn by following the guidelines and instructions provided by the manufacturer (remanufacturer).

(29) Modifications. Modification or alteration of an aerial platfonn or the fabrication and attaching of frameworks, or the mounting of attachments for holding tools or materials onto the platfonn or the guardrail system shall only be accomplished with the prior written pennission of the manufacturer (remanufacturer). Should the manufacturer (remanufacturer) no longer exist, a qualified person may approve such modifications. All modifications shall meet the applicable manufacturer's requirements as specified in section 4 (Responsibilities of manufacturers) of this Standard.

(30) Assistance to the operator. If an operator encounters any suspected malfunction of the aerial platfonn, or any hazard or potentially unsafe condition relating to capacity, intended

(19) Improper platform stabilization. The aerial platfonn shall

use or safe operation of the aerial platfonn, the operator shall

not be positioned against another object to steady the platfonn or improve stability.

(20) Misuse as a crane. The aerial platfonn shall not be used as

cease operation of the aerial platfonn and request further infonnation from the user.

shall immediately report to supervisor hazardous location(s) that become evident during uuo~.al"U1J (13) Hazardous location operation.

Operation platfonns not approved and marked for

a crane.

12

RESPONSIBILITIES MANUAL (31) Problem(s) or malfunction(s).

Any problems or malfunctions that affect the safety of operations shall be repaired prior to the use of the aerial platform.

(32) Carrying materials (larger than the platform.) The operator shall ensure only tools and materials which are evenly distributed and can be safely handled by a person(s) working from the platform, shall be transported.

(33) Rated horizontal force. The operator shall not permit personnel on the platform to exceed the manufacturer's (remanufacturer's) rated horizontal force.

(34) Bridge cranes. When an aerial platform is to operate within the area of travel of a bridge crane or similar equipment, steps shall be taken to prevent a collision with the aerial platform.

(35) Adequate support requirements. The operator shall ensure the support surface is adequate for the aerial platform and the load carried.

(36) Leveling the aerial platform. Outriggers and leveling devices supplied by the manufacturer shall be utilized to level the aerial platform when provided.

(37) Protecting against unauthorized use. The operator shall not use, rent, lease, or provide the aerial platform form of beneficial use to another entity authorization of the user.

8.11 Record of training. When provided or when obtained the operator's request, proof of training entity should be retained by the the following information: (1) Name of trainee.

(2) Name of entity providing (3) Name oftrainer(s).

(4) Clear identification that Elevating Work Platforms.

(5) Date of training.

Reprint from ANSIISIA A92.6 2006 9.4 Lessor as a user. When a lessor is the user of the aerial platform, the lessor shall have the responsibilities of users as specified in Section 7 of this standard.

9.5 Lessor as an operator. When a lessor is the operator of the aerial platform, the lessor shall have the responsibilities of operators as specified in Section 8 of this standard.

110. RESPONSIBILITIES OF LESSEES.

10.1 Basic principles. Sound principles of safety, training, inspection, maintenance, application, and operation consistent with all data available regarding the parameters of intended use and expected environment shall be applied in the performance of of lessees with due consideration of the the aerial platform will be carrying personnel. a Dealer. When a lessee is also the dealer for the amlfiu;tw:er) of the aerial platform, the lessee V~<'HnH"'~" of dealers as specified in Section 5 as an Owner. When a lessee is the owner of the platform, the lessee the responsibilities of owners as specified in 10.4 Lessee as a U platform, the lessee 'U"",nuu,",,, of users as specified in 10.5 Lessee a lessee is the operator of the have the responsibilities of 8 of this standard.

OF BROKERS.

11.1 Responsibilities upon sale. The broker shall: (1) Upon delivery, ensure the operating and maintenance manuals are provided to the new owner.

(2) Upon delivery, provide a copy of the current Manual of Responsibilities for Dealers, Operators, Users, Lessors, Lessees, and Brokers of Self-Propelled Elevating Work Platforms to the new owner.

(3) Maintain records of the. sale for a minimum of four (4) years.

11.2 Responsibilities with re-rents, leases, or any other form of beneficial use. When compensation is received as a result of a re-rent, lease or any form of beneficial use of an aerial platform, the broker shall: (1) Upon delivery, ensure the operating and maintenance manuals are provided to the user.

(2) Upon delivery, provide a copy of the current Manual of Responsibilities for Dealers, Operators, Users, Lessors, Lessees, and Brokers of Self-Propelled Elevating Work Platforms.

(3) Ensure operating personnel are familiarized with the aerial platform prior to use.

9. RESPONSIBILITIES OF

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

9.2 Lessor as a dealer. When a lessor is a dealer for the manufacturer of the aerial platform being leased, the lessor shall have the responsibilities of dealers as specified in Section 5 of this standard.

9.3 Lessor as an owner. When a lessor is the owner of the aerial platform being leased, the lessor shall have the responsibilities of owners as specified in Section 6 of this standard.

(4) Retain records of the transaction for a minimum of four (4) years.

13

Figure 1 - Typical Examples of Equipment Covered

I

SELF-PROPELLED ELEVATING WORK PLATFORM

MODEL V2033XL, V2033 Serial Number X21599064, X21599073, X21599077 & X31597070 & Above

ILLUSTRATED PARTS MANUAL

SHIPPING ADDRESS

MAIliNG ADDRESS

TIME CONDOR

TIME CONDOR

8300 IMPERIAL DRNE VVAco,TEXAS76712 (254)420-5200

P.O. Box 21447 VVAco,TEXAS76702-1447 (254) 420-5200

MANUAL

SIN

92383 May 1999 X21599064, X21599073, X21599077 &' X31597070 & Above

(

i 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®.

It is YOUR RESPONSmILITY 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 RESPONSmILITY to consider all of the personnel when making decisions regarding the intended use of this CONDOR®.

It is also YOUR RESPONSmILITY to understand and obey all federal, state, and local regulations regarding the operation and use of aerial work platforms. A copy of the ANSIISIA 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 ofthe 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 ofthis CONDOR®.

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

ii

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: (817) 420-5200 Telephone (817) 420-5299 Voice Mail (800) 443-5803 FAX

2.

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

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

3.

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

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

4.

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

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

MANUAL 92383 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

!

•

CONDOR® MODEL V2033XL & V2033 ILLUSTRATED PARTS MANUAL TABLE OF CDNIENfS INTRODUCfION ......................................................................................................................................... i SERVIc::E. INFORMATION ................................................................................................. ii SERIAL NUMBER TO MODEL DESIGNATION ........................................................... iii T.ABLE OF CONTE NTS ..••.•.•••••.•...••••••••••••••••••..••••.•..••..•.•.••••••••••••••...••••••••.••••••••.•••••..•..•... 1 FIGURE

DESCRIPTION

PAGE

A ........................................................... Serial Nuntber Location ............................................................. 2 B ........................................................... Reconunended Spare Parts List ................................................ 3 C ........................................................... liow to Order Parts ................................................................. 4,5 1.1 ........................................................... Final Installation V2033XL ......................................................... 6 1.2 ........................................................... Final Installation V2033 ............................................................... 8 2.1 ........................................................... Decal Installation ........................................................................ 10 3.1 ........................................................... Cltassis Assenilily V2033/XL .................................................. 12 3.2 ........................................................... liose Kit ....................................................................................... 14 3.3 ........................................................... Steer Cylinder .............................................................................. 16 3.4 ........................................................... Brake Cylinder ............................................................................ 17 3.5 ........................................................... flub Motor Assenilily ............................................................... 18 3.6 ........................................................... Drive Hub Assenilily................................................................. 19 3.7 ........................................................... Rear flub Assenilily ................................................................... 20 3.8 ........................................................... Tube Kit ....................................................................................... 21 3.9 ........................................................... Belly Pan Assenilily .................................................................... 22 3.10 ........................................................... Motor & Pump Assenilily........................................................ 26 3.11 ........................................................... Pump Assenilily ......................................................................... 27 3.12 ........................................................... Motor 24VDC Assenilily ......................................................... 28 3.13 ........................................................... Valve Installation ......................................................................... 30 3.14 ........................................................... Valve Assenilily .......................................................................... 32 3.15 ........................................................... Garger 115V/25A .................................................................... 34 3.16 ........................................................... Garger 115V/25A Mod......................................................... 35 3.17 ........................................................... C1J.arger 115V/60IiZ-25A124VDC ...................................... 36 3.18 ........................................................... ElectricalWuinglnstallation ..................................................... 38 4.1 ........................................................... Lower <:::Ontrol Box Assenilily ................................................ 40 5.1 ........................................................... Annstack Assenilily ................................................................... 48 5.2 ........................................................... Annstack Cylinder ..................................................................... 54 5.3 ........................................................... Manifold Assenilily .................................................................... 55 6.1 ........................................................... Platfonn Assenilily .................................................................... 56 6.2 ........................................................... 110 Volt Extension To Platfonn ............................................ 59 6.3 ........................................................... Upper <:::Ontrol Box Assenilily ................................................ 60 7.1 ........................................................... Travel Alann (Option) .............................................................. 64 7.2 ........................................................... Motion Alann (Option) ............................................................ 65 7.3 ........................................................... Strobe Light (Option) ............................................................... 66 7.4 ........................................................... Descend Alann (Option) .......................................................... 67 7.5 ........................................................... Slope Alann (Option) ............................................................... 68 7.6 ........................................................... Hour Meter (XL-Option) ......................................................... 69 7.7 ........................................................... Battery <:::Ondition Indicator (XL-Option) ............................. 70 7.8 ........................................................... Low-Voltage Warning Inteffilpt (XL-Option) ..................... 71

I

r

8.1 ........................................................... liolder Assenilily........................................................................ 72

J

9.1 ........................................................... E11.1ergency Lowering <:able Assenilily .................................. 73 MANUAL 92383-003

May 1999 SIN X21599064, X2IS99073, X21599077 & X3IS97070 & Above

•

FIGURE A-Serial Number Location

1 2

The CDNDOR® Model V2033XL & V2033 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 92383·003

May 1999 SIN )(21599064. )(21599073. )(21599077 & )(31597070 & Above

FIGURE B- Recommended Spare Parts List • CONDOR@ MODEL V2033XL &V2033 (1 UNIT-l YEAR OPERATION)

PARTNUMBER

DESCRIPTION

V2033XL

V2033

QTY

QTY

91029 ........................................ Nut Lug 1/2" ............................................................ 5 .................................... 5 55363-001 ................................ Stud Wheel 1/2"-20 x 13/4" ................................ 5 .................................... 5 54783_Q~.~.......................... c:able AsseJDbly, ElIlergency Lowering ................ 1 ..............~ .................... 1 54798 ........................................ G:>uple Nut, 10-32UNF ......................................... 1 .................................... 1 55471 ........................................ Plunger, lJand Retract Spring ................................. 3 .................................... 3 55241 ........................................ Spring Loaded Pull-Up Latch ................................ 3 .................................... 3 54048 ........................................ Latch Door .................................................•.............. 1 .................................... 1 67408 ........................................ ElelIleUt, Hydraulic Filter PIN 33430 ................... 5 .................................... 5 36085 ...............................:........ Fitting, S'Wivel 90° Elbow 6-6 ................................ 2 .................................... 2 51036 ........................................ S'Witch I..irni.t Body Only .......................................... 1 .................................... 1 51037 ........................................ Offset lJead I..irni.t S'Witch ....................................... 1 .................................... 1 51039-002 ................................ I..irni.t S'Witch, AnnIShort ........................................ 1 .................................... 1 54589 ........................................ G:>ntroller, Drive/Steer ........................................... 1 ............................. NI A 67939-015 ................................ Fuse, 15.Alnp .............................................................. 1 .................................... 1 67940 ........................................ Fuse I-Jolder ............................................................... 5 .................................... 5 52138 ........................................ Solenoid 24V ............................................................. 1 .................................... 1 206-00001-00 .......................... Diode .......................................................................... 9 .................................... 9 54438 ........................................ Relay, 24V SPDT Bosch .......................................... 1 .................................... 1 34547 ........................................ Jumper ........................................................................ 4 ............................. NI A 34542 ........................................ JUlIlper ................................................................. NI A .................................... 1 55982-002 ................................ Decallnstallation ....................................................... 1 ............................. NI A 55982-102 ................................ Decal, V2033XL Essentials ..................................... 1 ............................. NI A 55982-001 ................................ Decallnstallation ................................................ NI A .................................... 1 55982-101 ................................ Decal, V2033 Essentials .................................... NI A .................................... 1 55469 ........................................ li.ose Kit ..................................................................... 1 .................................... 1 55243 ........................................ Spring - Deck Latch ................................................. 1 .................................... 1 55333 ........................................ Olarger ....................................................................... 1 .................................... 1 54910-102 ................................ Receptacle ................................................................... 1 .................................... 1 54910-104 ................................ Mounting .................................................................... 1 ............................. NI A 51913 ........................................ Operator, Red P-Pull ............................................... 1 .................................... 1 51914 ........................................ Base, 1 NC G:>ntact. ................................................. 1 .................................... 1 52670 ........................................ Operator, 3 Pos Rot ................................................. 1 ............................. NI A 34464 ........................................ Base, NO/NC G:>ntacts .......................................... 1 ............................. NI A 52669 ........................................ Operator, Black P-Button ....................................... 1 ............................. NI A 52672 ........................................ Base, 1 NO G:>ntact, ................................................ 1 ............................. NI A 69146 ........................................ Operator, Green P-Button ...................................... 1 ............................. NI A 54913 ........................................ Operator Black/Black Double P-Button ............. 1 ............................. NI A 52029 ........................................ Base, 2 NO G:>ntacts ............................................... 1 .................................... 1 50075 ........................................ S'Witch .......................................................................... 1 .................................... 1 67758 ........................................ Toggle S'Witch ..................................................... NI A .................................... 1 52671 ........................................ Operator, 3 Pos Key ......................................... NI A .................................... 1

MANUAL 92383·003 May 1999 SIN X21599064, X21599073, X21599077 & JOI597070 & Above

•

FIGURE C-How to Order Parts 1.

When ordering parts for your CONDOR®, ensure that you are able to give the model and serial numbers of all units for which parts are needed. The serial number(s) will assist the TIME CONDORParts 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 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 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.

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 92383-003 May 1999 SIN )(21599064, )(21599073, )(21599077 & X31597070 & Above

•

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

I

ACCOUNT # C U S T

0 M E R

I N F

0

SALES ORDER #

PURCHASER NAME

NAME ADDRESS

R M A T I

CITY

0 N

)

(

CUST. PURCHASE ORDER NO.

ZIP

STATE

PHONE

S H I P

FAX

( I

)

ORDERDATE

I

I

T

0

~DDRESS

~ITY

STATE

PHONE

FAX

(

(

)

REQUEST DATE

I

ZIP

)

SPECIAL MARKS & NUMBERS

SHIPPING INSTRUCTIONS

PART NUMBER

QTY.

DESCRIPTION

FOR ORDER STATUS PLEASE CHECK APPROPRIATE BOX BELOW EMERGENCY

STOCK MANUAL 92383-003 May 1999 SIN X21599064. X21599073. X21599077 & X31597070 & Above

NOTES

•

FIGURE 1.1: Final Installation 'I

21

.12

22 1

15

18 19 20

2 14

MANUAL 92383-003 May 1999 SIN X21599064. X2 1599073. X21599077 & X3 1597070 & Above

FIGURE 1.1: Finallnstallation • r,

ITEM

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

~9

20 21 22 -23 -24 -25 -26 -27 -28 -29 -30 -31 -32 -33 -34 -35 -36 -37 -38 -39 -40

PART NUMBER

DESCRIPTION

QTY

M-V2033XI..-02 ............. Final Installation V2033/XI.. ............................................................... Ref. 55955 ............................... Cltassis Assembly {See page 12} ............................................................. 1 55958 ............................... Belly Pan Assembly {See page22} .......................................................... 1 BOW30055 ..................... Bolt, .38-16lJNC x 125 liex ................................................................... 2 BOW3OO57 ..................... Bolt, .37-16lJNC x 1.75 liex ................................................................... 2 BOW36703 ..................... Washer, .37 ID .81 00 Gr 8 SAE Flat................................................. 4 BOW34274 ..................... Nut, 3/8-16lJNC liex Lock ..................................................................4 55962XI.. ......................... Annstack Installation V2033XI..-02 {See page 48} ............................. 1 54616-009 ....................... Pin, V20126 20.38" Ann ..........................................................................2 54701 ............................... Block, Annstack Nylatron .................................................................•...... 2 54616-008 ....................... Pin, V20126 26.62" Ann ..........................................................................2 55279 ............................... Block, lIDPE Slide .................................................................................... 2 55971 ............................... Platfonn Assembly {See page 56} .......................................................... 1 55883 ............................... 110 Volt Installation {See page 59} ........................................................ 1 55870 ............................... Wrring Installation {See page 38} ............................................................ 1 54783-002 ....................... Cable Assembly, Emergency Lowering {See page 73} ...................... 1 67470-002 ....................... Hydraulic Oil Texaco lIDZ 32 ......................................................... 8GL .......................................... Nameplate, Scissor Ident................;......................................................... 1 55758 ............................... G>ver Weldtnent, Rfi Side ....................................................................... 1 55759 ............................... G>ver Weldtnent, ill Side ....................................................................... 1 54048 ............................... Latch, Door ................................................................................................ 2 55851 ............................... Box Assembly, Upper {See page 60} .................................................... 1 55869-002 ....................... Box Assembly, Lower Elec. {See page 40} .......................................... 1 BOW39002 ..................... Bolt, 1/4-20 x 314 Gr 8 liex lid ...........................................................4 BOW31401 ..................... Washer, 25 ID x .6300 Flat ................................................................. 4 BOW34272 ..................... Nut, .25-20lJNC Nylon Lock ................................................................. 4 55469 ............................... Iiose Kit {See page 14} ............................................................................ 1 55982XI.. ......................... Decal Installation {See page 10} ............................................................. 1 67837-007 ....................... Tie, 7 1/2" Black Nylon ........................................................................ 10 34354 ............................... Iiolder Assembly, Safety Manual {See page72} ................................... 1 67793 ............................... Oatnp, 2.75 Dia Cable .............................................................................. 2 BOW31401 ..................... Washer, .25 10 x .63 00 Flat ................................................................. 2 BOW34272 ..................... Nut, 25-20 lJNC Nylon Lock ............................................................... 2 92383-001 ....................... Operator's Manual ..................................................................................... 1 A630-V2033XI..-2 .......... Manual, Operator/MaintiParts ............................................................... 1 55844 ............................... Schematic, Electrical ................................................................................... 1 55309 ............................... Schematic, Hydraulic .................................................................................. 1 55954 ............................... Dwg, Final Assembly ................................................................................ 1 55469-Dwg .................... Dwg, Iiose Kit ........................................................................................... 1 QZN01004 ..................... Gloss Green Touch Up ............................................................................ 1 04-0081-57 ...................... Gray Primer ..................................................................................................

- Indicates Items Not Shown

MANUAL 92383"()()3

May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

FIGURE 12: Final Installation V2033

20

12

1

14

17 18 19

2 13

MANUAL 92383-003 May 1999 SIN X21S99064, X21599073, X2IS990n & )(31597070 & Above

FIGURE 1.2: Final Installation V2033 • ITEM

PART NUMBER

DESCRIPTION

Ref.

QTY

M-V2033-02 ................... Final Installation V2033 ........................................................................ Ref. 1 55955 ............................... Chassis Assembly V2033 {See page 12} ................................................ 1 2 55958 ............................... Belly Pan Assembly {See page 22} ......................................................... 1 -3 B0W30055 ..................... Bolt, .38-16lJNCx 1.25lfex ................................................................. 2 B0W30057 ..................... Bolt, .38-16 lJNC x 1.75 lfex ................................................................. 2 -4 -5 B0W36703 ..................... Washer, .37 ID .81 OD Gr 8 SAE Plat ................................................. 4 -6 B0W34274 ..................... Nut, 3/8-16 lJNC lfex Lock .................................................................. 4 7 55962 ............................... AnnstackInstallation {See page 48} ...................................................... 1 -8 54616-009 ....................... Pin, Ann 20.38" .......................................................................................... 2 54701 ............................... Block, Annstack Nylatron ........................................................................ 2 -9 -10 54616-008 ....................... Pin, Ann 26.62" .......................................................................................... 2 -11 55279 ............................... Block, Slide .................................................................................................. 2 12 55981 ............................... Platfonn Assembly {See page 56} ........................................................,. 1 13 55846 ............................... Wuing Installation {See page 38} ............................................................ 1 14 54783-002 ....................... Cable Assembly, Emergency Lowering {See page 73} ...................... 1 -15 .......................................... Hydraulic Oil Texaco fIDZ 32 ......................................................... 8GL -16 .......................................... Nameplate, Scissor Ident.......................................................................... 1 55758 ............................... <:OverWeldment, Rli Side ....................................................................... 1 17 18 55759 ............................... <:Over Weldment, LH Side ....................................................................... 1 19 54048 ............................... Latch, Door ................................................................................................ 2 20 55850 ............................... Box Assembly, Upper Elec. {See page 60} .......................................... 1 21 55869-001 ....................... Box Assembly, Lower Elec. { See page 40} ........................................ 1 BOW39002 ..................... Bolt, 1/4-20 x 3/4 Gr 8 lfex lid ........................................................... 4 -22 B0W31401 ..................... Washer, .25 ID x .63 OD Flat ................................................................. 4 -23 -24 BOW34272 ..................... Nut, 25-20 lJNC Nylon Lock ................................................................ 4 -25 55469 ............................... Iiose Kit {See page 14 .............................................................................. 1 -26 55982 ............................... Decal Installation {See page 10} ............................................................. 1 -27 67837-007 ....................... Tie, 71/2 " Black Nylon ........................................................................ 10 -28 34354 ............................... Holder Assembly, SafetyManual {See page 72} ................................. 1 -29 67793 ............................... Clamp, 2.75 Dia Cable .............................................................................. 2 -30 BOW31401 ..................... Washer, .25ID x .630D Plat. ................................................................... 2 -31 BOW34272 ..................... Nut, 25-20 lJNC Nylon Lock ................................................................ 2 -32 92350-001 ....................... Operator's Manual ..................................................................................... 1 -33 A630-V2033-1 ............... Manual, Op/MaintiParts ......................................................................... 1 -34 55843 ............................... Schematic,Electric ..................................................................................... 1 -35 55309 ............................... SchelIlatic, Hydraulic .................................................................................. 1 -36 55953 ............................... Dwg, M-V2033-01 Final Assembly........................................................ 1 -37 55469-DWG .................. Drawing, Hose Kit .................................................................................... 1 QZN01004 ..................... Gloss Green Touch Up ............................................................................ 1 39 -40 04-0081-57 ...................... Gray PrUner ..................................................................................................

- Indicates Items Not Shown

MANUAL 92383-003

May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

FIGURE 2.1: Decal Installation

PARTIAL SECTION A APPUES TO ALL MOOELS

12

REF

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o o o ARMSTAND

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00000 0 0 0 0 0 0 0 0 00000000 0 0 0 0 0 0 0 0 00000000

0

0

0

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0

0

0

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0 0

0

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0

0 0

0

0 0

0

0 0

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0

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0

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MANUAL 92383-003 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

18

FIGURE 2.1: Decal Installation • ITEM

PART NUMBER

QTY

DESCRIPTION

*21

55982XL .......................... Decal Installation ................................................................................... Ref. 55890 ................................ Decal V lJpper Operator Instructions V2033 ..................................... 1 .,. 55889 ................................ Decal V XL lJpper Operator Intructions V2033 XL ......................... 1 55894 ................................ Decal, V General caution ........................................................................ 1 54652-003 ........................ Decal, Guardrail!Cltain caution ............................................................. 1 55963-800 ........................ Decal, 800 Rated Load ............................................................................. 2 )(55963-750 ........................ Decal, 750 Rated Load ............................................................................. 1 55944 ..........•..................... Decal, 250R'WI.. On Ext. XL .................................................................. 1 55480-002 ........................ Decal, Lower Op Instruction .................................................................. 1 55480-00 1 ... ~ .................... Decal, Lower O:lntrols ............................................................................. 1 C56303 ................................ Decal, lIse Annstamd caution ............................................................... 1 54984-005 ........................ Decal, Rear BUII:lJ>er .................................................................................. 1 66973 ................................ Decal, Elect. Iiazard Keep Oear ............................................................ 2 55871-001 ........................ Decal, V lJpper Electrical Box Top ...................................................... 1 l 55856-00 1 :....................... Decal, V XL lJpper O:lntrol Box .......................................................... 1 55871-002 ........................ Decal, V Upper Electrical Box Front .................................................... 1 X 55856-002 ...................... ~~ V~ctrecal Box Front ............................................ 1 54984-007 ........................'~ HJt4a~ ............................................................................ 1 55940-023 ........................ Decal, (x)NDOR 3.45 x 23 .................................................................. 2 55984 ................................ Decal, V2033XL ........................................................................................ 2 55941-017 ........................ Decal, O:lndor "Bird" ............................................................................... 2 53259 ................................ Tape, Non-Skid 6" Black .............................................................. 1.50LF 66921 ................................ O:lating, Non-Skid Jet Black .................................................................... .

55982-DWG ................... Dwg. V 2033/XL Decal Installation ..................................................... 1 54984-006 ........................ Decal,·110V Extention To Platfonn V2033XL ................................. 1 c,.56302 ................................ Decal, Gushing Danger V2033XL ........................................................ 1

31

........................................... Naxneplate Scissors Indentification .................................................... Ref.

* *

55982-102 ........................ Decal Kit, V2033XL Essential ............................................................ Ref. 55982-101 ........................ Decal Kit, V2033 Essential ................................................................ Ref.

Ref *1

*2 *3 *4 *5 *6 *7

*8 *9 *10 *11

*12

*13 14 15 16 17 18 19 20

- Indicates Items Not Shown *Indicates Included In Essential Decals

?fRff r ,

~

r

2 1/4 MARGIN NO NON-SLIP COATING

PlANVIEW OF MODEL V2033

MANUAL 92383-003 May 1999 SIN X21S99064, X2IS99073, X21599077 & X31S97070 & Above

PARTIAL REAR VIEW OF MODELS V2033

•

FIGURE 3.1: dIassis Assembly V2033XL 32Pl

NOTES: 1. BRAKE RELEASE HANDLES (ITEM 31) MUST SWING FREEL Y. DO NOT TIGHTEN ITEMS 35, 36, & 37 ANY MORE THAN SNUG FIT (2 PL).

II

~

:

2. FOR ITEMS IDENTIFIED FINAL ASSY.

Q V

SEE HOSE KIT IN

3. SPINDLE ASSY INCLUDES SPINDLE, CASTLE NUT, WASHER & COTTER PIN. SPINDLE ASSY IS PART OF CHASSIS WELDMENT. 4. EACH HUB ASSY INCLUDES FIVE LUG NUTS.

2 Pl-REF SEE NOTE 3

2 Pl 2 Pl

27 _-..----"'\I~

SEE NOTE 1

",

TOP VIEW OF AXLE

gI3'~ -~fJ

I

BEllY PAN FR;T

~All

0

0

I

0

~

L

2

2 PL

TOP VIEW OF CHASSIS WELDMENT

TOP VIEW OF STEERING COMPONENTS 1.

LOenTE ITEM B INTO ITEMS 4 & 5.

May 1999 SIN X21S99064, X21S99073, X21S99077 &. X31597070 &. Above

(OJ

/

~.

FIGURE 3.1: C1J.assis Assembly V2033XL.

QTY

DESCRIPTION

ITEM

PART NUMBER

Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 -20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

55955 ................................ Assetnbly, Olassis V2033/XL ............................................................ Ref. 55956 ................................ Cl1assis Weldtnent ...................................................................................... 1 34145 ................................ BushingR# 81368 ...................................................................................... 2 02219 ................................ Elbow, 90° ~04 FJ04 ............................................................................ 2 55496-003 ........................ Knuckle Weldtnent, ill Str ..................................................................... 1 55496-004 ........................ Knuckle Weldtnent, Rlf Str ..................................................................... 1 54776 ................................ ThrustWasher,Ktngpin ............................................................................ 2 55402 ................................ Retainer,Kingpin ....................................................................................... 2 BOW39104 ...................... Bolt, Iiex lid .50-13UNC x 1.00 Gr 8 ................................................. 2 54775 ................................ COnnecting Ann, Steering ........................................................................ 1 81368-01-08 ..................... Bearing, .75"ID x 1.oo n OD x .50"L:..................................................... 4 B0W36708 ...................... Washer, Flat .75 .......................................................................................... 4 55111 ................................ Cylinder, 2.oo"Dia./6/81 n Steer {See page 16} .................................. 1 54035 ................................ Pin, Steering Cylinder ................................................................................ 2 66110-075 ........................ Washer, 3/4 n Ring Gear ........................................................................... 4 BOW38230 ...................... Pin, COtter .125"Dia. x 125 ..................................................................... 4 54644-001 .....................•.. Motor, 11.9 Hyd. Wheel {See page 18} ................................................ 2 B0W30109 ...................... Bolt, Iiex .50-13UNC x 2.25 .................................................................. 8 BOW36605 ...................... Nut, l/r13 .................................................................................................. 8 55302 ................................ Hub Assetnbly, Drive w/Studs {See page 19} .................................... 2 54779-Dwg ..................... Rear Hub Installation Drawing {See page 20} .................................... 1 BOW38232 ...................... COtter Pin, .12 x 1.75L ............................................................................. 2 54885-001 ........................ Adapter, MOR08 F0R10 1.00 Lg ......................................................... 1 54885-002 ........................ Adapter, MOR08 FR010 1.812 Lg....................................................... 1 54885-003 ........................ Adapter, MOR08 F0R10 2.625 Lg....................................................... 1 54885-004 ........................ Adapter, MOR08 F0R10 3.438 Lg....................................................... 1 36085 ................................ Fitting, Swivel 90° Elbow 8-8 ................................................................. 4 54929 ................................ Ttre & Wheel Assetnbly{Trre & Wheel Not Sold Seperatel:0 ........... 4 91029 ................................ Nut, .50-20UNF Wheel R# 30288 ....................................................... 10 54714 ................................ Brake Cylinder {See page 17} ................................................................. 2 54796 ................................ Pin,Brake .................................................................................................... 2 54795 ................................ I-Jandle Weldtnent, Brake Release ........................................................... 2 54779 ................................ Rear Hub Assetnbly {See page 20} ........................................................ 2 02236 ................................ Elbow, 900~04 MOO4 .......................................................................... 6 BOW30059 ...................... Bolt, Hex .38-16UNC x 2.25 Gr 5 ........................................................ 2 BOW30063 ...................... Bolt, Hex .38-16UNC x 325 .................................................................. 2 BOW36703 ...................... Washer, Flat .38"ID x .81 "aD ...............................................................4 B0W34274 ...................... Nut, Hex Lock 3/s-16UNC ............................................,""-................... 4

-38 -39

55955-DWG ................... Cl1assis Assetnbly Drawing ...................................................................... 1 55924 ................................ Splidle Assetnbly ........................................................................................ 2

c~','~~'c'>

- Indicates Items Not Shown

MANUAL 92383-003 May 1999 SIN X21599064, X21599073, X21599077 &. X31597070 &. Above

•

FIGURE 3.2: Hose Kit

r------l

fp-----~

:

L _____ ~

I

BELLY PAN BACK WALL

C--)

:

I

--

RIGHT

LIFT CYLINDER

2

I I I

-----J -----

RIGHT MOTOR

STEER

5

P2

PI

VALVE ASSY

HYDRAULIC TANK

3

ELECTRIC MOTOR

MANUAL 92383-003 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

FIGURE 3.2: Hose K i t .

ITEM

Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

PART NUMBER

DESCRIPTION

QTY

55469 ................................ Iiose Kit V2033 .........................................................•.......................... Ref. 66698-119.00 ................... Hose Assembly, # 06 66645 ]37 ST-ST ................................................. 1 66044-151.00 ................... Iiose Assembly, # 04 67685 ]37 ST-ST ................................................. 1 66702-019.00 ................... Iiose Assembly, # 10 66137]37 ST-ST ................................................. 1 66698-020.00 ................... Iiose Assembly, # 06 66645 J37 ST-ST ................................................. 1 66698-017.00 ................... Hose Assembly, # 06 66645 J37 ST-ST ................................................. 1 66696-012.5 ..................... Hose Assembly, # 04 66646]37 ST-ST ................................................. 1 66696-012.5 ..................... Iiose Assembly, # 04 66646 J37 ST-ST ................................................. 1 66696-012.5 ..................... Iiose Assembly, # 04 66646 J37 ST-ST ................................................. 1 66696-012.5 ..................... Iiose Assembly, # 04 66646 J37 ST-ST ................................................. 1 66700-026.00 ................... Iiose Assembly, # 06 66645 }37 ST-S1J ............................................... 1 66700-024.00 ................... Iiose Assembly, # 0666645 J37 ST-S1J ............................................... 1 66700-026.00 ................... Iiose Assembly, # 04 66646 J37 ST-S1J ............................................... 1 66700-025.00 ................... Iiose Assembly, # 04 66646 J37 ST-S1J ............................................... 1 66043-028.00 ................... Iiose Assembly, # 0367684 J37 S1J-S1J .............................................. 1 66043-019.50 ................... Iiose Assembly, # 03 67684 }37 S1J-S1J .............................................. 1

- Indicates Items Not Shown

MANUAL 92383-003 May 1999 SIN X21599064, X21599073, X21599077 &: X31597070 &: Above

•

FIGURE 3.3: Steer Cylinder

oWO

f-W

uo «z a:::w

f-f-

wX

a:::W nl.O OJ" ,.,-jc:i ~N

ITEM

Ref. 1 2 3 4 5 6 7 8 9

10 11 12

PART NUMBER

DESCRIPTION

QTY

55111 ................................ Cylinder, Steer ....................................................................................... Ref. 55111-100 ........................ SealKit ......................................................................................................... 1 55111-101 ........................ Lock Nut ..................................................................................................... 1 ........................................... Polypak (Included in Seal Kit 55111-100) ............................................. 2 ........................................... 00Ring (Included in Seal Kit 55111-100) .............................................. 1 55111-102 ........................ Piston (AlUlll) .............................................................................................. 1 55111-103 ........................ Jacket Assetnbly ......................................................................................... 1 55111-104 ........................ Piston Rod .................................................................................................. 1 ........................................... Polypak (Type B) (Included in Seal Kit 55111-100) ............................ 1 ........................................... 00Ring (Included in Seal Kit 55111-100) .............................................. 1 55111-105 ........................ Gland Nut ................................................................................................... 1 ........................................... Rod Wiper (Included in Seal Kit 55111-100) ....................................... 1 BOW32287 ...................... Jam Nut 5/8-18 ........................................................................................ 1 55111-106 ........................ Rod End ..................................................................................................... 1

- Indicates Items Not Shown

Revised January 1998 MANUAL 92383-003

May 1999 SIN X21599064. X21599073. X21599077 & J01597070 & Above

FIGURE 3.4: Cylinder, Brake •

I

® I

7/16-20 O-R:ING'-" PORT TVP

I.

I.

3.06

:I

10.18 EXTENDED 9.31 RETRACTED

QTY

ITEM

PART NUMBER

Ref.

54714 ................................ Cylinder, 1.75B x l.13R x .88 Stroke ................................................ Ref. 54714-100 ........................ SealKit ......................................................................................................... 1 54714-101 ........................ JacketAssernbly ......................................................................................... 1 54714-102 ........................ PistonRod .................................................................................................. 1 54714-103 ........................ Spring ........................................................................................................... 1 ........................................... Teflon Backup (Included in Seal Kit 54714-100) ................................. 1 ........................................... Polypak (Included in Seal Kit 54714-100) ............................................. 1 54714-104 ........................ Piston(Alutn} .............................................................................................. 1 ........................................... O'Ring (Included in Seal Kit 54714-100) .............................................. 1 ........................................... Polypak (Type 'Bj (Included in Seal Kit 54714-100) .......................... 1 ........................................... 00Ring (Included in Seal Kit 54714-100) .............................................. 1 54714-105 ........................ Gland Nut ................................................................................................... 1 ........................................... Rod Wiper (Included in Seal Kit 54714-100) ....................................... 1

1 2 3 4 5 6 7 8 9 10 11

DESCRIPTION

- Indicates Items Not Shown MANUAL 92383-003 May 1999 SIN Xl 1599064. XlI599073. X21599077 & X31597070 & Above

~

•

FIGURE 3.5: Hub Motor Assembly 10 1 9 1 6

1

8

4

1

1

1

1

17

3 10 1

11

2

PART NUMBER

Ref.

54644-001 ........................ Motor, 11.9 Hydraulic Wheel ............................................................. Ref. 54644-100 ........................ Seal Kit For Wheel Motor ....................................................................... 1 54644-101 ........................ Housing, Bearing ........................................................................................ 1 54644-102 ........................ Shaft & Bearing Kit (11/4 in Tapered) .................................................. 4 54644-103 ........................ Key (For Tapered Shaft) .......................................................................... 1 54644-104 ........................ Nut, trex (For Tapered Shaft) ............................................................... 1 54644-105 ........................ Plate, Wear .................................................................................................. 1 54644-106 ........................ Drive ............................................................................................................ 1 54644-107 ........................ Geroler ........................................................................................................ 1 54644-108 ........................ Drive, Valve ................................................................................................ 1 54644-109 ........................ PlateDrive .................................................................................................. 1 54644-110 ........................ Valve ............................................................................................................ 1 54644-111 ........................ Balance Ring ................................................................................................ 1 54644-112 ........................ Pin ................................................................................................................. 2 54644-113 ........................ Spring ........................................................................................................... 2 54644-114 ........................ Bolt ............................................................................................................... 4 54644-115 ........................ Housing, Valve /8-14 Staggered Ports) .............................................. 1 54644-116 ........................ Plug Assembly 7/ w20UNF ..................................................................... 1

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

DESCRIPTION

QTY

ITEM

r:

- Indicates Items Not Shown

MANUAL 92383-003

May 1999 SIN X2 1599064. X21599073. X21599077 & X31597070 & Above

, FIGURE 3.6: Drive Hub Assembly.

DESCRIPTION

QTY

ITEM

PART NUMBER

Ref.

55302 ................................ ffub AsselIlbly, Drive w/studs .......................................................... Ref. 289-00003-00 .................. Hub, 1.25 Taper Wheel ............................................................................ 1 55363-001 ........................ Stud, Wheel 1/2-20 x 1 3/4 .................................................................... 5 91029 ................................ Nut, .50-20 lJNF Wheel. ....................................................................... 10

1 2 -3

- Indicates Items Not Shown

MANUAL 92383-003

May 1999 SIN X21599064, X21599073. X215990TI & X31597070 & Above

•

/

FIGURE 3J: Hub Assembly, Rear Chassis Weldment Ref.

10

PART NUMBER

Ref.

54779 ................................ I-Iub Assembly ....................................................................................... Ref. 54779-109 ........................ I-Iub ..........................................•................................................................... 1 54779-101 ........................ InnerCltp .................................................................................................... 1 54779-102 ........................ InnerC:One .................................................................................................. 1 54779-106 ........................ Seal ............................................................................................................... 1 54779-103 ........................ 00ter Cltp ................................................................................................... 1 54779-104 ........................ Outer C:One ................................................................................................. 1 BOW36718-lID ............. Washer ......................................................................................................... 1 BOW1802 ........................ Slotted Nut, 3/4"-16lJNF ......................................................................... 1 BOW38233 ...................... C:Otter Pin, .125" x 2.00" .......................................................................... 1 54779-105 ........................ Dust cap ..................................................................................................... 1 54779-107 ........................ Stud .............................................................................................................. 5 54779-108 ........................ Stud Nut ...................................................................................................... 5

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

DESCRIPTION

QTY

ITEM

- Indicates Items Not Shown MANUAL 92383-003

May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

FIGURE 3. 8: Tube Kit . .

3 PL

LEfT SIDE

PI

BACK SIDE M3

TANK

MOTOR

NOTES: 2. FOR ITEMS IDENTIFIED FINAL ASSY. 3. FOR ITEMS IDENTIFIED

S ®

4. FOR ITEMS IDENTIFIED

~

SEE HOSE KIT IN SEE TUBE KIT. SEE CABLE KIT.

DESCRIPTION

QTY

ITEM

PART NUMBER

Ref.

55397 ................................ Tube Kit ................................................................................................. Ref. 55072 ................................ Tube AsseIDbly, M2 .............................................................,.................... 1 55067 ................................ Tube AsseIDbly, Mi .................................................................................. 1 55047 ................................ Tube AsseIDbly, M3 Bulkhead ................................................................ 1 55050 ................................ Tube AsseIDbly, M3 .................................................................................. 1 55048 ......................:......... Tube AsseIDbly, Cyl Vent to T ................................................................ 1 55324 ................................ Tube AsseIDbly, B ...................................................................................... 1 55051 ................................ Tube AsseIDbly, Brakes to T ................................................................... 1 55298 ................................ Tube AsseIDbly, T to Filter ...................................................................... 1 55076 ................................ Tube AsseIDbly, 52 .................................................................................... 1 55064 ................................ Tube AsseIDbly, 51 .................................................................................... 1 55063 ................................ Tube AsseIDbly, L ...................................................................................... 1

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

- Indicates Items Not Shown

MANUAL 92383-003 May 1999 SIN X21599064. X21599073. X21599077 & X31597070 & Above

, ~

NOTES: 1. REFER TO SHEET 2 FOR HYDRAULIC ASSEMBLY INFORMATION. 2. FOR ITEMS IDENTIFIED SEE HOSE KIT IN FINAL ASSY. 3. FOR ITEMS IDENTIFIED SEE TUBE KIT.

e

PL

4. FOR ITEMS IDENTIFIED 5. EST. WT. = 706 Ibs.

® E:9

~

2 PL

I...,)

4 PL

~ t::1:'

SEE CABLE KIT.

('I)

+

~

+ SOd

SOd

""'0

CHARGER BATTERY

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5

a GROUND STUD

TROJAN

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TROJAN

T-125

MOTOR

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T-125

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SEE NOTE 4

+

POS

+

FIGURE 3.9: Belly Pan Assembly., DESCRIPTION

QTY

ITEM

PART NUMBER

Ref.

55468 ................................ Belly Pan Assembly V2033XL ............................................................ Ref. 55958 ................................ Belly Pan Assembly V2033 .................................................................. Ref. 55481 ................................ Belly Pan Weldtnent V2033XL ............................................................... 1 55786 ................................ Belly Pan Weldtnent V2033 ..................................................................... 1 54989 ................................ Motor/Ptunp Assembly {See page 26} ................................................ 1 55379 ................................ Valve Installation {S~e page30} .............................................................. 1 55297 ................................ Tank Weldtnent, Hyd................................................................................ 1 50316 ................................ BreatherFiller ..........:.................................................................................. 1 52049 ................................ Gauge, Fluid Level .................................................................................... 1 04699-08 .......................... Plug, Socket Iiex .50 NPT ....................................................................... 1 02806 ................................ Straight, 11JI0 11P12 ................................................................................. 1 33430 ................................ Filter .........................:................................................................................... 1 110-1 ................................. -Filter EleIDeD.t .......................................................................................... 1 110-2 ................................. -Filter Iiead, Return Line ........................................................................ 1 00324 ................................ Elbow, ,90° 11J08 11P12 .......................................................................... 1 02430 ................................ Straight, 11J0411804 ................................................................................ 3 02431 ................................ Fitting, Straight 11J06 MB06 .................................................................... 2 02303 ................................ Elbow, 900 11J06 MB06 ........................................................................... 2 00345 ................................ Tee, 11J06 11J06 MB06 ............................................................................ 1 00334 ................................ Nut, Bulkhead 04 ....................................................................................... 5 00336 ................................ Nut,Bulkhead06 ....................................................................................... 5 02662 ................................ Elbow, 90° 11J06 M()o6 ......................................................................... 2 55398 ................................ <::able Kit (See Note 4) ............................................................................. 1 04674 ................................ Elbow, 90° 11J10 M()o8 L ..................................................................... 1 02407 ................................ Tee, 11J04 11J04 11P)4 ............................................................................. 1 55333 ................................ Q.arger Mod.115V/25A {See page 34-37} ........................................ 1 52138 ................................ Solenoid 24V .............................................................................................. 1 55334 ................................ JUlllper Assembly, 12 LG WIre .............................................................. 1 52627 ................................ Battery, 6VTrojan T125-WT .................................................................. 4 55505 ................................ Angle, BatteryTte DO'WIl22" .................................................................. 2 55506 ................................ J-Bolt, Battery Hold Do'WIl ..................................................................... 2 B0W36726 ...................... Washer, .31ID Split Lock ......................................................................... 3 BOW30055 ...................... Bolt, Iiex .38-16UNC x 1.25 .................................................................. 3 BOW30057 ...................... Bolt, Iiex .38-16UNC x 1.75 .................................................................. 2 B0W31433 ...................... Washer, .38 x .81"OD Flat SAE Gr 5 ................................................... 5 BOW34274 ...................... Nut, Iiex Lock 3/s"-16UNC .................................................................. 5 BOW30037 ...................... Bolt, Iiex .31-18UNC x 3.00 .................................................................. 3 B0W30029 ...................... Bolt, Iiex .31-18UNC x 1.00 .................................................................. 4 BOW31432 ...................... Washer, Flat .31"ID x .68"OD ............................................................... 4 BOW34273 ...................... Nut, Lock Iiex 5/ 16"-18UNC ................................................................. 4 BOW30003 ...................... Bolt, Iiex .25-20UNC x .875 ..................................................................4 BOW31401 ...................... Washer, Flat .25"ID x .63"OD ............................................................... 8 BOW34272 ...................... Nut, Iiex 25-20UNC Nylon Lock ........................................................4 55397 ................................ Tube Kit (See Note 3) .............................................................................. 1 04185 ................................ Fitting,Bulkhead Tee ................................................................................. 2 BOW34323 ...................... Nut, .25-20 UNC Wmg ............................................................................ 2

1 2 3 -4 5 6 7 8 9

10 11 12 13 14 15 16 17 -18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 -39 40 41

- Indicates Items Not Shown MANUAL 92383-003 May 1999 SIN X21599064, X21599073, X21599017 & X31591070 & Above

,.

, "'I1

1-4

~

I...J .~

~

@

t;g (l)

~ ""0

~

~

l

~

I ~

~ ~

Ii> (1)

LEFT SIDE

'--+-oS2 G1

!:::--o

"'~t;!

~'2l~~ 2 PL

?;S

j "" f BELLY PAN BACK WALL

2 PL

--<

S1

~~~ X,< r

~ §

8-

P2

I

SEE NOTE 3

FIGURE 3.9: Belly Pan Assembly . , DESCRIPTION

QTY

ITEM

PART NUMBER

Ref.

55468 ................................ Belly Pan Assembly V2033XL ............................................................ Ref. 55958 ................................ Belly Pan Assembly V2033 .................................................................. Ref. 55481 ................................ Belly Pan Weldment V2033XL ............................................................... 1 55786 ................................ Belly Pan Weldment V2033 ..................................................................... 1 54989 ................................ Motor/Pump Assembly {See page 26-29} .......................................... 1 55379 ................................ Valve Installation {See page 30} ............................................................. 1 55297 ................................ Tank Weldment, Hyd. ............................................................................... 1 50316 ................................ BreatherFiller ............................................................................................. 1 52049 ................................ Gauge, Fluid Level .................................................................................... 1 04699-08 .......................... Plug, Socket Iiex .50 NPT ....................................................................... 1 02806 ................................ Straight, h1J10 W12 ................................................................................. 1 33430 ................................ Fi1.ter ............................................................................................................. 1 110-1 ................................. -Filter Elexnent .......................................................................................... 1 110-2 ................................. -Filter liead ................................................................................................ 1 00324 ................................ Elbow, 90° h1J08 W12 .......................................................................... 1 02430 ................................ Straight, h1J04 MB04 ................................................................................ 3 02431 ................................ Fitting,Straighth1J06MB06 .................................................................... 2 02303 ................................ Elbow, 90oh1J06 MB06 ................................................ ~.......................... 2 00345 ................................ Tee, h1J06 h1J06 MB06 ............................................................................ 1 00334 ................................ Nut, Bulkhead 04 ....................................................................................... 5 00336 ................................ Nut, Bulkhead 06 ....................................................................................... 5 02662 ................................ Elbow, 90° !v1J06 M()()6 ......................................................................... 2 55398 ................................ uble Kit (See Note 4) ............................................................................. 1 04674 ................................ Elbow, 90° !v1J10 M()()8 L ..................................................................... 1 02407 ................................ Tee, !v1J04 h1J04 W)4 ............................................................................. 1 55333 ................................ Cl1arger Mod.115V/25A {See page 34-37} ........................................ 1 52138 ................................ Solenoid 24V .............................................................................................. 1 55334 ................................ JUlIlper Assembly, 12 LG WJ.re .............................................................. 1 52627 ................................ Battery, 6V Trojan T125-WT ..................................................................4 55505 ................................ Angle, Battery TIe Down 22" .................................................................. 2 55506 ................................ J-Boh, Battery Iiold Down ..................................................................... 2 BOW36726 ...................... Washer, .31ID Split Lock ......................................................................... 3 BOW3OO55 ...................... Bolt, liex .38-16UNC x 1.25 .................................................................. 3 BOW30057 ...................... Bolt, liex .38-16UNC x 1.75 .................................................................. 2 BOW31433 ...................... Washer, .38 x .81 "00 Flat SAE Gr 5 ................................................... 5 B0W34274 ...................... Nut, Iiex Lock 3/s"-16UNC .................................................................. 5 BOW30037 ...................... Bolt, liex .31-18UNC x 3.00 .................................................................. 3 BOW3OO29 ...................... Bolt, liex .31-18UNC x 1.00 .................................................................. 4 BOW31432 ...................... Washer, Flat .31"ID x .68"OD ............................................................... 4 B0W34273 ...................... Nut, Lock Iiex 5/16 "-18UNC ................................................................. 4 BOW30003 ...................... Bolt, liex 25-20UNC x .875 .................................................................. 4 B0W31401 ...................... Washer, Flat .25"ID x .63"00 ............................................................... 8 B0W34272 ...................... Nut, liex .25-20UNC Nylon Lock ........................................................ 4 55397 ................................ Tube Kit (See Note 3) .............................................................................. 1 04185 ................................ Fitting,Bulkhead Tee ................................................................................. 2 BOW34323 ...................... Nut, .25-20 UNC Wmg ............................................................................ 2

1 2 3 -4 5 6 7 8 -9

-10 11 12 13 14 15 16 17 -18 19 20 -21 -22 -23 -24 -25 -26 -27 28 29 30 31 32 33 34 35 -36 -37 -38 -39 40 -41

- Indicates Items Not Shown MANUAL 92383-003 May 1999 SIN X21599064, X21599073, X21599077 & lO I 597070 & Above

•

FIGURE 3.10: Motor & Pump Assembly

\

PART NUMBER

Ref. 1

54989 ................................ Motor/Putnp .Assembly...................................................................... Ref. 54761 ................................ Duplex Pwnp & Parts {See Page 27} .................................................. 1 54761-101 ........................ Seal Kit (Pwnp) .......................................................................................... 1 BOW30029 ...................... Bolt,!-lex .31"-18lJN"C x 1.00" .............................................................. 4 ........................................... Tag Nails ......................................................................................................

BOW31444 ...................... Washer, Flat 5/ 16 " ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4 54759 ................................ 24 Volt Motor {See Page 28} ................................................................ 1 54989-100 ........................ Gasket .......................................................................................................... 1 54760 ................................ ReplaceIDent COupling .............................................................................. 1 [Not Used] ............................................................................................................................................... 1

2

3 4 5 6 7 8

DESCRIPTION

QTY

ITEM

- Indicates Items Not Shown

MANUAL 92383-003 May 1999 SIN X21599064. X21599073, X2IS99077 & X31597070 & Above

FIGURE 3.11: Pump Assembly •

SECTION A-A A

14

9

10

18

17

6

13

15

1

7

© A

©.

HYDRAULIC SCHEMATIC

a

24

23

4

11

OUTLET PORTS

9/16-18 SAE

ITEM

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

PART NUMBER

DESCRIPTION

20

QTY

54761 ................................ DuplexPutnp &Parts ......................................................................... Ref. 54761-100 ........................ SealKit ......................................................................................................... 1 54761-103 ........................ GearfIousing ............................................................................................. 1 54761-108 ........................ DrivePin ..................................................................................................... 1 ........................................... C>il Seal (in seal kit) ..................................................................................... 1 54761-112 ........................ Drive Shaft .................................................................................................. 1 ........................................... Lee Plug ....................................................................................................... 1 54761-107 ........................ 375 Gear Face ............................................................................................ 1 ........................................... Gasket (in seal kit) ...................................................................................... 1 54761-102 ........................ Needle Bearing ........................................................................................... 1 54761-101 ........................ IdlerShaft .................................................................................................... 1 54761-105 ........................ Stator ............................................................................................................ 1 54761-106 ........................ Screw ........................................................................................................... 8 54761-109 ........................ ShearPin ...................................................................................................... 1 ........................................... PlasticPlug .................................................................................................. 1 ........................................... Gasket (in seal kit) ...................................................................................... 1 54761-111 ........................ Woodruff Key ........................................................................................... 1 ........................................... PlasticPlug .................................................................................................. 1 54761-110 ........................ OeascentRing ............................................................................................ 1 54761-104 ........................ GearHousing ............................................................................................. 1

- Indicates Items Not Shown

MANUAL 92383-003

May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

\ •

FIGURE 3.12: Motor 24VDC Assembly

-l----lNAMEPLATE

21

MANUAL 92383-003 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

FIGURE 3.12: Motor 24VDC Assembly • ITEM

Ref. 1 2 3 4 5 6 7

8

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

PART NUMBER

DESCRIPTION

QTY

54759 ................................ Motor, 24VDC Assembly .................................................................. Ref. ........................................... O>Inplete Stator Assembly ...................................................................... 1 NSS ................................... <:::OIDplete Tenninal Assembly ................................................................. 2 ........................................... ScrewIiexIIDup 3/8".16 .................................................................. 2 ........................................... Jam Nut, Iiex 3/8"·16 ............................................................................... 2 ...........................................Jam Nut, Iiex 3/8"_16 ............................................................................... 2 ........................................... Insulator ....................................................................................................... 4 ........................................... Insulator ....................................................................................................... 2 ........................................... Lock Washer, Split 3/8" ............................................................................ 2 ........................................... Lock Washer, Ext. TIH 3/8 " .................................................................. 4 ........................................... Field <:::oil Assembly .................................................................................. 1 ........................................... FieldPole ..................................................................................................... 4 ........................................... Screw, BTIN IID Socket, 3/8"-16 X s/s" ............................................. 8 ........................................... Field <:::Oil Tenninal .................................................................................... 1 ........................................... Loctite,222 .................................................................................................... ........................................... Pulley <:::Over ................................................................................................ 1 ........................................... Screw, Socket IID # 10-32 x1.00" ......................................................... 4 54759-117 ........................ <:::OIDplete Annature Assembly................................................................ 1 54759-118 ........................ Fan ................................................................................................................ 1 54759-119 ........................ Bearing,Pulley ............................................................................................ 1 54759-120 ........................ Bearing, <:::01llIIl .......................................................................................... 1 ........................................... <:::OIDplete <:::01llIIl <:::Over Assembly ....................................................... 1 54759-122 ........................ <:::OIDplete Brush Ring Assembly ............................................................. 1 54759-123 ........................ Brush Spring ............................................................................................... 8 54759-124 ........................ BrushAssembly.......................................................................................... 2 ........................................... Screw, RH Slotted # 10-32 x 3/4 " ............... ~ ........................................... 4 ........................................... Nut, Iiex # 10-32 ....................................................................................... 4 ........................................... Washer Bearing Spring .............................................................................. 1 ........................................... Screw, Iiex IID # 10-32 x 2.00" ............................................................. 4 54759-129 ........................ Brush Inspection <:::Over ............................................................................ 1 ........................................... Screw, PHIID # 10-32 x 1-3/ 4 " ............................................................. 1 ........................................... Nut, Square # 10-32 .................................................................................. 1 ........................................... Insulator ....................................................................................................... 1 ........................................... Screw, RH Slotted 1/4".20 x 3/8" ............................................................ 2 ........................................... LockWasher,Ext. TIHl/4 " .................................................................. 2 54760 ................................ <:::oupling Assembly ............................................................................... Ref

NSS - Not Sold Separately - Indicates Items Not Shown

MANUAL 92383-003 May 1999 SIN X21S99064. X21599073. X215990n & X31597070 & Above

•

FIGURE 3.13: Valve Installation

P1

~

REAR VIEW

LEFT END VIEW MANUAL 92383-003 May 1999 SIN X21599064, X21599073, X21599077 & )(31597070 & Above

FIGURE 3.13: Valve Installation.

\ .!I"

CREEP

o o

o RIGHT END VIEW

PART NUMBER

Ref.

55379 ................................ Valve Installation ................................................................................... Ref. 55296 ................................ Valve Assembly {See Page 32-33} ......................................................... 1 54892 ................................ Valve, Load Cbntrol ................................................................................. 2 02525 ................................ Straight, ~04 MC>04 ............................................................................... 3 02448 ................................ Straight, ~06 MC>06 ............................................................................... 5 00458 ................................ Straight, ~08 MC>08 ............................................................................... 1 04579 ................................ Elbow, 90° ~06 MC>06 ll .................................................................. 1 04682 ................................ Tee, ~04 MC>04 ~04 ........................................................................... 1 04003 ................................ Nut, up # 04 ............................................................................................. 2

1 2 3 4 5 6

7 8

DESCRIPTION

QTY

ITEM

- Indicates Items Not Shown

MANUAL 92383-003

May 1999 SIN X21599064. X21599073, X21599077 & )(31597070 & Above

•

FIGURE 3.14: Valve Assembly

A

B

I

4t

~

~

12

A

B

RIGHT END VIEW

FRONT VIEW

=

=

=

=

BACK VIEW B-B

SERVICE PARTS:

l J

LEFT END VIEW A-A

55296-100 REXROTH QUAD RING KIT. 4 RINGS PER KIT. 55296-101 COIL

~

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

MANUAL 92383-003 May 1999

SIN X21599064. X21599073. X21599077 & X31597070 & Above

FIGURE 3.14: Valve Assembly •

DESCRIPTION

QTY

ITEM

PART NUMBER

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

55296 ................................ Valve Assetnbly ..................................................................................... Ref. 55337-001 ........................ Manifold, Valve .......................................................................................... 1 54646-004 ........................ Valve, Drive ................................................................................................ 1 54646-001 ........................ Valve, Steer ................................................................................................. 1 54646-005 ........................ Valve, Select ................................................................................................ 1 54639 ................................ G.rtridge, 2 Way No Spool Valve .......•................................................. 2 54852-052 ........................ Orifice, 0.052 Dia IfF 10 ......................................................................... 1 54641 ................................ <:attridge, 4 Way No Spool Valve ......................................................... 1 54634 ................................ G.rtridge, Flow Divider Valve ................................................................ 1 54890 ................................ G.rtridge, Dir. Act Relief Valve .............................................................. 2 54640 ................................ G.rtridge, Oteck Valve ............................................................................. 1 54889 ................................ Urtridge, Flow G>ntrol Valve ............................................................... 1 54622 ................................ G.rtridge, Needle Valve ........................................................................... 1 54638 ................................ G.rtridge, Sequence Valve ........................................................................ 1

- Indicates Items Not Shown

MANUAL 92383-003 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

FIGURE 3.15: Cllarger 115V/25A Mod.

\

\

11

BLK

BATTERY CHARGER REO 24

PART NUMBER

Ref.·

55333 ................................ ClJ.arger, 115V125A Mod................................................................... Ref. 54908 ................................ ClJ.arger, 115V/60HZ-25A124VDC{See Page 36-37} ..................... 1 BOW23065 ...................... Ring Terminal, 12Ga. 3/8 Stud .............................................................. 2

1 2

DESCRIPTION

QTY

ITEM

- Indicates Items Not Shown

MANUAL 92383-003 May 1999 SIN X21599064. X21599073. X21599077 & X31597070 & Above

FIGURE 3.16: Otarger 115V/25AMod.8

14 8LK

BATTERY CHARGER 22 1/2_

-J

QTY

ITEM

PART NUMBER

Ref.

55901 ................................ Otarger, 115V/25A Mod................................................................... Ref. 54908 ................................ Otarger, 115V/60HZ-2SAl24VDC {See Page 36-37} .................... 1 BOW2306S ...................... Ring Tenninal, 12Ga. 3/8 Stud .............................................................. 2

1 2

DESCRIPTION

RED

- Indicates Items Not Shown

MANUAL 92383-003 May 1999 SIN X21599064. X21599073. X21599077 & )(31597070 & Above

•

FIGURE 3.17: Ctarger l1SV/60HZ-2SAl24VDC

(

\0

)

20

O~~~\\:\\II1II/IU##~Jo

DC

PERES

I

TERMINAL, 3/8 RING 2 PLCS.\

I I I I I

BL"'~ DC CORD:

10

RfD~

~O

#12 A WG, 2 PL

60±1--l 2 PLCS.

III

.281 X .625 SLOT MOUNTING HOLES 4 PLCS. (IN BASE LEG)

I

AMMETER, 0-30 AMP

r

1~ II II

~

I

I I I I

I ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~

~

®

MANUAL 92383-003 May 1999 SIN X2IS99064, X21599073, X21599077 & X31597070 & Above

~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~

®

~

I

\~ I

I

lOs

VENTILATION LOUVERS ON BACK SIDE

FIGURE 3.17: Otarger 115V/60HZ-25N24VDC •

ELECTRIC TIMER BLACK RED GREEN TRANSFORMER

FAN RED or WHITE

TO BATTERIES

BLACK

2

BLACK

WHITE 120 Voc INPUT _GREEN WIRE NOT USED ON SOME MODELS.

I'

ITEM Ref.

PART NUMBER

DESCRIPTION

QTY

54908 ................................ <1targer, 115V/60HZ-25A124VDC ................................................ Ref. 54908-1d1 ........................ Transfonner Assembly 54908-102 ........................ Heatsink Assembly, with Diodes 54098-103 ........................ Ammeter 54908-104 ........................ Electronic Timer Assembly 54908-105 ........................ Capacitor, 6.0 :MFD,660VAC 54908-106 ........................ Fuse Assembly 54908-107 ........................ Case Assembly 54908-108 ........................ Bushing, 7W-2, Insulator For Cordset 54908-109 ........................ COrdset, DC, 75", No Plug 54908-110 ........................ ACReceptacle

- Indicates Items Not Shown

MANUAL 92383-003 May 1999 SIN X21599064. X21599073. X21S99077 & X31597070 & Above

+

CABLE FROM LOWER CONTROL BOX TO HYDRAULIC VALVES # ~

r-r--

rr-

r-rr-r-r-r--

I 2 4 6 7 8 lOA 80 IIA 12 16

==. =::lI

r,::= === ==== ==== ==

CIRCUIT DESCRIPTION GROUND FORwARD DRIVE VALVE REVERSE RIGHT STEER VALVE lEFT UP PLATFORM SELECT VALVE FAST DRIVE SPEED DECELERATION VALVE CREEP DRIVE SPEED VALVE POSITRACTION VALVE SIGNAL HORN OP1l0N SPARE

COLOR GRN BlU BlU lK ORN ORN/BlK WHT BlK WHT/BlK BlK/WHT GRN/BlK REDIBLK RED

CABLE FROM LOWER CONTROL BOX TO UPPER CONTROL BOX

~ir

'1~1~

~

r--

r-r-r-r-- 8 r-- 9

Ii

::I~

11

II

r::w~_

I --

IRED~lK1

.... ~~gg~~I~~~(~ ,

BlK

, 1 2 3 4 5 6 7

"""CID

10

,fIOSt·)

r--

11

r--

12

!i 0

19 20 2\

~~

OPTIONAL 16GA/2C 67295-035

2 Pl

P

","'0

,'-GRN H6-0RN

J

. 68-WHT '2-BlU

~

[

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

I'!> 1'.::

,--12-GRN/BlK

r4

8 ""

~

I'!>

f

WELD ON STUD AT CHASSIS

0

,,-GRN

~

J8D=WHT/BlK

r3 r8 @

23

r-r--

14 15

I 3

I=BlK 69-WHT

) VALVE ON

@

rJ V

SELECT

@@

@ @

=

~ 5' SLOPE SENSOR

~

OPTION

'8B=WHT '1 ... CRN

'1-0RN

5B=BlK 5B-BlU

o

SIGNAL

r CONTACTOR

GROUND GROUND

POWER POWER

OPTIONAL ISGA/BC 67295-024 CABLE FROM lOWER CONTROL BOX. REFER TO STANDARD CABLE SHOWN BELOW

SPARE-RED OPTIONAL SIGNAL HORN

f\

18 19

6Pl

@

@

1415

o

~~~~~-~'""

N11A=BlK/WHT

U

h

8B=WHT

SIGNAL

'I=GRN

GROl)ND

o

CONTACTOR

-.- ...... -- .. --"',_ .. =BlK

POWER

STANDARD CABLE FROM lOWER CONTROL BOX

NOTES: 1. SEE 5491B-DWG FOR 110V EXT 2. THIS DWG SUPERCEDES 54916.

~

\

CIRCUIT DESCRIPTION GROUND-SPARE. IF NO OPllONS WA DRIVE POWER TO UPPER CONTROLS REVERSE DRIVE BATTERY GAGE OPTION LEFT STEER RIGHT STEER uP PLATFORM DOWN PLATFORM FAST DRIVE SPEED CREEP DRIVE SPEED POSITRACTION

BELOW ARE USTED CONDUCTORS IN CABLE THAT IS PART OF CERTAIN OPTIONS. (REF OPTIONAL 16GA/ISC 67295-003) GRN """T SLOPE ALARM OPTION RED WHT OVERRIDE lOW VOLT OPTION BlUIWHT INDICATE lOW VOLT OPTION BLKIRED SIGNAL HORN OPTION

:

C

cn

•

STEER

ORN ORNIBLK WHT WHT/BLK BlK BLK/WHT GRN/BlK

, 17 h~ ~~ 19. :: ,

r-

@ @

@@ DRI>t

. N'OA=BlK 17-0RN/BlK

. ,'6=RED/BlK ,,-GRN

13

SiElf 5

~

,4=BlU/BlK

,,6=RED/BlK

,

r - - 16

I·GRN

~

ALARM OPTIONS

COLOR GRN Bl RED BlU /BLK REDIBLK

2Pl

, ::!l

~

IJ,j

~

r

~

~

t.g

FIGURE 3.18: Wrring Installation •

ITEM \1'\'

Ref. 1

2 3 4 5 6

7 8 9

10

11 12 13 14 15 16 17 18 19 20 21 I

t,

22 23

PART NUMBER

DESCRIPTION

QTY

55870 ................................ WtringInstallation ................................................................................. Ref. 55331 ................................ JUlllper Asselllbly 3" Lg WIre ................................................................. 6 55330-001 ........................ JUlllper Asselllbly21 1/ 2 " Lg WIre ......................................................... 1 55330-002 ........................ JU1Dper Asselllbly 24" Lg WIre ............................................................•.. 1 55330-003 ........................ JU1Dper Asselllbly 14 liz" Lg WIre ......................................................... 1 55878 ................................ Switch Asselllbly, V Cltassis Litnit .......................................................... 1 55868 ................................ Spacer, .5"00 x # 10 ID x .5L N}ion .................................................. 2 B0W31148 ...................... Screw, Round lid # 10-32lJNF x 2 ...........................................••.......... 2 BOW31233 ...................... Nut, Iiex Keps # 10-32 ...•..............................................................•.•....... 2 67837-006 ...........•............ 'fie, Nylon 6." Black ................................................................................... 1 55222 ............................•... <::Over, Cltassis Elec. Tertninal ................................................................. 1 34552-008 ........................ TemUnal Strip ..............................•....•......................................................... 1 B0W31130 ...................... Bolt, Round lid #8-32rnC 1/2" .......................................................... 2 BOW31232 ...................... Nut, Iiex Keps # 8-32rnC ..........•....................................•.................... 2 54952 ................................ Support Weldrnent, <:able ....................................................................... 1 BOW38219 ...................... pin, <::Otter 3/32 x 1-1/2 LG .................................................................. 1 BOW34575 ...................... Bolt, Grriage .25-20rnC x .75L ........................................•................. 2 54926 ................................ Tray, Extension <:able ............................................................................... 1 BOW30002 ...................... Bolt, Iiex 25-20rnC x .75 .................................................................... 3 BOW31431 ...................... Washer, 1/4 SAE Grade 5 Flat .............................................................. 6 B0W34272 ...................... Nut - 25-20rnC Nylon Lock ............................................................ 11 65099-12 .......................... Oa.tnp - .750 DIA Olsh. Loop .............................................................. 2 67281-005 ........................ Wrapping, 3/4" Black/Spiral ...........................................................66LF. 55329 ................................ Cylinder I-Iamess Asselllbly...................................................................... 1

- Indicates Items Not Shown

MANUAL 92383-003

May 1999 SIN X21599064, X21599073, X215990n & X31597070 & Above

•

FIGURE 4.1: Box Assembly- Lower Control

o

o

o

o

-----------'1

III III III III III

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

lL ___________ J

I I I

I I I I I I I I

L ___ _

MANUAL 92383-003 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

FIGURE 4.1: Box Assembly- Lower Control . .

DESCRIPTION

QTY

ITEM

PART NUMBER

Ref. -1 -2 3 4 5 6 7 8 -9 10 11 12 13 14 15 16 -17 -18 -19 20 21 -22 -23 -24 25 26 -27 28 29 30 -31 -32 -33 -34 -35 -36 -37 -38 -39 -40

55869-002 ........................ Box Assetnbly - Lower O>ntrol ........................................................ Ref. 55488 ................................ Box, Mach. Lower O>ntrol ..................................................................... 1 55893 ................................ Decal- V14/18 Lower Box El Tags .................................................... 1 51913 ................................ Operator, Red P-Pull ................................................................................ 1 51914 ................................ Base + 1 NCO>ntact ............................................................................... 1 52671 _.............................. Operator, 3P()s Rot Key ZB2-Bg3 ...................................................... 1 52029 ................................ Base + 2 NO O>ntacts ............................................................................. 1 50075 ................................ S-witch, (Ref PIN 67760) ......................................................................... 1 54438 ................................ Re1ay, 24V SPDT Bosch ........................................................................... 1 206-00001-00 .................. Diode ........................................................................................................... 9 67114-013 ........................ Strain Relief 1 NPT .62/.75 ..................................................................... 1 67114-008 ........................ O>nnector, Strain Relief ............................................................................ 1 67114-009 ........................ Strain Relief, 3/4" NPT .62/.75 ............................................................... 2 67124-003 ........................ Locknut, 1" NPT ....................................................................................... 1 67124-002 ........................ Locknut, 3/4 NPT o>nduit ...................................................................... 3 67123-003 ........................ Seal, O>nnector Elect 1" ........................................................................... 1 67123-002 ........................ Seal, O>nnector Elect. 3/4" ••.•.•.•••......•.......••.........••..••..•..•••.••..•••....•••..•.•.• 3 BOW23022 ...................... RingTounge ............................................................................................... 3 67837-006 ........................ Tie, Nylon 6" Black ................................................................................... 8 B0W31430 ...................... Washer, Flat # 10 ID ................................................................................. 1 BOW31129 ...................... Screw, Slot Round Hd 8-32UNC x 3/ 8" .............................................. 1 BOW31232 ...................... Nut, flex Keps # 8-32UNC .................................................................... 1 B0W31124 ...................... Screw, Round Hd # 6-32 x 1//Lg ........................................................ .4 B0W31231 ...................... Nut, flex Keps # 6-32 .............................................................................. 4 BOW31428 ...................... Washer, Flat # 6 .......................................................................................... 4 67295-024 ........................ Cable, 8 Cond. 16AWG Type SO ............................................. 9.50IP. 67295-004 ........................ Cable, 12 Conductor 16Ga .............................................................. 5IP. 34552-016 ........................ Tenninal Strip ............................................................................................. 2 58251 ................................ Wrre, 12GA- White ............................................................................ 4IP 67940 ................................ Holder, Fuse ............................................................................................... 1 67939-015 ........................ Fuse, 15Ga 1/4" x 1-1/4" .•...........•..........•.............•...............•............•....... 1 58292 ................................ Wtre, 16 GA- White ........................................................................... lIP BOW23028 ...................... Tenninal8 Stud 16/14GA Fork ......................................................... 52 66720-001 ........................ Disconnect, STA-KON Female ............................................................. 6 BOW23087 ...................... Tenninal, Female Push-On .250W ......................................................... 3 67960-006 ........................ Tenninal, Ring 10 16-14AWG ................................................................ 2 BOW23024 ...................... Ring, Tongue 16-14 Ga 1/4 Stud ............................................................ 1 BOW23025 ...................... Tenninal, Ring Tongue 16-14 Ga ........................................................... 1 BOW18578 ...................... Tenninal, Piggyback R 67963 .................................................................. 1 BOW23087-2 .................. Tenninal, Female Push-On .250W ......................................................... 2 67961-006 ........................ Tenninal 8 Stud 12/10GA Fork ......................................................... 10

-51 -52 -53

A626-2633 ....................... Low Volt AlannIlnterrupt ................................................................. Ref. A309-2633 ....................... Motion Alann ....................................................................................... R.ef.

A310-2633 ....................... Strobe Light ........................................................................................... R.ef.

67295-003 ........................ XL Models 16ga/16cond ................................................................... Ref.

- Indicates Items Not Shown MANUAL 92383-003 May 1999 SIN X21599064. X21599073. X21599077 & X31597070 & Above

G

FIGURE 4.1: Box Assembly- Lower Control

,--------------------------------

---------------5

-----l

1

"DOWN"

5G

"up"

8

A 50-12 GA

5G

12 GA

5 '2 GA 272 PL

224 PL

_______ j ________'_9 _~ _________ J

234 PL

L-----

244 PL

'!..YQ_--

VALIlES SEE SHEET

I

,..-------

I

13

SEE SHEET "

-- - - -- - - -- - -

SEE SHEET

13

-- ---- - --- - - ---- -- -- - - - ---,

I

I NOTES: 1. THIS SHEET SHOWS "STANDARD", SEE SHEET 3 FOR 0 2. CONNECT "REO/BLK" TO SPARE, AS SHOWN. ,. ALL WIRING TO BE 16 GA, EXCEPT CIRCUITS 3,5, '" 51 4. SEE v.1RING DRAWING FOR COLOR TO CIRCUIT NUMBER

L ________________________________ J

MANUAL 92383-003 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

FIGURE 4.1: Box Assembly- Lower Control.

ITEM

I

Ref. -1 -2 3 4 5 6 7 8 -9 10

11 12 13 14 15 16 -17 -18 -19 20 21 -22 -23 -24 25 26 -27 28 29 30 -31 -32 -33 -34 -35 -36 -37 -38 -39 -40 -51 -52 -53

I

PART NUMBER

DESCRIPTION

QTY

55869-002 ........................ Box Assembly - Lower O>ntrol ........................................................ Ref. 55488 ................................ Box, Mach. Lower O>ntrol ..................................................................... 1 55893 ................................ Decal- V14/18 Lower Box EI Tags .................................................... 1 51913 ................................ Operator, Red P-Pull ................................................................................ 1 51914 ................................ Base + 1 NCO>ntact ............................................................................... 1 52671 ................................ Operator, 3POS Rot Key ZB2-Bg3 ...................................................... 1 52029 ................................ Base + 2 NO O>ntacts ............................................................................. 1 50075 ................................ Switch, (RefP/N67760) ......................................................................... 1 54438 ................................ R.elay,24VSPDTBosch ........................................................................... 1 206-00001-00 .................. Diode ........................................................................................................... 9 67114-013 ........................ Strain Relief 1 NPT .62/ .75 ..................................................................... 1 67114-008 ............•.•......•.. O>nnector, Strain Relief ......................•..................................................... 1 67114-009 ........................ Strain Relief, 3/4" NPT .62/.75 ............................................................... 2 67124-003 ........................ Locknut, 1" NPT ...........•........................................................................... 1 67124-002 ........................ Locknut, 3/4 NPT O>nduit ...................................................................... 3 67123-003 ........................ Seal, O>nnector Elect 1" ........................................................................... 1 67123-002 ........................ Seal, O>nnector Elect. 3/4 n ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 3 BOW23022 ...................... Ring Tounge ............................................................................................... 3 67837-006 ........................ Tie, Nylon 6" Black ................................................................................... 8 BOW31430 ...................... Washer, Flat # 10 ID ................................................................................. 1 BOW31129 ...................... Screw, Slot Round lid 8-32UN"C x 3/8" .............................................. 1 BOW31232 ...................... Nut, flex Keps #8-32UN"C .................................................................... 1 BOW31124 ...................... Screw, Round lid #6-32 x 1/2 "Lg ......................................................... 4 B0W31231 ...................... Nut, flex Keps # 6-32 .............................................................................. 4 BOW31428 ...................... Washer, Flat # 6 .......................................................................................... 4 67295-024 ........................ Cable, 8 O>nd. 16AWG Type SO ............................................. 9.50LF. 67295-004 ........................ Cable, 12 O>nductor 16Ga .............................................................. 5LF. 34552-016 ........................ Tenninal Strip ............................................................................................. 2 58251 ................................ WIre, 12GA - White ............................................................................ 4LF 67940 ................................ I-Iolder, Fuse ............................................................................................... 1 67939-015 ........................ Fuse, 15Ga 1/4" x 1- 1/ 4 " ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1 58292 ................................ WIre, 16 GA - White ........................................................................... 1LF BOW23028 ...................... Tenninal 8 Stud 16/14GA Fork ......................................................... 52 66720-001 ........................ Disconnect, STA-KONFemale ............................................................. 6 BOW23087 ...................... Tenninal, Female Push-On .250W ......................................................... 3 67960-006 ........................ Tenninal, Ring 10 16-14AWG ................................................................ 2 BOW23024 •..................... Ring, Tongue 16-14 Ga 1/4 Stud ............................................................ 1 BOW23025 ...................... Tenninal, Ring Tongue 16-14 Ga ........................................................... 1 BOW18578 ...................... Tenninal, Piggyback R 67963 .................................................................. 1 BOW23087-2 .................. Tenninal, Female Push-On .250W ......................................................... 2 67961-006 ........................ Tennina18 Stud 12/10GA Fork ......................................................... 10 A626-2633 ....................... Low Volt AlannIlntenupt ................................................................. Ref. A309-2633 ....................... Motion Alann ....................................................................................... Ref. A310-2633 ....................... Strobe Light ........................................................................................... Ref. 67295-003 ........................ XL Models 16ga/16cond ................................................................... Ref.

- Indicates Items Not Shown MANUAL 92383-003 May 1999 SIN X21599064. X21599073. X21599077 & X31597070 & Above

e

FIGURE 4.1: Box Assembly - Lower Control

0

1n ,J ,U

0

\

24" INSIDE

BOX

I

I I I

0

20" INSIDE

BOX 2 PL

0

34

3S" CABLE SHEATH

CABLE 16GA/SC (REF) TO MOTOR CONTACTOR/ 5' SLOPE SENSOR OPTION

(REF)

67964-002 5' SLOPE OPTION

(REF)

67964-002 5' SLOPE OPTION (REF)

(REF)

(REF)

BOW23025

(REF)

5' SLOPE OPTION

5' SLOPE

67960-006 S' SLOPE OPTION

MANUAL 92383-003 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

67964-002 OPTION

FIGURE 4.1: Box Assembly- Lower Control • L

DESCRIPTION

QTY

ITEM

PART NUMBER

Ref. -1 -2 3 4 5 6 7 8 -9 10 11 12 13 14 15 16 -17 -18 -19 20 21 -22 -23 -24 25 26 -27 28 29 30 -31 -32 -33 -34 -35 -36 -37 -38 -39 -40

55869-002 ........................ Box AssenIbly - Lower wntrol ........................................................ Ref. 55488 ................................ Box, Mach. Lower wntrol ..................................................................... 1 55893 ................................ Decal- V14/18 Lower Box EI Tags .................................................... 1 51913 ................................ 000rator,RedP-Pull ................................................................................ 1 51914 ................................ Base + 1 NC O>ntact ............................................................................... 1 52671 ................................ Operator, 3P()s Rot Key ZB2-Bg3 ...................................................... 1 52029 ................................ Base + 2 NO wntacts ............................................................................. 1 50075 ................................ Switch, (Ref P/N 67760) ......................................................................... 1 54438 ................................ Relay, 24VSPDTBosch ........................................................................... 1 206-00001-00 .................. Diode ........................................................................................................... 9 67114-013 ........................ Strain Relief 1 NPT .62/.75 ..................................................................... 1 67114-008 ........................ wnnector, Strain Relief ............................................................................ 1 67114-009 ........................ StrainRelief, 3/4" NPT .62/.75 ............................................................... 2 67124-003 ........................ Locknut, 1" NPT ....................................................................................... 1 67124-002 ........................ Locknut, 3/4 NPT wnduit ...................................................................... 3 67123-003 ........................ Seal, O>nnector Elect 1" ........................................................................... 1 67123-002 ........................ Seal, wnnector Elect. 3/4 " ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 3 BOW23022 ...................... RingTounge ............................................................................................... 3 67837-006 ........................ Tie, Nylon 6" Black ................................................................................... 8 BOW31430 ...................... Washer, Flat # 10 10 ................................................................................. 1 BOW31129 ...................... Screw, Slot Round Hd 8-32UNC x 3/8" .............................................. 1 BOW31232 ...................... Nut,:Hex Keps # 8-32UNC .................................................................... 1 BOW31124 ...................... Screw, Round Hd #6-32 X 1/2"Lg ......................................................... 4 BOW31231 ...................... Nut,:Hex Keps # 6-32 .............................................................................. 4 BOW31428 ...................... Washer, Flat # 6 .......................................................................................... 4 67295-024 ........................ Cable, 8 wnd. 16AWG Type SO ............................................. 9.50LF. 67295-004 ........................ Cable, 12 wnductor 16Ga .............................................................. 5LF. 34552-016 ........................ TenninalStrip ............................................................................................. 2 58251 ................................ WIre, 12GA- White ............................................................................ 4LF 67940 ................................ I-Iolder, Fuse ............................................................................................... 1 67939-015 ........................ Fuse, 15Ga 1/4 " x 1- 1/ / ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1 58292 ................................ WIre, 16 GA- White ........................................................................... 1LF BOW23028 ...................... Tenninal 8 Stud 16/14GA Fork ......................................................... 52 66720-001 ........................ Disconnect, STA-KONFemale ............................................................. 6 BOW23087 ...................... Tenninal, Female Push-On 250W ......................................................... 3 67960-006 ........................ Tenninal, Ring 10 16-14AWG ................................................................ 2 BOW23024 ...................... Ring, Tongue 16-14 Ga 1/4 Stud ............................................................ 1 BOW23025 ...................... Tenninal, Ring Tongue 16-14 Ga ........................................................... 1 BOW18578 ...................... Tenninal, Piggyback R 67963 .................................................................. 1 BOW23087-2 .................. Tenninal, Female Push-On 250W ......................................................... 2 67961-006 ........................ Tenninal8 Stud 12/10GA Folk ......................................................... 10

-51 -52 -53

A626-2633 ....................... Low Volt AlannIlnterrupt ................................................................. Ref. A309-2633 ....................... Motion Alann ....................................................................................... Ref. A310-2633 ....................... Strobe Light .....................................................................................;..... Ref. 67295-003 ........................ XL Models 16ga/16cond ................................................................... Ref.

- Indicates Items Not Shown MANUAL 92383-003 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

\ •

\

FIGURE 4.1: Box Assembly- Lower Control

i---------------------------------r--------------s I I

I I

I

I

(5 cTn1J -Mbod' """iJ'l'11lil

I I

MOTION ALARM

9

·OOWN"

~

8

·UP·

A :5t-----/ 80!:) 80 I - -

f- +::v

~~f-----" SF

\: S

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9

v-- = 10

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11

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12

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6

v-- ~

r-- ~ •

12 GA

~

~

3

~9PL

1

1

!'Qi

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I

PL

,---

-

~---

---

SEE SHEET

lOW VOlT OPTION

53

SlROBE UCHT OPTION

5

58

- 1---- c------ - - - - ------LJL ETC.

51

I

2 PL

(24' PL

I

l:OGA

50

~~

(,§ 4 PL '------ -

~ 5E

~

12 GA

7

~.

5E

16

2

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3

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7

':§

VALVES

/13

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'--

so 0< ~A

n=l

OPTION

~

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12 GA

~~--

SEE SHEET #3

I I I

58

- - - - - - - - - ----+-- - - - - - - - - - - I

~'!.O!~I!..

___ CONTACTOR

SEE SHEET #3

I I

.

0

.

5 12 GA J8

3.

---------(REf) 1 EA. BOW18S 78 (REF) 1 EA. Bow23087 S' SLOPE OPTION

I I

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

J ~

1

[,

~~

~~ ~~ It-.. ~ 8B

~ 1 ~

~ ~

0

1

2 3 4

I I

I I I I I I

~

ALARM

INTERRUPT

I I

~

©

/LOWVOlTAGE BATTERY PROTECTION OPTION

RESET

5 6

GROUND

7

POWER

I

I

I I

L ________________________________ ~

MANUAL 92383-003 May 1999

SIN X21599064, X21599073. X21599077 & )(31597070 & Above

NOTES: 1. n·us SHEET SHOWS All OPTIONS. SEE SHEET 2 FOR "STANDARD", 2. CONNECT "REO/BU<" TO SPARE, AS SHOWN. IF NO ALARM OPTION. CONNECT "RED /BU<" TO CIRCUIT 8e FOR MOTION AlARM OPTION. CONNECT "REO/BLK" TO CIRCUIT 9 FOR DESCEND ALARM OPTION. CONNECT "REO/BLK" TO CIRCUIT 80 FOR TIRAVEL ALARM OPTION. J. ALl \\'IRING TO BE 16 GA, EXC€PT CIRCUITS 3,5, " so AS MARKED. 4. IF lOW VOlT OPTION IS USED. THEN DO NOT USE JUMPER BETWEEN SA ANO 88.

5, SEE ""RING DRAWING FOR COlOR TO CIRCUH NUMBER TABLE.

FIGURE 4.1 Box Assembly- Lower Control DESCRIPTION

QTY

ITEM

PART NUMBER

Ref. -1 -2 3 4 5 6 7 8 -9 10

55869-002 ........................ Box Assenilily - Lower O:>ntrol ........................................................ Ref. 55488 ................................ Box, Mach. Lower O:>ntrol ..................................................................... 1 55893 ................................ Decal- V14/18 LowerBoxEI Tags .................................................... 1 51913 ................................ ()perator, Red P-Pull ................................................................................ 1 51914 ................................ Base + 1 NCO:>ntact ............................................................................... 1 52671 ................................ ()perator, 3PC>S Rot Key ZB2-Bg3 ...................................................... 1 52029 ................................ Base + 2 NO O:>ntacts ............................................................................. 1 50075 ................................ Switch, (Ref PIN 67760) ......................................................................... 1 54438 ................................ Relay, 24V SPDT Bosch ........................................................................... 1 206-00001-00 .................. Diode ........................................................................................................... 9 67114-013 ........................ StrainRelief 1 NPT .62/.75 ..................................................................... 1 67114-008 ........................ ()jnnector, Strain Relief ............................................................................ 1 67114-009 ........................ Strain Relief, 3/4" NPT .62/.75 ............................................................... 2 67124-003 ........................ Locknut, 1" NPT ....................................................................................... 1 67124-002 ........................ Locknut, 3/4 NPT O:>nduit ...................................................................... 3 67123-003 ........................ Seal, O:>nnector Elect 1" ........................................................................... 1 67123-002 ........................ Seal, Cbnnector Elect. 3/4" ....................................................................... 3 BOW23022 ...................... Ring Tounge ............................................................................................... 3 67837-006 ........................ TIe, N~on 6" Black .....................................................:............................. 8 BOW31430 ...................... Washer, Flat # 10 ID ................................................................................. 1 B0W31129 ...................... Screw, Slot Round Hd 8-32UNC x 3/8 n .............................................. 1 BOW31232 ...................... Nut, !-rex Keps # 8-32UNC .................................................................... 1 BOW31124 ...................... Screw, Round Hd #6-32 x 1/2"Lg ......................................................... 4 BOW31231 ...................... NUt, !-rex Keps # 6-32 .............................................................................. 4 BOW31428 ...................... Washer, Flat # 6 .......................................................................................... 4 67295-024 ........................ Cable, 8 O:>nd. 16AWG Type SO ............................................. 9.s0lF. 67295-004 ........................ Cable, 12 O:>nductor 16Ga .............................................................. 5lF. 34552-016 ........................ TenninalStrip ............................................................................................. 2 58251 ................................ WIre, 12GA - White ............................................................................ 4IF 67940 ................................ I-fulder, Fuse ............................................................................................... 1 67939-015 ........................ Fuse, 15Ga 1/4" x 1-1/4" ........................................................................... 1 58292 ................................ WIre, 16 GA - White ........................................................................... llF BOW23028 ...................... Tenninal8 Stud 161 14GA Fork ......................................................... 52 66720-001 ........................ Disconnect, STA-KONFemale ............................................................. 6 BOW23087 ...................... Tenninal, Female Push-On .250W ......................................................... 3 67960-006 ........................ Tenninal, Ring 10 16-14AWG ................................................................ 2 BOW23024 ...................... Ring, Tongue 16-14 Ga 1/4 Stud ............................................................ 1 BOW23025 ...................... Terminal, Ring Tongue 16-14 Ga ........................................................... 1 BOW18578 ...................... Terminal, Piggyback R 67963 .................................................................. 1 BOW23087-2 .................. Terminal, Female Push-On .250W ......................................................... 2 67961-006 ........................ Tenninal8 Stuc\ 12/10GA Fork ......................................................... 10

r-

11

i

I

12 13 14 15 16 -17 -18 -19 20 21 -22 -23 -24 25 26 -27 28 29 30 -31 -32 -33 -34 -35 -36 -37 -38 -39 -40 -51 -52 -53

A626-2633 ....................... Low Volt AlannIlntenupt ................................................................. Ref. A309-2633 ....................... Motion Alann ....................................................................................... Ref. A310-2633 ....................... Strobe Light ........................................................................................... Ref. 67295-003 ........................ XL Models 16ga/16cond ................................................................... Ref.

- Indicates Items Not Shown MANUAL 92383-003 May 1999 SIN X2IS99064. X2IS99073. X2IS990n & J01S97070 & Above

0

. . FIGURE 5.1: Annstack Assembly

/

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I

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/

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5v'

MANUAL 92383-003

May 1999 SIN X21599064, X2IS99Q73, X21599Q17 & Xl I S97070 & Above

FIGURE 5.1: Armstack Assembly •

I" ~,-

DESCRIPTION

QTY

ITEM

PART NUMBER

Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 -33 34 -35

55962XL .......................... Annstack Assembly.............................................................................. Ref. 55418-001 ........................ Ann Weldtnent, Lower Outer ................................................................ 1 55418-002 ........................ Ann Weldtnent, Lower Inner ................................................................. 1 55418-003 ........................ Ann Weldtnent, Left Middle Outer ....................................................... 1 55418-004 .......................• Ann Weldtnent, Right Middle Outer ..................................................... 1 55418-005 ........................ Ann 'Wledtnent, Middle Inner ................................................................. 1 55418-006 ........................ Ann Welchnent, lJpper Outer ................................................................ 1 55418-007 ........................ Ann Weldtnent, Upper Inner .................................................................. 1 81367-007 ........................ Bearing, 1.50 ID x 2.50 OD x 1/8 W {See page 52} ..................... 14 54616-002 ........................ Shaft, Ann Pivet 6.88 Lg {See page 52} ..............................................4 54616-oo1 ........................ Shaft, AnnPivet 1825 Lg {See page 52} ............................................ 5 67281-005 ........................ Wrapping - 3/4" Black! Spiral .................................................... 2.83IF 66388-001 ........................ o>llar, 11/2" Shaft {See page 52} ..................................................... 14 B0W3oo36 ...................... Belt .31-18lJN"Cx2.75 GRS Ifex ...................................................... 15 B0W31432 ...................... Washer - .31 ID x .68 OD Flat ............................................................ 17 B0W34273 ...................... Nut - 5/16-18lJN"C Iiex Lock ........................................................... 11 56130-020 ........................ Iiamess; V2033XLMain uble .............................................................. 1 02662 ................................ Elbew 90 lv.1J06 MOO6 ............................................................................ 1 67998-001 ........................ Screw .38-16 x 1.0" Thrd Fnnng ........................................................... 1 BOW32606 ...................... Oarnp - 1" DIA Wrre Leem .................................................................. 7 B0W9977 ........................ O-Ring - .375 ID x .500 OD .................................................................. 1 B0W30000 ...................... Belt 25-20lJN"C x .50 GRS Iiex ........................................................... 2 BOW31401 ...................... Washer - 25ID x .63 OD Flat ................................................................ 2 BOW30035 ...................... Belt .31-18lJN"Cx2.50 GRS Ifex ......................................................... 2 55083 ................................ Manifeld Assembly, 2633 Lift Cylinder {See page 55} ..................... 1 55715 ................................ Bracket Weldtnent, V14/18 Lower uble ............................................ l 54798 ................................ Nut - 10-32UNF C:Oupling ..................................................................... 1 54705 ................................ Cylinder - 3 x 49.31 2033XL1 2633 Lift {See Page54} ..................... 1 34145 ................................ Bushing - (R# 81368) {See page 48} ......................................................4 B0W36780 ...................... Nut, Iiex 25-20lJN"C Nylen Lock ........................................................ 8 54616-004 ........................ Pin - V20/26 06.50" Ann ........................................................................ 1 55027 ................................ Pin (Weldtnent) - 2633 Lift Cylinder ...................................................... 1 02236 ................................ Elbew 90 lv.1J04 MOO4 ............................................................................ 1 55962-DWG ................... Annstack DWG; V2033/XL-02 ............................................................ 1 67295-017 ........................ uble, 3 C:Onducter 12GA {1l0 Velt to' Platferm} .............. 31.50IF 54783-002 ........................ EmergencyLowering uble {See Page 73} .......................................... .

- Indicates Items Not Shown

MANUAL 92383·003 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

FIGURE 5.1: Arrnstack Assembly

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"'~j(~) MANUAL 92383-003

May 1999 SIN X21599064. X21599073. X21599077 & X31597070 & Above

FIGURE 5.1: Annstack Assembly • PART NUMBER

Ref.

55962XL .......................... Arn1stack Assetnbly.............................................................................. Ref. 55418-001 ........................ Ann Weldtnent, Lower Outer ................................................................ 1 55418-002 ........................ Ann Weldtnent, Lo-wer Inner ................................................................. 1 55418-003 ........................ Ann Weldtnent, Left l\1iddle Outer....................................................... 1 55418-004 ........................ Ann Weldtnent, Right Middle Outer ..................................................... 1 55418-005 ........................ Ann 'Wledtnent, Middle Inner ................................................................. 1 55418-006 ........................ Ann Weldtnent, lJpper Outer ................................................................ 1 55418-007 ........................ Ann Weldtnent, lJpper Inner .................................................................. 1 81367-007 ........................ Bearing, 1.50 ID x 2.50 00 x 1/8 W {See page 52} ..................... 14 54616-002 ........................ Shaft, Ann Pivot 6.88 Lg {See page 52} .............................................. 4 54616-001 ........................ Shaft, Ann Pivot 18.25 Lg {See page 52} ............................................ 5 67281-005 ........................ Wrapping - 3/4" Black! Spiral .................................................... 2.83LF 66388-001 ........................ Collar, 11/2" Shaft {See page 52} ..................................................... 14 B0W30036 ...................... Bolt .31-18lliCx2.75 GRSliex ...................................................... 15 B0W31432 ...................... Washer - 31 ID x .68 00 Flat ............................................................ 17 B0W34273 ...................... Nut - 51 16-18lliC liex Lock ........................................................... 11 56130-020 ........................ Iiamess; V2033XL 11a.in <:able .............................................................. 1 02662 ................................ Elbow 90 11;J06 MOO6 ............................................................................ 1 67998-001 ........................ Screw .38-16 x 1.0" Thrd Fnnng ........................................................... 1 BOW32606 ...................... Clunp - 1" OIA WIre Loom .................................................................. 7 B0W9977 ........................ O-Ring - .375 ID x .500 00 .................................................................. 1 BOW30000 ...................... Bolt .25-20lliC x .50 GRSliex ........................................................... 2 B0W31401 ...................... Washer- .25IOx.63 00 Flat ................................................................ 2 BOW30035 ...................... Bolt .31-18lliCx2.50 GRSliex ......................................................... 2 55083 ................................ :Manifold Assembly; 2633 Lift Cylinder {See page 55} ..................... 1 55715 ................................ Bracket Weldtnent, V14/18 Lower <:able ............................................ 1 54798 ...............:................ Nut - 10-32lJNF Coupling ..................................................................... 1 54705 ................................ Cylinder - 3 x 49.31 2033XLI 2633 Lift {See Page54} ..................... 1 34145 ................................ Bushing - (R# 81368) {See page 48} ......................................................4 BOW36780 ...................... Nut, liex .25-20lliC Nylon Lock ........................................................ 8 54616-004 ........................ Pin - V20126 06.50" Ann ........................................................................ 1 55027 ................................ Pin (Weldtnent) - 2633 Lift Cylinder ...................................................... 1 02236 ................................ Elbow 90 11;J04 MOO4 ............................................................................ 1 55962-0WG ................... Armstack OWG; V2033/XL-02 ............................................................ 1 67295-017 ........................ <:able, 3 Conductor 12GA {110 Volt to Platform} .............. 31.50LF 54783-002 ........................ EmergencyLo-wering <:able {See Page 73} ...........................................

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 -33 34 -35

DESCRIPTION

QTY

ITEM

- Indicates Items Not Shown

MANUAL 92383-003 May 1999 SIN X21599064, X21599073, X215990TI & X31597070 & Above

\ •

FIGURE 5.1: Annstack Assembly

4PL~ 5 PL

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e

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I

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-

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10 PL 12 SEE NO TE1 #

SECTION C-C

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2 PL rrn

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12

SEE NOTE

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SECTION 8-8 4 PL

8

13

2 PL rrnl

-

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2 PL 12 SEE NOTE

#1

SECTION A-A 1.

IF ITEM 12 HAS MANUFACTURER STAMPED ON ONE SIDE, PLACE STAMPED SIDE TOWARD ARMSTACK.

MANUAL 92383-003 May 1999 SIN X21599064. X21599073, X21599077 & X3 1597070 & Above

1

FIGURE 5.1: Annstack Assembly . , ITEM

Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 -33 34 -35

PART NUMBER

DESCRIPTION

QTY

55962XI.. .......................... Annstack .AsseIIlhly.............................................................................. Ref. 55418-001 ........................ Ann Weldntent, Lower Outer ................................................................ 1 55418-002 ........................ Ann Weldtnent, Lower Inner ................................................................. 1 55418-003 ........................ Ann Weldtnent, Left Middle Outer ....................................................... 1 55418-004 ........................ Ann Weldtnent, Right Middle Outer ..................................................... 1 55418-005 ........................ Ann Wledntent, Middle Inner ................................................................. 1 55418-006 ........................ Ann Weldment, lJpper Outer ................................................................ 1 55418-007 ........................ Ann Weldtnent, lJpper Inner .................................................................. 1 81367-007 ........................ Bearing, 1.50 ID x 2.5000 x 1/8 W {See page 52} ..................... 14 54616-002 ........................ Shaft, Arm Pivot 6.88 Lg {See page 52} ..............................................4 54616-001 ........................ Shaft, Arm Pivot 1825 Lg {See page 52} ............................................ 5 67281-005 ........................ Wrapping - 3/4" Black! Spiral .................................................... 2.83LF 66388-001 ........................ Collar, 11/2" Shaft {See page 52} ..................................................... 14 B0W30036 ...................... Bok .31-18UN"C x 2.75 GRS Iiex ...................................................... 15 B0W31432 ...................... Washer- .31 ID x .68 00 Flat ............................................................ 17 B0W34273 ...................... Nut - 5/16-18UN"C Iiex Lock ........................................................... 11 56130-020 ........................ Iiamess; V2033XI.. Main <:able .............................................................. 1 02662 ................................ Elbow 90 11}06 MOO6 ............................................................................ 1 67998-001 ........................ Screw .38-16 x 1.0" Thrd Fnnng ........................................................... 1 BOW32606 ...................... Oatnp - 1" DIA WIre Loom .................................................................. 7 B0'W9977 ........................ O-Ring - .375 ID x .500 00 .................................................................. 1 BOW30000 ...................... Bolt 25-20UN"C x.50 GRS flex ........................................................... 2 BOW31401 ...................... Washer - 2510 x .63 OD Flat ................................................................ 2 BOW30035 ...................... Bolt .31-18UN"Cx 2.50 GRS Iiex ......................................................... 2 55083 ................................ Manifold .AsseIIlhly; 2633 Lift Cylinder {See page 55} ..................... 1 55715 ................................ Bracket Weldtnent, V14/18 Lower <:able ............................................ 1 54798 ................................ Nut - 10-32UNF Coupling ..................................................................... 1 54705 ................................ Cylinder - 3 x 49.31 2033XI..I 2633 Lift {See Page54} ..................... 1 34145 ................................ Buslllng - (R# 81368) {See page 48} ......................................................4 B0W36780 ...................... Nut, flex 25-20UN"C Nylon Lock ........................................................ 8 54616-004 ........................ Pin - V20/26 06.50" Ann ........................................................................ 1 55027 ................................ Pin (Weldtnent) - 2633 Lift Cylinder ...................................................... 1 02236 ................................ Elbow 90 11}04 MOO4 ............................................................................ 1 55962-0WG ................... Annstack OWG; V2033/XI..-02 ............................................................ 1 67295-017 ........................ <:able, 3 Conductor 12GA {110 Volt to Platfonn} .............. 31.50LF 54783-002 ........................ Emergency Lowering <:able {See Page 73} ...........................................

- Indicates Items Not Shown

MANUAL 92383-003 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

FIGURE 5.2: Annstack Lift Cylinder Assembly

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

==~~~'=4145~

~~~~~~~~

____

~

DESCRIPTION

II~

QTY

ITEM

PART NUMBER

Ref.

54705 ................................ AnnstackLift Cylinder Assetnbly ...................................................... Ref. 54705-100 ........................ SealKit .......................................................................................................... .

54705-101 ........................ castle Nut .....................................................................................................

54705-102 ........................ cast Iron Ring ..............................................................................................

54705-103 ........................ Piston (Steel) ..................................................................................................

54705-104 ........................ Wear ring .......................................................................................................

54705-105 ........................ Jacket Assetnbly ...........................................................................................

54705-106 ........................ PistonRod ....................................................................................................

54705-107 ........................ Gland Nut ................................................................................•....................

55221 ................................ Flow G:>ntrol Valve, Lift Cylinder ...........................................................

- Indicates Items Not Shown

MANUAL 92383·003 May 1999 SIN X21599064. X21599073. X21599077 & X31597070 & Above

FIGURE 5.3: Manifold Assembly.

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ITEM

Ref. 1 2 -3

PART NUMBER

I

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DESCRIPTION

QTY

55083 ................................ Manifold Assembly ............................................................................. Ref. 54596-001 ........................ Manifold, Lift Cylinder ............................................................................. 1 54635-001 ........................ Valve, 2W NC SPCL Cartridge .............................................................. 1 00417 ................................ Plug, M()()4 ................................................................................................ 1

- Indicates Items Not Shown

MANUAL 92383-003 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

\

•

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FIGURE 6.1: Platfonn Installation ...J

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FIGURE 6.1: Platform Installation . , DESCRIPTION

QTY

ITEM

PART NUMBER

Ref.

55971 ................................ PlatfonnInstallation ............................................................................. Ref. 55967 ................................ Platfonn Weldtnent ................................................................................... 1 55968-001 ........................ Toeboard Weldtnent, lH ........................................................................ 1 55968-002 ........................ Toeboard Weldtnent, RfI ........................................................................ 1 54682 ................................ Mount Weldtnent, Ext. Deck Roller ...................................................... 4 54689 ................................ Roller, Ext. Deck ....................................................................................... 4 55476 ................................ Deck Weldtnent, Extension ..................................................................... 1 55970 ................................ Iiandrail Weldtnent, Ext ........................................................................... 1 55241 ................................ Latch Assembly, Deck .62-11 UNCMnt............................................. 1 55473 ....................~........... Iiandrail Weldtnent, Side .......................................................................... 2 55470 ................................ Gate, Lift up ............................................................................................... 1 55471 ................................ Plunger,Latch ............................................................................................. 2 55243 ................................ Spring, Deck Latch .................................................................................... 2 55031 ................................ Split Ring, Zinc Plated ............................................................................... 2 BOW30036 ...................... Bok, .31-18 UNC x 2.75 Gr 5 I-Jex ....................................................... 4 BOW2548 ........................ S-Hook ........................................................................................................ 1 164-00013-0 ..................... d::tain 2/0 ........................................................................................ 2.62IF. 50286 ................................ d::tain Snap .................................................................................................. 1 BOW34273 ...................... Nut, I-Jex Lock .31-18UNC ................................................................ 38 B0W36718-:HI) ............. Washer, Flat 3/4" SAE Thick .................................................................. 2 B0W30002 ...................... Bolt, I-Jex.25-20 UNC x .75 ................................................................. 16 B0W30008 ...................... Bolt, I-Jex .25-20 UNC x 2.00 .............................................................. 10 BOW34131 ...................... Washer, .2510 x .63 00 Flat ............................................................... 20 BOW34272 ...................... Nut, 25-20 UNC Nylon Lock ............................................................. 26 BOW30029 ...................... Bolt, I-Jex .31-18 UNC x 1.00 .............................................................. 14 BOW34602 ...................... Bolt, Our .31-18 UNCx 1.25 ............................................................. 16 BOW31432 ...................... Washer, Flat .31 10 x .68 00 .............................................................. 56 55207 ................................ Iiandrail Foot, Round ............................................................................... 2 55563 ................................ Weldrnent, Lock Mnt. Bracket ................................................................ 1 BOW36708 ...................... Washer, .750 Flat ........................................................................................ 2 54582 ................................ Block,Bearing ............................................................................................ 2 55971-DWG ................... Dwg, Platfonn Assembly ........................................................................ 1 54952 ................................ <1lble Support Weldrnent ........................................................................ 1

~

1 2 3 4 5

6 7 8 -9 -10

11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 -31 32

- Indicates Items Not Shown

MANUAL 92383-003 May 1999 SIN X21599064, X21599073. X21599077 & X3 1597070 & Above

•

This page intentionally left blank

/ MANUAL 92383-003 May 1999 SIN )(21599064, )(21599073, )(21599077 & )(31597070 & Above

FIGURE 6.2: 110 Volt Extension To Platfonn • GREEN

WHITE LOCA TED AT PLATFORM

BLACK

I - - - - - - { 11

LOCA TED ON RIGHT SIDE OF PL TFRM NOTES: 1. CABLE, 12GA/3c. IS IN BIM OF ARMSTACK.

1 - - - - - SEE NOTE 1

2.

BOL T & NUT, FOR ITEM 11, IS IN BIM OF PL TFRM ASSY.

8 REF. LEFT

GOLD SCREW

FRONT OF CHASSIS

REF 54984-006 DECAL, 110V

BLACK

GREEN SCREW

GREEN WHITE

7

SIL VER SCREW

PART NUMBER

Ref. 1 2 3 4 5 6 7 8 9 10

55883 ................................ 110 Volt Extension To Platfonn ....................................................... Ref. 40956 ................................ Oudet Box, Platfonn ................................................................................ 1 66357 ................................ Receptacle, Ground Fault ......................................................................... 1 66358 ................................ C:Over, Weathetproof ................................................................................ 1 67114-003 ........................ Strain Relief, 1/2 NPT .37/.5 .................................................................. 1 67124-001 ........................ Locknut, 1/2 NPT Strain Relief ............................................................. 1 67123-001 ........................ Seal, C:Onnector Elect. 1/2" ..................................................................... 1 52710 ................................ Plug, 110V ................................................................................................... 1 55036-001 ........................ Grommet, 1/2 ID 1/4 x 13/16 Dia GRV ......................................... 1 BOW32603 ...................... Clamp, Wtre Loom .50 ............................................................................ 1 BOW34272 ...................... Nut, lfex Lock .25-20 lJN'C ................................................................... 1 BOW32582 ...................... Oamp .......................................................................................................... 1 BOW31105 ...................... 10-32 x .75 Slotted Pan lfead .................................................................. 2 BOW31233 ...................... Nut, I-Jex Keeps # 10-32 .......................................................................... 2 55883-DWG ................... Dwg, 110V Ext......................................................................................... 1 67295-017 ........................ 12 Gage 3 O:mductor Cable ..................................................... 31.50LF.

11

, r

I,

12 13 -14 -15

- Indicates Items Not Shown

DESCRIPTION

QTY

ITEM

MANUAL 92383-003 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

FIGURE 6.3: Upper Control Box Assembly

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MANUAL 92383-003

May 1999 SIN X21599064, X21599073, X21599077 & X3 I 597070 & Above

CONDOR SERVICE PART NUMBER

OEM PART NUMBER

DESCRIPTION

QTY

54589-100

RUBBER BOOT

37165-101

MICROSWITCH IN ROCKERGRIP

2.00

54589-106

MICROSWITCH IN JOY STICK

56306-100

BOOt ROCKER S~TCH

2.00 1.00

56306-101

PUSH BUTTON SPST

1.00

56306-102

ACTUATOR

1.00

MANUFACTURER: OEM MANUFACTURER'S PART NUMBER: HANDLE TRAVLES 17' AND IS SPRING -

RETURNED TO CENTER.

WITH 2 MICROSWITCHES ACTUATED AT 13".

WITH ROCKERSWITCHES FOR STEERING ATOP HANDLE. WITH "GRIP-LEVER" ACUTATED ON-OFF SWITCH.

UNLESS OTHERII!SE NOTED: DECIMAlS ± .1

TOLERANCES: FRACTIONS ± 1/16 ± I" ANGLES

12V'

5URF'ACE FINISH PROJECTION OF VIEWS

.X .XX .XXX

± .03 ± .010 TITLE

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TIME CONDOR CORPORATION 8300 IMPERIAL DRIVE WACO, TEXAS 76712

CONTROLLER,

rv,

All. DIMENSIONS ARE IN INCHES LTR.

LTR.

D.C.N. NO.

DATE

APPR.

11896 D.R.N. NO. _ .. _- .... -

DRAWN

K SNYDER

5/25/98

AIDRA~NG

NO.

56306

CHECKED -

DATE

-~

APPROVED

SCALE

1/1

ISHEET

1 OF 1

FIGURE 6.3: Upper Control Box Assembly •

DESCRIPTION

QTY

ITEM

PART NUMBER

Ref.

55851 ................................ lJpper C:Ontrol Box Assetnbly ........................................................... Ref. 55855 ................................ Box, VXL Upper C:Onttol ....................................................................... 1 56306 ................................ C:Ontroller, BMS4RMl1329 ............................•............•........................... 1 51913 ................................ Operator-Push Pull ..........................................•......................................... 1 51914 ................................ Base + INC C:Ontact .............................•.................................................. 1 52670 ................................ Operator, 3 Pos Rot.................................................................................. 1 34464 ................................ Base + 1 NO + 1 NC C:Ontacts ............................................................. 1 56068 ................................ Insert, C:Ontrol Box Plastic 4.9"L ............................................................ 2 52672 ................................ Base + 1 NO C:Ontact .............................................................................. 1 69146 ................................ Operator, Green Pushbutton .................................................................. 1 54913 ................................ Operator, Blk/Blk Dual S'Witch .............................................................. 1 52029 ................................ Base + 2 NO C:Ontacts ............................................................................. 1 54910-104 ........................ Mtg. Base, AG Base .................................................................................. 1 54910-102 ........................ Recep. Scr. Tetnl# 1-16 ........................................................................... 1 67837-006 ........................ Tie, Nylon 6" Black ................................................................................... 5 BOW31120-1 .................. Screw, SIt. Pan # 4-40 UNC x 1/2" Lg ................................................4 BOW31242 ...................... Nut, #4-40 UNC ...................................................................................... 4 58292 ................................ WIre, 16 Ga White .............................................................................. 8LF. 34384 ................................ C:Ontact Block, NC .................................................................................... 1 55851-DWG ................... Dwg, Box Assetnbly, Upper C:Ontrol ................................................... l

1 2

3 4

5 6 7 8 9

10 11

12 13

14 15 16 17 18 -19 31 32 33 34 35 36 37

Note:

A620-2633 ....................... BatteryC:Ondition Indicator (Option) ............................................... Ref. A353-2633 ....................... Slope Alann (Option) .......................................................................... Ref. A626-2633 ....................... LowVolt AlannIIntenupt (Option) ................................................ Ref. A304-2633 ....................... Signal Iiom (Option) ........................................................................... Ref.

Upper C:Ontrol Box Assetnbly 55851 does not include decals.

For Upper C:Onttol Box decals see Decal Installation PagelO, Figure 2.1.

- Indicates Items Not Shown

MANUAL 92383-003 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

, ::!l

I

ALARM

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INSIDE OF OPEN LID

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OPTIONAL LOW VOLTAGE

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EMERGENCY

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DRIVE SPEED SELECTOR SWITCH

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DRIVE FORWARD

3 3A

CONTROL POWER

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FROM GRIPSWITCH

4

DRIVE REVERSE

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+24VDC BATTERY

6

STEER LEFT

7

STEER RIGHT RAISE PLATFORM

9

LOWER PLA TFORM

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DRIVE FAST

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FIGURE 6.3: Upper Control Box Assembly . ,

DESCRIPTION

QTY

ITEM

PART NUMBER

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

55851 ................................ lJpper O>ntrol Box Assembly ........................................................... Ref. 55855 ................................ Box, VXL lJpper O>ntrol ....................................................................... 1 56306 ................................ O>ntroller, BMS4RM11329 ..................................................................... 1 51913 ................................ Operator-Push Pull .................................................................................... 1 51914 ................................ Base + 1NC O>ntact ................................................................................ 1 52670 ................................ Operator, 3 Pos Rot.................................................................................. 1 34464 ................................ Base + 1 NO + 1 NC O>ntacts ............................................................. 1 56068 ................................ Insert, O>ntrol Box Plastic 4.9"L ............................................................ 2 52672 ................................ Base + 1 NO O>ntact .............................................................................. 1 69146 ................................ Operator, Green Pushbutton .................................................................. 1 54913 ................................ Operator, BlkIBlk Dual Switch .............................................................. 1 52029 ................................ Base + 2 NO O>ntacts ............................................................................. 1 54910-104 ........................ :Mtg. Base, AG Base .................................................................................. 1 54910-102 ........................ Recep. Scr. Tenn# 1-16 ........................................................................... 1 67837-006 ........................ 'Tie, Nylon 6" Black ................................................................................... 5 BOW31120-1 .................. Screw, SIt. Pan # 4-40 UNC x 112" Lg ................................................4 BOW31242 ...................... Nut, #4-40 UNC ...................................................................................... 4 58292 ................................ WJ.re, 16 Ga White .............................................................................. 8IF. 34384 ................................ O>ntact Block, NC .................................................................................... 1 55851-DWG ................... Dwg, Box Assembly, Upper O>ntrol ................................................... 1

31 32 33 34 35 36 37

A620-2633 ....................... BatteryO>ndition Indicator (Option) ............................................... Ref. A353-2633 ....................... Slope Alann (Option) .......................................................................... Ref. A626-2633 ....................... Low Volt AlannIInterrupt (Option) ................................................ Ref. A304-2633 ....................... Signal Hom (Option) ........................................................................... Ref.

- Indicates Items Not Shown

MANUAL 92383-003 May 1999 SIN X21599064, X21599()73, X21599077 & X31597070 & Above

/7

•

FIGURE 7.1: Travel Alann (Option)

DESCRIPTION

QTY

ITEM

PART NUMBER

Ref.

A301-2633 ....................... Travel Alann .......................................................................................... Ref. 80188-024 ........................ Wobbulator and Speaker ......................................................................... 1 67295-035 ........................ <:able, 16Ga./2 G:>nductor SJO ..................................................... 2LF BOW23027 ...................... Tenninal 6 Stud 16/14Ga. Spade ......................................................... 4 55036-001 ........................ Gronunet, 1/2"ID 1/." x 13/ 16"Dia. GlV.............................................. 1

-1 -2 -3 -4

- Indicates Items Not Shown

MANUAL 92383-003 May 1999 SIN X21599064, X21599073, X21599077 &. X31597070 & Above

FIGURE 7.2: Motion Alann (Option) •

DESCRIPTION

QTY

ITEM

PART NUMBER

Ref.

A309-2633 ....................... Motion Alann ....................................................................................... Ref. 80188-024 ........................ Wobbulator and Speaker ......................................................................... 1 67295-035 ........................ Cable, 16Ga.l2 O:>nductor SJO ..................................................... 2I.F BOW23027 ...................... Tenninal 6 Stud 16/14Ga. Spade ......................................................... 4 55036-001 ........................ Gronunet, 1/2"ID 1/4" x 13/ 16"Dia. Grv.............................................. 1 206-00001-00 .................. Diode ........................................................................................................... 2

-1 -2 -3 -4 -5

- Indicates Items Not Shown

MANUAL 92383-003 May 1999 SIN X21599064. X21599073. X21599077 & X31597070 & Above

•

FIGURE 7.3: Strobe Light (Option)

REF. RIGHT SIDE VIEW OF PLATFORM.

PART NUMBER

Ref.

A310-2633 ....................... Strobe Light ........................................................................................... Ref. 58395 ................................ Light Amber Strobe 12-72 VDC .......................................................... 1 BOW31400 ...................... Washer, Flat # 10 ...................................................................................... 3 BOW31144 ...................... Screw, Slot Rnd. # 1O-32UNF x .50 ..................................................... 3 55400 ................................ Mount - Strobe Light 14" ....................................................................... 1 BOW34001 ...................... Bolt, ffix 25-20UNC x 1.00 ................................................................. 2 BOW31432 ...................... Washer, Flat .31 ID x .68 OD ............................................................... 2 BOW36780 ...................... Nut, Hex .25-20UNC Nylon Lock ...................................................... 2 67295-035 ........................ Cable, 16Ga./2 O:mductor SJO .................................................. 50LF 52672 ................................ Base + 1 NO 0>ntact ZB2BZI0l ....................................................... 2 58259 ................................ WIre, 18Ga. Black-Bulk ..................................................................... lLF

1 2 3 4 5 6 7 8 9 10

DESCRIPTION

QTY

ITEM

- Indicates Items Not Shown

MANUAL 92383-003 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

FIGURE 7.4 Descend Alarm (Option) • DESCRIPTION

QTY

ITEM

PART NUMBER

Ref.

A312-2633 ....................... Descend Alann .....................................................................................Ref. 80188-024 ........................ Wobbulator and Speaker 24V ............................................................... 1 67295-035 ........................ uble, 16Ga./2 Cbnductor SJO .................................................... 2:LF BOW23027 ...................... Tenninal 6 Stud 16/14Ga. Spade ......................................................... 4 55036-001 ........................ Gronunet, 1/2"ID 1/4" x 13/ 16"Dia ........................................................ 1 34542 ................................ Jumper ......................................................................................................... 1

-1 -2 -3 -4 -5

- Indicates Items Not Shown

MANUAL 92383-003 May 1999 SIN X21599064, X21599073, X2 1599077 & X31597070 & Above

•

FIGURE 7.5: Slope Alann (Option) PART NUMBER

Ref.

A353-2633 ....................... Slope Alann ........................................................................................... Ref. 32002 ................................ Slope Sensor 2-Axis ................................................................................. 1 BOW30002 ...................... Bolt, Iiex .25-20lJN"C x .750 ................................................................. 2 BOW31432 ...................... Washer, Flat .31 ID x .68 00 ............................................................... 2 67295-024 ........................ Cable, 8 Conductor 16AWG Type SO ........................................ 7LF BOW23003 ...................... Tenninal Ring # 6796022-18 # 10 Stud ............................................... 2 34644 ................................ Alann ........................................................................................................... 1 58259 ................................ WJre, 18Ga. Black-Bulk ..................................................................... 2LF

-1 -2 -3 -4 -5 -6 -7

DESCRIPTION

QTY

ITEM

- Indicates Items Not Shown

MANUAL 92383-003

May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

FIGURE 7.6: Hour Meter (XL-Option) •

8B=WHT #1=BLK

#1=BLK

8B=WHT

REFERENCE MOTOR CONTACTOR

DESCRIPTION

QTY

ITEM

PART NUMBER

Ref.

A619-2633 ....................... HourMeter ............................................................................................ Ref. 80027 ................................ Meter, liour 4/40V DC ......................................................................... 1 67840-001 ........................ Bracket, Gage Mounting .......................................................................... 1 BOW30003 ...................... Bolt, flex .25-20lJNC x .875 ................................................................. 2 BOW31401 ...................... Washer, Flat .25 ID x .63 OD ...............................................................4 BOW36780 ...................... Nut, flex .25-20lJNC Nylon Lock ...................................................... 2 67295-035 ........................ Cable, 16Ga./2 Conductor SJO .................................................... 6LF BOW23087 ...................... Coupler - R# 67963 16-14 Female ......................................................... 2 67960-006 ........................ Tenninal Ring - 16-14 # 10 Stud ........................................................... 2 67837-004 ........................ Tie, Nylon-4" Black ................................................................................... 4

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

- Indicates Items Not Shown

MANUAL 92383-003 May 1999 SIN X21599064, X21599073, X21599077 & X31597070 & Above

•

FIGURE 7.7: Battery Condition Indicator (XL-Option)

PART NUMBER

Ref.

A620-2633 ....................... BatteryC:Onditon Indicator ................................................................. Ref. 37716 ................................ Meter, 24V Battery ................................................................................... 1 37993 ................................ Meter Guard ............................................................................................... 1 58300 ................................ WIre, 16Ga.-Black .............................................................................. 2LF 67963-001 ........................ C:Oupler - 22-18 Male ............................................................................... 2

-1 -2 -3 -4

DESCRIPTION

QTY

ITEM

- Indicates Items Not Shown

MANUAL 92383-003 May 1999 SIN X21599064, X21599073, X21599077 & X3 I 597070 & Above

FIGURE 7.8: Low-Voltage Warning Interrupt (XL-Option) • DESCRIPTION

QTY

ITEM

PART NUMBER

Ref.

A626-2633 ....................... Low-Voltage Warning Interrupt ........................................................ Ref. 54169 ................................ LowVoltage Interrupt 24V ................................................................... 1 54967-104 ........................ Operator, Blue IllUIllPushbutton ........................................................... 1 55902 ................................ Base + NO/NC Contact w/24V Bulb ................................................ 1 58259 ................................ Wrre, 18Ga. Black-Bulk ..................................................................... 6IF 54935 ................................ Decal- Low Volt Warning/Override ................................................... 1 BOW31141 ...................... Screw, Slotted Rnd. # 10-24 x 2.00 ....................................................... 2 B0'W31288 ...................... Nut, Ifex # 10-32 ...................................................................................... 2 BOW31430 ...................... Washer, Flat # 10 ID ................................................................................ 4

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

- Indicates Items Not Shown

MANUAL 92383-003 May 1999 SIN X21599064, X21599073, X21599077 & )(31597070 & Above

•

FIGURE 8.1: Holder Assembly

PART NUMBER

Ref.

34354 ................................ Holder Assetnbly .................................................................................. Ref. 65158 ................................ C:Onduit, EI PVC ....................................................................................... 1 65150 ................................ Flex up, Safety Manual Holder ............................................................. 2

1 2

DESCRIPTION

QTY

ITEM

- Indicates Items Not Shown

MANUAL 92383-003

May 1999 SIN X21599064, X21599073, X215990n & X31597070 & Above

FIGURE 9.1: Emergency Lowering Cable Assembly.

DESCRIPTION

QTY

ITEM

PART NUMBER

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

54783-002 ........................ Emergency Lowering Cable Assembly {Service Parts} ................ Ref. 54783-100 ........................ Red "T' Knob .............................................................................................

54783-101 ........................ 1/4-28 Jatn Nut ...........................................................................................

54783-102 ........................ Bezel ...............................................................................................................

54783-103 ........................ Lock Washer .................................................................................................

54783-104 ........................ 1/16-20 Jatn Nut ........................................................................................

54783-109 ........................ Silicone Lube ................................................................................................

54783-110 ........................ G>nduitFitting .............................................................................................

54783-111 ........................ Tube Seal .......................................................................................................

54783-113 ........................ Rod Seal ........................................................................................................

54783-115 ........................ SiliconeLube ................................................................................................

54783-116 ........................ 10-32 Jatn Nut .............................................................................................

54783-117 ........................ End up ........................................................................................................

- Indicates Items Not Shown

MANUAL 92383"()()3

.

May 1999

SIN X21599064. X21599073. X21599077 & X31597070 & Above