CONDOR Scissor Lift V2033XL V2033 Operator's & Parts Manual Sn X935-97051 - PDF DOWNLOAD

CJ SELF-PROPELLED ELEVATING WORK PLATFORM

MODEL V2033XL, V2033 Serial Number X935-97051

OPERATOR'S, MAINTENANCE, AND PARTS MANUAL

SHIPPING ADDRESS

MAILING ADDRESS

TIME CONDOR

TIME CONDOR

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

WACO, TEXAS 76702-1447

P.O. Box 21447 (254) 420-5200

MANUAL 92350 JANUARY 1997 SIN )(935-97051 ~

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INTRODUCTION

The primary purpose ofthis 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 wili maximize operating efficiency. The various decals attached to this CONDOR® contain vital information. Read all decals before operating this CONDOR®.

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

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It is also YOUR RESPONSIBILITY to understand and obey all federal, state, and local regulations regarding the operation and use of aerial work platforms. A copy of the ANSI/SIA A92.6-1990 Manual of Responsibilities is attached for your use.

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

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

SERVICE & MAINTENANCE Many 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 92350-001 JANUARY 1997 SIN X935-97051

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A div. of TIME Manufacturing Company CONDOR® SERVICE INFORMATION

1.

If you need assistance or have any service or maintenance questions, CONDOR® service and parts personnel are always available by phone or fax. The telephone numbers are: (817) 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 IMPERIALDRIVE,P.O. Box21447, WACO, TEXAS 76702-1447 817-420-5200, 817-666-4544 FAX 0

MANUAL 92350-001 JANUARY 1997 SIN X935-97051

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iii TABLE OF CONTENTS

IN'TRODUCTION .•••.•......•.•..•.....•..•.•....•.....•..••••.....•••...•.•..•••.•••......•...•......•.....••...•..•.•.••........•..•.•..••••.....•••• ; SERVICE INFORMATION ..•••••••.•••••.•.•.•.•...••.•.....••.•••••...•..•.•......•.•••.........•••••.....••.•.•.•.•••••.•.••••..•...•..•••.•• u TABLE OF CONTENTS •••..•.•..•..•..•....••.•.•.•~ .•.•.•.•••.•....•••••....•........•.•••....•••••..••...••...•...•••...••••...••••.•••••.•.• iii

I. PREPARATION, 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. MACIllN"E OPERATION ....•.••.••......•.••••••.••.•••..••.•..•.•...•..••.••.•..••...•...••...••........••.•••••.•..•...•.......••....•.• 2 A. B. C. D. E. F. G.

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Rated Work 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 92350-001 JANUARY 1997 SIN X935-97051

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

I.

PREPARATION. INSPECTION. AND MAINTENANCE

STEERING:

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®.

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 TillS 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 MACHINE 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:

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

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

C. EMERGENCY LOWERING

D

MANUAL 92350-001 JANUARY 1997 SIN X935-97051

Check emergency lowering function by pulling red T-handle.

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D. PLATFORM AND UPPER CONTROL STATION that lift-up entry gate is functional D Check and that chain is secure.

D D D D

D

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

tight and clean and free of corrosion.

Check for missing bolts & nuts - Replace before operating.

indicator lights and meter are not damaged.

II. CONDO" 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.

the hydraulic tank fluid level with D Check the platfonn all the way down. Fluid must

CAUTION CONDOR® MUST BE OPERATED ON FIRM, LEVEL GROUND ONLY. A. RATED WORK LOAD

The platfonn will support a combined weight equal to the unit's rated work load-including personnel, tools, and equipment-throughout the working envelope of the CONDOR®.

be visible in sight glass. Add Shell Tellus T-32 Hydraulic Fluid if required. Ensure that the breather cap is clean and in place on the tank.

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

Total rated work load is not to exceed 750 Ibs. (340 kg) including two occupants.

Check for hydraulic leaks at all fittings and valves.

B. LOWER CONTROLS CAUTION ARM STAND MUST BE USED WHEN MAINTENANCE PERFORMED ON CONDOR® REQUIRES SCISSOR ARM'S TO BE RAISED.

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 Make sure the battery charger and the

Check that extension deck is locked in place.

E. HYDRAULIC SYSTEM

D

D Keep battery tops clean and dry.

D Keep vent caps tightly in place.

D Check that battery cable connections are

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.

1. To engage ann stand, raise platfonn, then rotate stand until it hangs vertically.

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

MANUAL 92350-001 JANUARY 1997 SIN X935·97051

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

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

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.)

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

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

NOTE: Chain should be snapped in place across entry.

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

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

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

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

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

E. LIFT-UPENTRYGATE 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 92350-001 JANUARY 1997 SIN X935·97051

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LOWER CONTROLS

RED EMERGENCY STOP BUTTON

OPERATING --:-_ _ _ INSTRUCTIONS

RAISEILOWER BUTTONS

~_~ I

CONTROL STATION_--~~--~-:T SELECTOR SWITCH ! i

CONTROL CIRCUIT BREAKER

1 .

UPPER CONTROLS RIGHTILEFT STEER ROCKER SWITCH POSITRACTION SWITCH

DRIVE CONTROL HANDLE

REDEMERGENCY __----+-~~~~~~ STOP BUTTON

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RAISEILOWER BUTTONS

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HIGHILOW/CREEP DRIVE SPEED SELECTOR SWITCH

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POWER BUTTON MANUAL 92350-001 JANUARY 1997 SIN X935-97051

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F. DECK EXTENSION

B. RAMP METHOD

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

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The ramp should be set, not steeper than this CONDOR®'s rated gradeability, which for Model V2033IXL is 140 or 25%, or a rise of 30 inches in a run of 10 feet.

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

G. 'REMOVABLE' UPPER CONTROL BOX

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

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

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.

m. MOVING FROM JOB-SITE TO

-)

JOB-SITE

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

WEIGHT(#) 3,300Ibs.

WEIGHT(KG) 1496 kg .

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

(SEE III. 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 92350..001 JANUARY 1997 SIN X935-97051

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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 orentIy 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° 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.)

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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 92350-00 I JANUARY 1997 SIN X935-97051

NOTES

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) ~AL 92350-001

SANIJARY 1997 IN X935-9705 1

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APPENDIX: DECALS ILLUSTRATION

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SEC7iC\l 8-i3

PARTIAL SECTION A-A

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MANUAL 923S()"()()1 JANUARY 1997 SIN X93S-970S1

APPENDIX: DECALS ILLUSTRAnON

PART NUMBER

Ref *1 *2 *3 *4 *5 6 *7

55487 ............................ Decal Installation ...................................................................... Ref. 54984-001 ..................... Decal, Upper Oper. Instructions .................................................... 1 54652-001 ..................... Decal, Itemized Caution Notes ...................................................... 1 54984-002 ..................... Decal, Rated Work Load ............................................................... 2 55480-002 ..................... Decal, LowerOper. Instructions ................................................... 1 54652-003 ..................... Decal, Guardrail/Chain Caution .................................................... 1 54984-007 ..................... Decal, Hydraulic Fluid .................................................................. 1 54652-002 ..................... Decal, Arm Stand Caution .............................................................. 1 54984-005 ...................... Decal, Rear Bumper ...................................................................... 1 66973 ............................ Decal, Electric Hazard Keep Clear ................................................ 2 54984-006 ..................... Decal, 110 Volt Ext. To Platform .................................................. 1 69473-002 ..................... Decal, Die-Cut, CONDOR 3.45 x23 ............................................ 2 54985 ............................ Decal, Die-Cut ............................................................................... 2 55291 ............................ Tape, OrnlRed 3" .............................................................. 17.75LF. 55480-001 ..................... Decal, Lower Controls .................................................................. 1 53259 ............................ Tape, Non-Skid 6"W Black ................................................ 1.67LF. 66921 ........... :................ Coating, Non-Skid Jet Black ............................................... .27GL.

*8 *9 10 11 12 13 *14 15 16 21 *22 *23

*

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QTY

ITEM

DESCRIPTION

...................................... Nameplate, Scissors Ident........................................................ Ref. 54976-001 ..................... Decal, Upper Control Box Top ..................................................... 1 54976-002 ..................... Decal, Upper Control Box Front ................................................... 1 55487-001 ..................... Decals, V2033 Essential ........................................................... Ref.

- Indicates Items Not Shown *Indicates Included In Essential Decals

) MANUAL 92350-001 JANUARY 1997 SIN X935·97051

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APPENDIX: DECALS ILLUSTRATION

1

OPERA TING INSTRUCTIONS • TUR~ ":::\~ROLS" SWITCH, S\J LO'~'jER CO~TRc)L ?;'.~::L. TO '~UPPER" ::::Sl~:C~ -: :::;::c:~;;:-=: =-QOM PLATF0~M. • IN AN ::\/::~GENCY, PUSH RE;J BUTTON. 'f0 OPERA 7~ ~~OM ?LA. TFOR\/. 3JT~ ~::= 3,j:'C;,\S, ,:;-..j LQ'XER AND ON .;"ClER CONTROLS, )/UST BE PULLED OL'-:-.

• TO RAISE .l.ND LC'XER PLAT;:-JRM, PL;SH AND HOi...: :-i~ GREt:\ "~O·:.;:~" BLi~:="", ':">.jD P~·S~ iHt: "RA;St:" OR "LO'::;::~" BUTTON. RELEASE BU"TTONS TO STOP VOVEMEN~.

• SELECT :RVE SPEED ViIT" ,:-1'0 "!-i:GH/LO':':/CRE;::P" S,'iiTCH. A liMIT S:.. "TCH AUTOMATICALLY CUTS BACK THE S"'EED AS T;.jE PLA~;:-CRM :S p" S;::O. • TO DRIVE O'CRWARD OR REV;::RSE, SQUEEZE LEVER S;'iITCH aN HANDl;::, AND ::e;S- OR "'0L.L. ;.jANDLE iN THE \, -[\jDED DIRECTION OF TRAVEL, RELEASE _EVER SWiTCH TO SiOP MOVEMENT. LE',:NG GO Or HANDLE A,,-SO :.,:.._ STOP ;g;VEMENT. • BRAKES ':''<E AUTOMATICALLY RELEASED WHENEVE'< ,HE DRIVE HAND:..E :S \.10V;::J. LET GO cO' THE HANDLE TO AUTOMA TlCALL Y SET ,;-iE BRAKES.

I

• TO IMPRC'/;:: DRIVE TRACTICN, DEPRESS AND HOLD "POSITRACT!ON" S;.:TCH. THIS WILL AuTOMA TICALL Y CUT-OUT HIGH SPEED.

t·

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II.

TO STEER :..t:f'T OR RIGHT, SQUEEZE LEVER SVVITCH ON HANDLE, AND SEPRESS ::::;CKER S~\'TCHES ON TOP cO' HANDLE IN THE iNTENDED DIRECTION C<=" nAVEL. STEERING S NOT AuTOMA TICALL Y SELF -CENTERiNG. 3E SURE THE S-:-;::ERiNG :.'-,EE_S PO,:-';T fN THE =: ~~CTIQN YOU :/t..NT 2EFOR:: LEiTING GO !~E STt:i:R S:.:-:-':H.

:=-

) 2 DO NOT OPERATE THiS CONDOR'" UNTiL YOU ;-iAVE BEEN PROPER:'" Y TRAINE::: "ND HAVE COMPlt:TEL Y READ AND-uNDERSTOOD THE O?t:RA TOR'S MANUAL ,;--A T :s L.C:::; -t:D 0\ ;'-i!S CONDOR.'"

2.

PRIC~ TO EACH DAY'S ~SE. CHECK TO MAKE S...:Rt: ALL FUNCTIONS AKC :,::::=<.t.,:-:i\G ::JqCP~RLY. ?ERFO;=(M ALL i~SPECT:C~S REQUIRED BY SEC-;-,QN 6 OF Ti-iE ANSi 92.3 S- ~.'<~ARD.

3. DO '\J~ USE THE CONCOR"', ,,,. T IS MAi..FU":::~;'JN!NG OR JAMAGEC ,\; A1\ v :.~ v, GR ,O' "'I-'E WiND BL.OHS ::JVER i5 MPH. 4 DO \iOT DRIVE ON A SLOPE UNLESS T'-<E PlATFCRM IS rUlLY LO.\ERED. 5. RAiSe: THE PLA TFORM ONLY WHEN THE CONDOR" 'S ON FIRM, LEVEL GROu:-,;C. 6. ALWAYS LOOK IN THE DiRECTION IN liHICH ,H'O: PLATFORM IS MOV:NG. ,'jATC'" FOR, AND AVOiD, OVERHEAD OBSTRUCT'ONS AND ANYTHING EL.SE bA -;- \/JAY STR!KE PLATFORM, PERSONNEL, OR CONTROLS. 7. THIS CONDOR'" IS NOT ELECTRICALLY iNSULA -;-EJ. MAINTAIN SAFE CLEARANCES FROM ELECTRICAL POv'jER L:NES. 8. FOLLO:: INSTRUCTIONS IN OPERA TOR'S MANUAL ":HEN SERVICING SA TTER!ES. EACH REPLACEMENT BA. TTERY MUST 'SEIGH Ai ,-EAST 55 Ibs. DRY AND 66 ::s.:JET. REP:"'AC::MENT TIRES MUST BE SAME A.S F"AC,CRY ORIGINN_S. 10. iN CASE OF AN EMERGENCY, PUSH THE RED ";C\\ERGENCY STep" su nON. ~.

) MANUAL 92350-001 JANUARY 1997 SIN X935-97051

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APPENDIX: DECALS ILLUSTRATION

3

RA TED WORK LOAD ON :::XTENSiJN ;S 250L8SJK

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CNL Y,

750L8S OR

5

GUARDRAILS AND SAFEiY C:-iAiNS rv1UST BE SEC~~ED L,ND USED A.T ALL nlES 545S2-CC3

HYDRAULIC FLUID

6

7

10

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STAND CLEAR UNLESS ARM STAND is i\.J PLACE 54652-0C2

8 FORKLIFT POCKET

EMERGENCY LOWERING

) MANUAL 92350·001 JANUARY 1997 SIN X935·97051

BRAKE RELEASE

FORKLIFT :: POCKET

APPENDIX: DECALS ILLUSTRATION

9

ELECTROCUTION HAZARD KEEP CLEAR DEATH OR SERIOUS INJURY CAN RESULT FROM CONTACT WITH THIS EQUIPMENT OR VEHICLE IF IT SHOULD BE ELECTRICALLY CHARGED.

21882-001

4

THIS MACHINE IS NOT INSULATED ELECTROCUTION HAZARD MAINTAIN SAFE CLEARANCES FROM ELECTRICAL LINES AND APPARATUS. YOU MUST ALLOW FOR BOOM SWAY, ROCK OR SAG AND ELECTRICAL LINE AND LOAD SWAYING. THIS AERIAL WORK PLATFORM DOES NOT PROVIDE PROTECTION FROM CONTACT WITH OR PROXIMITY TO AN ELECTRICALLY CHARGED CONDUCTOR. YOU MUST MAINTAIN A CLEARANCE OF AT LEAST 10 FEET BETWEEN ANY PART OF THE WORK PLATFORM OR LOAD AND ANY ELECTRICAL LINE OR APPARATUS CARRYING UP TO 50,000 VOLTS. ONE FOOT ADDITIONAL CLEARANCE IS REQUIRED FOR EVERY ADDITIONAL 30.000 VOLTS OR LESS. DEATH OR SERIOUS INJURY WILL RESULT FROM CONTACT OR INADEQUATE CLEARANCE.

MANUAL 92350-001 JANUARY 1997 SIN X935-97051

APPENDIX: DECALS ILLUSTRATION

1,0 VOLT EXTENSION TC PLATFORM

10

,OPERA ilNG iNSTRUCTIONS

17

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54964-006'

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-:-0 2PERA TE. BUTiCN MUST 8E ~UL_::::: Q\.,;: . .. ALSO. iF A.PPUCABL£. BA TTER':" JiS::::~~Nt::~ S~V1TCH MUST BE ·'C~" TO OP;::RA. 7E.~

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:. F'USI-i '·RAISE" QR "~:JWER" gt.:7~GI\S TO MOVE PLA TFORM.

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;. 'uRN SWiTCH TO "uPPER" PQS,"'lON "'0 OPERATE ,ROM "LATFORM.

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Ti-!iS UNIT is NOT ::::,-ECTRICA~,-V" iNSUL-A.:t=:D. SELF-?ROPELLED ELEVATiNG WORi< P,-AT~ORM CONFORMS ALL APPLICABLE REQ~IREMENTS OF ANSi A92.5-'990 51340

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MANUAL 92350-001 JANUARY 1997 SIN X93S-970SI

LOWER

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SELF-PROPELLED ELEVATING WORK PLATFORM

MODEL V2033XL, V2033 Serial Number X93S-970S1

MAINTENANCE MANUAL

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SHIPPING ADDRESS

MAILING ADDRESS

TIME CONDOR

TIME CONDOR

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

VVACO, TEXAS 76702-1447

P.O. Box 21447 (254) 420-5200

MANUAL 923S()'OO2 JANUARY 1997 MANUAL 923S0·002 JANUARY 1997 SIN X93S·970S1

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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 of theCONDOR®, and to provide the information necessary to maintain and service the CONDOR®.

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

It is also YOUR RESPONSIDILITY to understand and obey all federal, state, and local regulations regarding the operation and use of aerial work platforms. A copy of the ANSI/SIA Manual of Responsibilities is attached for your use: ANSI/SIA A92.5-1992 is provided for Boom-Supported Elevating Work Platforms, and ANSI/SIA 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 of the product. Repairs and adjustments should only be made by trained and qualified personne1. Please refer to the maintenance and parts sections ofthe Condor Division Operation, Maintenance, & Parts Manual for information on service and maintenance of the CONDOR®.

NOTE:

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

ii

A div. of TIME Manufacturing Company

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 IMPERIAL DRIVE, P.o. Box21447, WACO, TEXAS 76702-1447' 817-420-5200, 817-666-4544 FAX

-'~'---

iii

A div. of TIME Manufacturing Company

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

by Condor Divisionis free from defects inmaterial and workmanship arising under normal use and servicein the case of majorweldments, (chassis, turret, and booms), for a period of five (5) years after the original shipment of the 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 ofparts not approved by Condor Division 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 e}..iend this Warranty in any way. If the purchaser has used its own order form, no additional or different warranty terms contained in the purchasers form willbe 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 putpose. Any applicable implied warranty shall be limited in duration to the warranty period.

8300ImperialDrive, P.O. Box21447, Waco, Texas76702-1447·817-666-4545,817-666-4544FAX Form No.513-3M-392

Effective Date 9/1/90 Printed in U.S.A.

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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 PERIODl.

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

5.

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

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

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

)

,_0_,'_0

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 oftheCONDOR® 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.1. sheet and return itto 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, if they 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.

Oth er 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 of installation or any liability for direct, indirect, or consequential damages or delay resulting from the defect.

5.

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

6.

Troubleshooting: Troubleshooting is not covered or reimbursable. However, 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 if the 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 of time 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 (RIA) number. You will be asked for a Dealer Claim Number. As noted in Section 2, Item A, ofthe W arrantyClaim 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 RIA number issued must be logged in the appropriate section of the claim form, and the gold copy (RIA) of the form must be returned with the parts being returned.

NOTE: DO NOT SHIP ANY RETURN PARTS WITHOUT A RETURN AUTHORIZATION (RIA) NUMBER Doing so may result in parts getting lostin 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 Warrranty will be required to be shipped back to Condor Division FREIGHT PREPAID. No freight collect shipments will be accepted.

)

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CONDOR® Model V2033XL, V2033

MAINTENANCE MANUAL TABLE OF CONTENTS

IN"lRODUCTION ................... ........ .......... ........ .............. .......... ...... ............... ... ...... ............... i CONDOR® SERVICE INFORMATION ............................................................................ ii SELF-PROPELLEDWARRAN"TY ....................................................................................... iii

)

Table ofContents ...................................................................................................................

1

Specifications .........................................................................................................................

3

Recommended Tool List .........................................................................................................

4

Serial Number Location ..........................................................................................................

5

Hydraulic System Description ..................................................................................................

7

Pres sure Adj ustment Procedures ................................. ................ ...... ...... ...............................

11

Electrical System Description... .............. ...... .......... .. .. ........ .......... ................ ...... .. .......... ........

15

Machine Options Description ........... .................... ............ ................ .................... .......... ........

19

Battery SeIVice .....................................................................................................................

23

Preventive Maintenance ..... .. .... .... .. .................... .............. ................ ............ .......... ................

31

HydraulicFluid Specifications ................................................................................................

41

BatteryChargerTroubleshootingGuide ..................................................................................

43

BoltTorqueChart ................................................................................................................

53

) MANUAL 92350·002 JANUARY 1997 SIN X935-97051

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NOTES

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) MANUAL 92350-002 JANUARY 1997 SIN X935-97051

•

SPECIFICATIONS SPECIFICATIONS

V2033XL

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 Wheel Base Tires

26 ft.

20 ft.

39.5" 93" 33" 79" 50" 92.5" x30" 7501bs.

3,36101bs.

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 Key Switch

* * * *

MotionlMovement 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 of the CONDOR® read, understand and conform to these regulations. Ultimate compliance to prevailing OSHA regulations is the RESPONSIBILIT of the employer utilizing the equipment.

MANUAL 92350·002 JANUARY 1997 SIN X935·97051

•

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

Volt/Ohm Test Meter Hydraulic 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 ftllbs 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, 1/4" 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 923 50-002 JANUARY 1997 SIN X935-97051

Serial Number Location . .

1 2

The CONDOR® Model V20331XL 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 .

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MANUAL 92350-002 JANUARY 1997 SIN X935·97051

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This Page Intentionally

Left Blank

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MANUAL 923S0-002 JANUARY 1997 SIN X93S-970S1

)

HYDRAULIC SYSTEM DESCRIPTION

•

The following is a detailed description of the 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 V20331XL 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 of the open-center valve type, meaning that the hydraulic fluid circulates back to the tank when the pump is running and no functions are being operated. All lift and drive functions can be performed from the platform console, while ONLY lift functions are available from the lower control console.

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

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

)

DO NOT MIX HYDRAULIC FLUIDS.

MANUAL 92350-002 JANUARY 1997 SIN X935-97051

•

PUMP/MOTOR

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 of the pump is only used for drive, while the other pump section supplies fluid for steering, lift, or to increase the drive speed when directed to the drive circuit.

HYDRAULIC TANK ELECTRIC MOTOR

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 avariety of cartridge valves to achieve the operation of the cylinders and motors for the machine functions. These individual functions are described in detail below.

Batteries

Ground Controls

Main Valve Assembly

Battery Charger

FIG. 3

MACHINE FUNCTIONS

The hydraulic functions of the CONDOR® model V20331XL includes: forward and reverse drive with three selectable speeds at limited height, spring appliedlhydraulically released brake cylinders, left and right steering, and platform raising or lowering. Each of these functions are performed by the main valve assembly via electrical control signals. A detailed description of the electrical controls and their circuits can be found in the Electrical System Description of this maintenance section.

DRIVE FUNCTION

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

\) MANUAL 92350·002 JANUARY 1997 SIN X935·97051

~------------~~--------------------~~ Drive Directional Control Valve

Control Valve

r-----,

Flow Divider/Combiner

Valve

Creep Speed Solenoid Valve

Creep Speed Needle Valve

FIG. 4

DRIVE FUNCTION (cont'd)

Pump flow circulates through the main valve assembly and back to tank if no functions are activated when the pump is running. Once the directional control valve shifts, fluid is directed to one of the 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 V2033IXL 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 of hydraulic section).

,) MANUAL 92350'()02 JANUARY 1997 SIN X93S-970S1

•

DRIVE FUNCfION (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 ofwhich 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

Steer Directional Control Valve

Check Valve Cartridge

Creep Valve

FIG. 5

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

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

Connecting Arm Steer Cylinder

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

This will direct fluid from the P2 pump to the 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 of the machine, under the rear bumper plate. Descent speed is controlled by a flow control valve (See FIG. 3), in which clockwise rotation decreases descent speed, while counterclockwise rotation increases the descent speed.

MANUAL 92350-002 JANUARY 1997 SIN X935-97051

()

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 "GI" 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 "RVI" to 2700 psi while observing the gauge reading from the "GI" port.

After setting, lock the adjustment screw with the j am nut.

High Drive Pressure Adjustment

1.

2.

)

3.

4.

Select high speed at upper control box.

Observe the pressure reading at the "GI" 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, "CBI" and "CB2", are factory set. If they are not functioning properiy, 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 "FCI" to obtain a 25-35 second descent from a fully raised position.

) MANUAL 92350-002 JANUARY 1997 SIN X935·97051

-""-"

-~'---"

•

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

1.

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

2.

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

3.

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

4.

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

5.

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

"G2" Gauge Port (Reads Steer!lift!

High Drive Pressure)

-7+-+----

"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 92350·002 JANUARY 1997 SIN X935·97051

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) MANUAL 92350-002 JANUARY 1997 SIN X935-97051

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 The model V2033 IXL scissor uses four, 6 volt DC batteries, each having a 23 5 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 off of a 115 volt alternating current (Ae), 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 of the charger can be found in the Battery Charger Troubleshooting Guide beginning on page 67.

Main Manifold Assembly

FIG. 9

CIRCUIT BREAKER/FUSE

)

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

MANUAL 92350-002 JANUARY 1997 SIN X935-97051

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

Pump/MotorContactor Electric Motor

LOWER CONTROL FUNCTIONS Located above the left rear wheel is the lower control box, which provides a junction :r Emergency Stop Button connection through the use of two 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 of the lift function only; drive is not available from this control box. The lower control box a 15 Amp Circuit Breaker/Fuse contains an emergency stop button which must be 4 pulled out to supply power to both control boxes.

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

EMERGENCY

PLATFORM

RAISE

LOWER

OPP

CONTROLS

:

LOWER

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

MANUAL 92350-002 JANUARY 1997 S/N )C935-97051

UPPER CONTROL FUNCTIONS (cont'd)

PositractionButton (black)

Cut-Away View of Slip-Fit Insert

Emergency Stop Button /

_____ m

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Lift Controls

Power Button (green)

Cable Harness Plug

Drive Controller w/Steer Rocker Switch Drive Speed Selector

Hidden View of Slip-Fit Insert

FIG. 15

Integrated in the forward edge of the drive handle is a grip lever which is a substitute for the foot switch commonly used on other machines. The grip lever must be squeezed to perform drive (movement of the handle), or steer (activation of the rocker switch) functions. This lever, however, does not affect the lift controls. Movement of the drive handle 13° in either direction will 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 92350-002 JANUARY 1997 SIN X935-97051

•

NOTES

)

) MANUAL 92350-002 JANUARY 1997 SIN )(935-97051

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

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

5°SLOPE ALARM (OPTION)

)

This option sounds an alarm when the V2033!XL is 50 or more out oflevel. A 50 omni-directional sensor is mounted in the belly pan to sense a 50 out-of-level condition. In this situation, a fast pulse/loud tone alarm at the upper control box (See FIG. 13), is activated until the machine is returned to a less than 50 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 50 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 (50 or greater), the sensor's white wire (connected to the alarm), becomes grounded after a few second delay, through circuits inside the sensor.

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

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

Slope Alann 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 of the upper control box (See FIG. 14). The hom is only operable when the control selector switch is in the "UPPER" position.

MANUAL 92350·002 JANUARY 1997 SIN X935·97051

•

LOW VOLTAGE BATTERY PROTECfION SYSTEM (OPTION)

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

Terminal 7 of the module is the battery input voltage, while terminal 6 is machine ground. Terminals 1 & 2 are normally open contacts which close during a low voltage condition and turns on an amber indicator light (pushbutton) at the upper control box. The system can be overridden by pressing the pushbutton on the side of the upper control box (See FIG. 14), which energizes terminal 5 of the 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 25.5 volts during re-charging.

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

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 of the platform. The alarm signal is activated from two different circuits; one energizes the pump motor contactor, and the other energizes the holding valve for platform lowering (pump not running). A diode is used in each circuit to prevent unintended feedback.

HOUR METER (OPTION)

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

MANUAL 92350·002 JANUARY 1997 SIN X935-97051

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This Page Intentionally

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) MANUAL 92350-002 JANUARY 1997 SIN X935-97051

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

Suggested battery tools and their use are described below.

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

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

BATTERY CARRIER

)

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

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

CAUTION Low battery voltage (discharged) requires higher current draw to do the same work. This high current draw WILL DAMAGE the electric motor, relay contacts and the batteries. DO NOT OPERATE theCONDOR® with a battery DISCHARGED or that has a specific gravity of 1.130 or LESS. Routine servicing of the battery should proceed as follows: First, make a visual inspection for defective cables, loose connections, corrosion, cracked cases or covers, loose hold-downs and deformed or loose terminal posts. If any parts such as cables, hold-downs or the battery appear to be unserviceable, it is recommended that they be replaced.

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

MANUAL 92350-002 JANUARY 1997 SIN X935·9705!

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

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

The second item in routine servicing of conventional batteries is to check the electrolyte level in all cells. 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" (13mm) above the tops of the separators. Do not overfill any cell. When a cell is overfilled, the excess electrolyte may be forced from the cell by the gas formed in the battery. This will cause excessive corrosion of adjacent metal parts, reduced performance and shorter life.

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

STEP 1 - VISUAL INSPECTION For protection, wear a face shield. First, visually inspect the battery. Check for container, cover or terminal damage that might cause leakage of electrolyte or internal damage. If serious damage is found, replace the battery. Check the electrolyte level in each cell. Ifbelow the tops of the plates in any cells, fill all cells with water to just above the tops of the separators and charge for 15 minutes at 1525 amps to mix the water with the electrolyte. If electrolyte levels are above the tops of the plates, continue to Step 2.

) .

STEP 2 - HYDROMETER TEST Using the hydrometer, measure and record the specific gravity (sp. gr.), corrected to 80 degrees F (26.7C) ofthe electrolyte in each cell. If the range (highest-lowest) is 50 points (0.050 sp. gr.) or greater or the lowest is less than 1.225 sp.gr., charge the battery at the recommended rate or until all cells are 1.225 sp.gr. or greater and the range is less than 50 points. If no amount of charging will achieve these

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 VENTI LATED 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 92350-002 JANUARY 1997 SIN X935·97051

)

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

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

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

A.

Disconnect battery cables starting with ground cable.

B.

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

C.

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

D.

Connect current transducer (if necessary) to appropriate lead.

E.

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

F.

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

G.

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

H.

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

I.

If test voltage is below minimum, replace battery.

)

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

STEP 1- VISUAL INSPECTION

)

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

MANUAL 92350-002 JANUARY 1997 SIN X935-97051

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

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

A.

Disconnect battery cables starting with ground cable.

B.

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

C.

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

D.

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

E.

Apply test load for 15 seconds.

F.

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

G.

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

H.

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

)

STEP 3 - OPEN CIRCUIT VOLTAGE TEST If the battery failed the load test, the state of charge must be checked. If a hydrometer is not available, the stabilized open circuit voltage can be used to indicate the state of charge. Allow at least 10 minutes after the load test for the voltage to stabilize, then measure and record the open circuit voltage.

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

F.)

OPEN CIRCUIT VOLTS

PERCENT CHARGE

12.6 or greater 12.4 - 12.6 12.2 - 12.4 12.0 - 12.2 11.7 - 12.0 11.70rIess

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. If the state of charge is less than 75%, the battery should be charged at the recommended rate and time, and the load test repeated. If the battery passes the load test, return it to service. If it fails the load test again, replace it and refer to the next chapter to determine, the cause of failure.

MANUAL 92350·002 JANUARY 1997 SIN X935·97051

,)' .

DETERMINING CAUSES OF BATTERY FAILURE

•

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

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

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

The following should be checked: 1.

Corroded Battery Terminals or Connectors

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

2.

Electrical Circuit Leakage

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

Check for leakage using one of the following methods.

A.

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

B.

Ohmmeter - Disconnect the positive cable at the battery. Connect anohmmetertothe disconnected cable end and to the chassis. A resistance measurement of under 100 ohm indicates aload of 0.1 amp or more and indicates the equipment electrical system should be tested and repaired.

C.

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

)

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

3.

Charging System

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

) MANUAL 92350'()02 JANUARY 1997 SIN )(935·97051

FIGURE: X

SATTERY TESTING CHART STE P1

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

IOBVIOUS DAMAGE I

I NO OBVIOUS DAMAGE I

I REPLACE BATTERYI

I CHECK ELECTROLYTE LEVELl

I

BELOWTOP OF PLATES IN ONE OR I MORE CELLS

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

I

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

STE P2

I HYDROMETER TEST I

I

J

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

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

I

I I RECHARGE I

/DISCHARGE AT 150 AMPS FOR 15\ SECONDS

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

I

I CONTINUE TO STEP 31

)

I

IREPLACE BATTERyJ I LOAD TEST I

STEP 3

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

I I

I

I VOLTAGE BELOW CHART VALUEI

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

I I REPLACE BATTERyl VOLTAGE CHART ESTIMATED ELECTROLYTE TEMPERATURE

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

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

9.6 9.5 9.4 9.3 9.1 8.9 8.7 8.5

MANUAL 92350·002 JANUARY 1997 SIN X935-97051

)

FIGURE:Y

SATTERY TESTING CHART STEP 1

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

I I

I

IOBVIOUS DAMAGE I

NO OBVIOUS DAMAGE I

I

I

\ REPLACE BATTERY\

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

. STEP 2

I FIXED LOAD TESTI

I 1. ATTACH TESTER CLAMPS TO BATTERY TERMINALSIN 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 OaF, -18°C).

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

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

I

I

I

I

)

IPROCEED TO STEP 3 I STEP 3

I

BATTERY PASSES LOAD TESl1 RETURN TO SERVICE. I

\ BATTERY FAILS LOAD TESTJ

\ OPEN CIRCUIT VOLTAGE TESlj

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 DID NOT PASS THE LOAD TEST, IT SHOULD BE REPLACED - THEN PROCEED TO STEP 4.

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

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

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

MANUAL 92350-002 JANUARY 1997 SIN X935-97051

NOTES

)

) MANUAL 92350-002 JANUARY 1997 SIN X935-9705\

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

Procedure:

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

IMPORTANT: If damage is evident, remove the CO NDOR® 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 tum, tum spindle nut counterclockwise one castellation, or until cotter pin will pass through spindle and spindle nut. Secure cotter pin, ensure that hub will rotate. Reinstall wheel assembly; torque wheel nuts to 120 ft lbs.

MANUAL 92350-002 JANUARY 1997 SIN X935-97051

•

2.

Hydraulic System Fluid Level:

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

Return Filter:

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

Tank Breather:

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

Hydraulic Tank:

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

Suction StrainerMDL, MD1, ANDMDC:

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. 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 the charging cycle is complete.

)

) MANUAL 92350·002 JANUARY 1997 SIN X935·97051

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 tom, 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 92350·002 JANUARY 1997 SIN X935·97051

•

c.

OPERATIONAL TEST Instrument C h e c k ) 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 retum 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 retum 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 92350-002 JANUARY 1997 SIN X935-97051

PREVENTIVE MAINTENANCE DAILY INSPECTION MON

ITEM

TUES

WED

HOURS

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

--'

FRI

SAT

SUN

Z 1// / / / / /

I

VISUAL INSPECTION

-,

THURS

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

.-'1

MANUAL 92350-002 JANUARY 1997 SIN X935-97051

•

PREVENTIVE MAINTENANCE INSPECTION 50 HOUR INSPECTION A.

CHASSIS Visual Inspection:

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

Steering Cylinder:

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

Steering Connecting Arm:

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

Steering Knuckles:

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

Wheels:

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

Drive Motors:

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

Brake Cylinders:

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

Inspect cylinders and retaining bolts for damage and proper installation.

Hydraulic Hoses and Fittings:

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

Tires:

Inspect for excessive or abnormal wear, cuts and abrasions.

Belly Pan:

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

Battery Charger:

Inspect for damage. Verity 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 923S0-002 JANUARY 1997 SIN X93S-970S1

)

B.

ARMSTACK Visual Inspection: Lift Cylinder Hoses and Fittings:

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.

Limit Switch:

UpperlLower Electrical Junction:

) Armstack Bearing Pads (chassis):

Inspect cylinder pins and retaining bolts for security.

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

Remove terminal strip cover and inspect wiring for corrosion and tightness. If rust or corrosion are present, clean with a wire brush and coat terminal connections with a spray corrosion inhibiter or high temperature grease.

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

)

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

Electrical Cable:

Lift Cylinder Pins and Retaining Bolts:

C.

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

•

Platform Entrance Lift Gate and Latch Assemblies:

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

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

MANUAL 92350-002 JANUARY 1997 SIN X935-97051

•

C.

PLATFORM (conttd) Extension Deck and Latch Assembly:

Electrical Cable:

D.

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

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

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 92350-002 JANUARY 1997 SIN X935·97051

PREVENTIVE MAINTENANCE 50 HOUR INSPECTION MON

ITEM

I

TUES

WED

Visual Inspection Steering Cylinder Steering Connecting Arm Steering Knuckles Wheels Drive Motors Brake Cylinders Hydraulic Hoses and Fittings Tires ~-"

)

Belly Pan

~-'

Battery Charger Wiring and Electrical Connections Electric Motor and Pump

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

PLATFORM

J

FRI

SAT

SUN

rzV IVV V IVV IV HOURS

CHASSIS

THURS

Visual Inspection

MANUAL 923 50-002 JANUARY 1997 SIN X935-97051

•

PREVENTIVE MAINTENANCE 50 HOUR INSPECTION

;)

(cont'd) MON

ITEM

rz /

I

HOURS

TUES

WED

THURS

FRI

SAT

SUN

/ ; // 1// /

PLATFORM (cont'd)

Platfonn Pivot ShaftslRetaining Bolts Platfonn Bearing Pads Platfonn Entrance Lift GatelLatches Extension Deck and Latch Assembly Electrical Cable Manual Storage Container MDL MOl and MDe Models

LOWER CONTROL BOX Visual Inspection--External Visual Inspection--Internal

/~)

Manual Tube Holder MDDModels

UPPER CONTROL BOX Visual Inspection--External Visual Inspection--Intemal

) MANUAL 92350-002 JANUARY 1997 SIN X935-9705J

HYDRAULIC FLUID SPECIFICATIONS FOR CONDOR® AERIAL WORK PLATFORMS

Shell Tellus - T32 Hydraulic Fluid

Viscosity SUS@ 100°F SUS@210°F

155 47

Viscosity Index

154

Flash Point of

325°

Pour PointOF

-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.a. Hydraulic #23

CAUTION

DO NOT MIX DIFFERENT FLUIDS

) MANUAL 92350-002 JANUARY 1997 SIN X935-97051

•

NOTES

)

/

MANUAL 92350-002 JANUARY 1997 SIN X935-97051

.)

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

CAUTION REPAIRS BY QUALIFIED PERSONNEL ONLY.

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

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

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

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

) MANUAL 92350-002 JANUARY 1997 SIN X935-97051

•

PARTA-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.

WARNING If the plug or receptacle is broken, twisted, bent or loose and does not make good electrical contact, have it replaced by a qualified serviceman immediately DO NOT USE THE CHARGER IN THIS CONDITION AS FIRE OR PERSONAL INJURY CAN RESULT.

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

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

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

MANUAL 92350·002 JANUARY 1997 SIN X935-97051

)

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 ofthe 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. Ifthe circuit is not complete, individually check the continuity of the power supply cord, primary transformer coil and all connections.

PART B - RELAY CLOSES BUT NO TRANSFORMER HUM AND AMMETER DOES NOT REGISTER Check to be sure the power supply cord is securely connected to a live AC outlet. When three-prong to two-prong adapters are used, they tend to work loose resulting in a poor connection. Check the AC line fuse or circuit breaker and, if possible, measure the AC line voltage at the outlet to be sure AC power is present.

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

)

If AC poweris 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. Ifthe circuit is not complete, check the wiring of the power supply cord, transformer primary coil leads and the Electronic Timer Kit. Ifthe charger is wired correctly, individually check the continuity of the power supply cord, transformer primary coil and relay.

PART C- RELAY CLOSES AND TRANSFORMER HUMS BUT AMMETER DOES NOT REGISTER If the relay closes and the transformer hums, the charger AC circuit and Electronic Timer Kit are functioning properly. Ifthe ammeter does not register, a fault in the charger DC circuit exists and a continuity check must be performed. Disconnect the power supply cord from its outlet and the DC output connector from the battery connector, and check the charger fuse. If a fuse link is blown, refer to Section 2 - "Charger Fuse Blows" for further tests. If the fuse checks good, use a low voltage continuity tester to perform the following tests: 1.

Connectthe 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. If the 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 92350·002 JANUARY 1997 SIN X935·97051

•

2.

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

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

OPEN CAPACITOR - When the ohmmeter leads are connected to the capacitor terminals, the meterneedle 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.Ifthe capacitor is open or shorted, it must be replaced.

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

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

)

3.

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

PART D - ELECTRONIC TIMER KIT REPLACEMENT The Electronic Timer Kit should always be replaced as a complete assembly. The tools required are: a Phillips head screwdriver, 3/8" and 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 pane1. 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 92350·002 JANUARY 1997 SIN X935·97051

)

•

Connect the black lead of the power supply cord to tenninal # I on the Electronic Timer Kit and the white lead of the power supply cord to tenninal #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 tum when tightening the nut. Reconnect the green wire of the Electronic Timer Kit along with the transfonner secondary lead to the diode lead terminal.

CAUTION Be sure all connections are clean and tight. Also check to be sure all wires and tenninals 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 if one or both fuse links are blown and refer to Part A or PartB fortestprocedures.

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

MANUAL 92350-002 JANUARY 1997 SIN X935-97051

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

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

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

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

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

MANUAL 92350-002 JANUARY 1997 SIN X935·97051

SECTION 3 - AMMETER READS 30 AMPS FOR MORE THAN 30 MINUTES

This high output condition is caused by misuse, connecting the charger to an incorrect battery system which is lower than 24 volts. A common error is to install one or more of the 6 volt batteries in a 24 volt battery pack reverse polarity. Using a suitable DC voltmeter, test to be sure all batteries in a battery pack are correctly wired and also test the battery pack voltage at the charging connector. After charging for 3 0 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 of one diode. Refer to Section 2 - "Charger Fuse Blows" for troubleshooting procedures. On rare occasions a short circuit failure of the transformer coils may cause the output to be low. Refer to section 7 - «Transformer Short or Burn Out" for test procedures.

CAUTION

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

SECTION 5 - CHARGER TURN OFF MALFUNCTIONS

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

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

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

) MANUAL 92350·002 JANUARY 1997 SIN X935-97051

•

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 s u p p l y , . outlet is live, proceed with the next step. ) To determine if the charger did shut off too soon, disconnect and reconnect the charger DC output connector. This will restart the charger. Observe charger output on the ammeter.

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. If the specific gravity readings are more than 30 points (.030) lower than normal full charge readings, the electronic timer has malfunctioned and the complete Electronic Timer Kit must be replaced. Refer to Section 1, Part D - "Electronic Timer Kit Replacement" for correct procedures.

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

As batteries age, individual cells may weaken, causing a reduction in battery capacity. This condition normally results in a finish charge 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 off too soon. The battery is aging naturally and the charger is working properly. When the batteries will no longer perform as required, they should be replaced.

PART B -

CHARGER DOES NOT TURN OFF

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

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

MANUAL 92350·002 JANUARY 1997 SIN X935·97051

' )

•

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

If a precision digital type DC voltmeter is available, a test to verify that the Electronic Timer has malfunctioned can be made. Connect the charger to the batteries and allow to charge normally. After the charge rate has tapered to its lowest point, measure the battery terminal voltage using a DC voltmeter capable of reading in increments of. 00 1 volts. Continue charging and check the battery voltage reading every hour. If the battery voltage increases less than. 0 12 volts, or if the battery voltage decreases between successive hourly readings, the charger should turn off If the charger does not turn off, the Electronic Timer has malfunctioned and the complete Electronic Timer Kit must be replaced.

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

SECTION 6 - AC LINE FUSE OR CIRCUIT BREAKER BLOWS

)

If this occurs when the charger power supply cord is connected to an oudet, 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 oudet and the DC output connector from the battery connector, then check to be sure the Electronic Timer Kit is NOT bypassed. With a suitable continuity tester, check the circuit across the power supply cord prongs as shown. THE CIRCUIT SHOULD NOT BE COMPLETE. If the circuit is complete, check the relay contacts to be sure they are open and have not welded closed. If the relay contacts are open, the power supply cord is shorted and must be replaced. If the 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 adj acent 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 of lower voltage than specified on the charger (See Section 3). Darkening of all the transformer secondary coil windings is an indication of possible overheating damage. A low or complete lack of output would be observed on the ammeter, however, the transformer may hum or the AC line fuse or circuit breaker may blow when the charger is turned on. To test the transformer, disconnect the power supply cored from its oudet 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 92350-002 JANUARY 1997 SIN X93S-970S1

•

DANGER

!)

HIGH VOLTAGE: With the charger operating, the charger capacitor voltage is approximately 650 volts AC. Use extreme caution when worldng 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. If the 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 suitableAC voltmeter. Ifthe measured voltages are substantially lower than those shown, the transformer is shorted internally and must be replaced.

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

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

.)

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

) MANUAL 92350-002 JANUARY 1997 SIN X935-97051

APPENDIXA

A div. of TIME Manufacturing Company

BOLT TORQUE CHART BASIC STRESS

lENSILE STRENGTII (T) MIN

MAJOR AREA

PROOF LOAD (P)

SQ. IN

SAE GRADE (1951)

NOMINAL

DJA

lHREADS

INCH

GRADE 5

SAE GRADE 5

GRADES

CLAMP

ASSEMBL YTORQUE R=.2OODRY -.150LUB

SAE GRADE 8 CLAMP

ASSEMBL YTORQUE

4-40

.1120

.00604

120KSI 85KSI

150KSI

120KSI

LOAD LBS. 380

8LB-IN

6LB-IN

LOAD LBS. 540

12LB-IN

9LB-IN

4-4lS

.1120

.00661

120KSI

85KSI

150KSI

120KSI

420

9LB-IN

7LB-IN

600

13LB-IN

IOLB-IN

b-:H

.1380

..00909

120KSI

b-4U

.1380

T

.01015

P

T

P

R~.200DRY

R~.15OLUB

8SKSI

l50KSI

120KSI

580

16LB-IN

12LB-IN

820

23LB-IN

17LB-IN

120KSI 8SKSI

150KSI

120KSI

640

ISLB-IN

13LB-IN

920

25LB-IN

19LB·IN

8-32

.1640

.01400

120KSI 85KSI

150KSI

120KSI

900

30LB-IN

22LB-IN

1260

41LB-IN

31LB-IN

lS-~b

;1640

.01474

120KSI 85KSI

150KSI

120KSI

940

31LB-IN

23LB-IN

1320

43LB-IN

32LB-IN

10-24 10-32 114-20

.1900

.01750

120KSI 8SKSI

150KSI

120KSI

1120

43LB-IN

32LB-IN

1580

6OLB-IN

45LB-IN

.1900

.0200

120KSI

8SKSI

150KSI

120KSI

1285

49LB-IN

36LB-IN

1800

68LB-IN

51LB-IN

.2500

.03180

120KSI

85KSI

l50KSI

120KSI

2020

8LB-FT

75LB-IN

2860

12LB-FT

9LB-FT

lI4-:llS

.2500

.03640

120KSI 85KSI

l50KSI

120KSI

2320

10LB-FT

86LB-IN

3280

14LB-FT

10LB·FT

)/ Ib-llS

.3125

.05240

120KSI

150KSI

120KSI

3340

17LB-FT

13LB-FT

4720

25LB-FT

18LB-FT

.3125

.05800

120KSI 85KSI

l50KSI

120KSI

3700

19LB-FT

14LB-FT

5220

25LB-FT

20LB-FT

.3750

.07750

120KSI 8SKSI

150KSI

120KSI

4940

30LB-FT

23LB-FT

7000

45LB-FT

35LB-FT

5/16-24 3/8-16 3/8-24 7/17-14 7/16-20 112-13 112-20 9/16-12 9/16-18

85KSI

.3750

.08780

120KSI 8SKSI

150KSI

120KSI

5600

35LB-FT

25LB-FT

7900

50LB-FT

35LB-FT

.4375

.10630

120KSI

85KSI

150KSI

120KSI

6800

50LB-FT

35LB-FT

9550

70LB-FT

55LB-FT

.4375

.11670

120KSI 85KSI

150KSI

120KSI

7550

55LB-FT

4OLB-FT

10700

80LB-FT

6OLB·FT

5000

.14190

120KSI

8SKSI

150KSI

120KSI

9050

75LB-FT

55LB-FT

12750

110LB·FT

8OLB·FT

5000

.15990

120KSI

8SKSI

150KSI

120KSI

10700

90LB-FT

65LB-FT

14400

120LB-FT

9OLB-FT

.5625

.18200

120KSI 8SKSI

150KSI

120KSI

11600

1l0LB·FT

80LB-FT

16400

15OLB·FT

110LB-FT

.5625

.20300

120KSI 8SKSI

150KSI

120KSI

12950

120LB-FT

90LB-FT

18250

170LB-FT

130LB-FT

;)flS-l1

.6250

.22600

120KSI 85KSI

150KSI

120KSI

14400

15OLB-FT

1l0LB-FT

20350

220LB·FT

170LB-FT

5/8-18 3/4-10 3/4-1b 7/8-9 7/8-14 1-8 1-12 1 1/8-7 1118-12 11/4-7 1 1I4-12 13/8-6 13/8-12 1 1I2-6 1 112-12

.6250

.25600

120KSI

8SKSI

150KSI

120KSI

16950

18OLB-FT

13OLB-FT

23000

24OLB-FT

180LB-FT

.7500

.33400

120KSI 8SKSI

150KSI

120KSI

21300

260LB-FT

200LB-FT

30100

38OLB-FT

280LB-FT

.7500

.37300

120KSI

85KSI

150KSI

120KSI

23800

300LB-FT

220LB-FT

33600

420LB-FT

320LB-FT

.8750

.46200

120KSI

85KSI

150KSI

120KSI

29500

520LB-FT

390LB-FT

41600

600LB-FT

460LB-FT

.8750

50900

120KSI 85KSI

150KSI

120KSI

32400

570LB-FT

43OLB-FT

45800

660LB-FT

500LB-FT

1.000

.60600

120KSI 85KSI

150KSI

120KSI

38600

770LB-FT

58OLB-FT

54500

9OOLB-FT

680LB-FT

1.000

.66300

120KSI 8SKSI

150KSI

120KSI

42300

85OLB-FT

63OLB-FT

59700

l000LB-FT

740LB-FT

1.1250

.76300

10SKSI

74KSI

150KSI

120KSI

42300

800LB·FT

6OOLB·FT

68700

1280LB-FT

96OLB-FT

1.1250

.85600

IOSKSI

74KSI

150KSI

120KSI

47500

88OLB-FT

66OLB-FT

77000

1440LB-FT

108OLB-FT

12500

.96900

10SKSI 74KSI

150KSI

120KSI

53800

1120LB-FT

84OLB-FT

87200

1820LB-FT

1360LB-FT

1.2500

1.0730

105KSI

74KSI

150KSI

120KSI

59600

1248LB-FT

920LB-FT

96600

2000LB-FT

OOLB-FT

13750

1.1550

lOSKSI

74KSI

150KSI

120KSI

64100

1468LB-FT

1100LB-FT

104000

2380LB-FT

8OLB-FT

1.3750

13150

105KSI

74KSI

150KSI

120KSI

73000

1680LB-FT

1260LB-FT

118400

2720LB-FT

204OLB-FT

15000

1.4050

105KSI 74KSI

150KSI

120KSI

78000

1940LB-FT

1460LB-FT

126500

3160LB-FT

2360LB-FT

15000

1.5800

105KSI 74KSI

l50KSI

120KSI

87700

2200LB-FT

1640LB-FT

142200

3560LB-FT

2660LB-FT

N01ES:

l.1HIS CHART SHOWS RECOMMENDED BOLT TORQUES. 2. TORQUE = R X D X T R = .150 FOR LUB CONDITIONS R = .200 FOR DRY CONDmONS 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 92350-002 JANUARY 1997 SIN X935-97051

APPENDIXB

A div. of TIME Manufacturing Company

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

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

PROPERTY CLASS 8.8

PROPERTY CLASS 9.8

PROPERTY CLASS 10.9

PROPERTY CLASS 12.9

DIAMETER

DRY LUBRICATED THREADS THREADS

DRY THREADS

LUBRICATED THREADS

DRY THREADS

LUBRICATED THREADS

DRY THREADS

LUBRICATED THREADS

M4

27.5*

17*

30*

18*

38.5*

24*

53*

32.5*

M5

56.5*

33.5*

61*

37*

78*

47*

107*

65*

M6

95*

57.5*

103*

61*

132*

79*

180*

109*

M8

19

12

21

13

27

16

37

22

MlO

39

23

42

25

53

32

73

44

M12

67

40

73

44

92

55

127

76

M14

107

64

116

69

146

89

203

122

M16

167

100

181

108

230

138

316

190

M20

325

195

352

211

449

269

617

370

M24

562

337

609

386

775

465

1066

640

M30

1117

670

1210

726

1540

924

2188

1271

MANUAL 92350-002 JANUARY 1997 SIN X935·97051

)

SELF-PROPELLED ELEVATING WORK PLATFORM

MODEL V2033XL, V2033 Serial Number X935-970S1

ILLUSTRATED PARTS MANUAL

)

SHIPPINGADDRESS

MAILING ADDRESS

TIME CONDOR

TIME CONDOR

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

WACO, TEXAS 76702-1447

P.O. Box 21447 (254) 420-5200

MANUAL92350-003 January 1997 SIN X935-97051 Parts Book Revised 1199

_--------

()

c

(

'-

'\

i

INTRODUCTION

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

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

It is also YOUR RESPONSmILITY to understand and obey all federal, state, and local regulations regarding the operation and use of aerial work platforms. A copy of the ANSI/SIA 92.6-1990 Manual of Responsibilities is attached for your use.

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

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

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

NOTE:

Please refer to the Condor Parts section of the Operation, Maintenance, & Parts Manual for information pertaining to your machine.

MANUAL 92350-003 Janwuy 1997 SIN X935-97051

II

CONDOR® SERVICE INFORMATION

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

(254) 420-5200 Telephone (254) 420-5299 Voice Mail (800) 443-5803 FAX

2.

There are numerous written Maintenance Procedures availabl e for this CONDO R®.

Theseprocedures are available through the Condor Service Departmentto 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 servi ce or sales persons for a schedule. Remember, training of mechanics is the responsibility oftheir employer, but Condor Service Schools help youprovidethis 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-propell ed models; and #92334 for truck-mountedmodels.

)

TIME CONDOR

) 8300 IMPERIAL DRIVE,

P.o. Box 21447, WACO, TEXAS 76702-1447<254-420-52005, 254666-4544 FAX

•

CONDOR® MODEL V2033XL & V2033 ILLUSTRATED P ARTS MANUAL TABLE OF CONTENTS IN'fRODUCTION .................................................................................................................. i SERVICE INFORMATION ........••.•••............•........•.........................•.....••..••................. ii SERIAL NUMBER TO MODEL DESIGNATION •.........••••.....••......••......................... iii TABLE OF CONTENTS............................................................................................... 1 FIGURE

DESCRIPTION

PAGE

A .................................................. SerialNumber Location ................................................... 2 B .................................................. RecommendedSpare Parts List ........................................ 3 C .................................................. Howto Order Parts ...................................................... 4,5 1.1 .................................................. FinalInstallation V2033XL ............................................... 6 1.2 .................................................. Final Installation V2033 .................................................... 8 2.1 .................................................. DecalInstallation ............................................................ 10

)

3.1 .................................................. Chassis Assembly V2033XL ............................................ 12 3.2 .................................................. Chassis Assembly V2033 ......................•.......................... 14 3.3 .................................................. Hose Kit ..................................................•..................... 16 3.4 .................................................. Lift Cylinder ................................................................... 18 3.5 .................................................. Steer Cylinder ................................................................. 19 3.6 .................................................. BrakeCylinder ................................................................ 20 3.7 .................................................. HubMotorAssembly ..................................................... 21 3.8 .................................................. Hub Assembly ................................................................ 22 3.9 .................................................. Tube Kit ................. ,...................................................... 23 3.10 .................................................. BellyPanAssembly ......................................................... 24 3.11 .................................................. Motor & Pump Assembly .............................................. 28 3.12 .................................................. Pump Assembly ............................................................. 29 3.13 .................................................. Motor24VDCAssembly ............................................... 30 3.14 .................................................. Valve Installation ............................................................ 32 3.15 .................................................. Valve Assembly .............................................................. 34 3.16 .................................................. Charger 115V/25A ........................................................ 36 3.17 .................................................. Charger 115V/25AMod ................................................ 37 3.18 .................................................. Charger 115V/60HZ-25A124VDC ................................ 38 3.19 .................................................. Electrical Wiring ............................................................. 40 4.1 .................................................. Lower Control Box Assembly ........................................ 42 5.1 .................................................. ArmstackAssembly ........................................................ 50 5.2 .................................................. Armstack Cylinder .......................................................... 56 5.3 .................................................. ManifoldAssembly ......................................................... 58 5.4 .................................................. Manifold ........................................................................ 59 6.1 .................................................. Platform Assembly ......................................................... 60 6.2 .................................................. 110 Volt Extension To Platform ..................................... 63 6.3 .................................................. Upper Control Box Assemb ly ........................................ 64

n \o"""b

(9'l

,)

7.1 .................................................. Travel Alarm (Option) ...................................................' 6 7.2 .................................................. Motion ~larm (Ol?tion) ................................................. .". "10 7.3 .................................................. StrobeLlght(Option) .................................................... 6 - 7 ( 7.4 .................................................. DescendAlarm(C?ption) ................................................ 9 .,. '12" 7.5 .................................................. SlopeAlarm (Option). ····················································1..., S 7.6 .................................................. Hour Meter (XL-Option) .............................................. 1 ." 7 i.L 7.7 .................................................. BatteryConditionIndicator(XL-Option) ....................... ... '7 T 7.8 .................................................. Low-Voltage Warning Interrupt (Xt-Option) ................. ., 7.9 .................................................. Larger Batteries IPOS (XL-Option) ...............................

- 7b

75

MANUAL 92350-003 January 1997 SIN X935-97051

FIGURE A-Serial Number Location

•

1 2

)

The CONDOR®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 thefront steering knuckle kingpin.

......

. .. "

..

;"to:

\

MANUAL 92350-003

Janwuyl997 SIN X935-97051

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 ................................. CableAssembly,EmergencyLowering ............. 1 ....................•........ 1 54798 ................................. Couple Nut, 10-32UNF .................................. 1 ............................. 1 55471 ................................. Plunger, Hand Retract Spring ............................ 3 ............................. 3 55241 ................................. Spring Loaded Pull-Up Latch ........................... 3 ·............................. 3 54048 ................................. Latch Door ..................................................... 1 ............................. 1 67408 ................................. Element,HydraulicFilterP/N33430 ................ 5 ............................. 5 36085 ................................. Fitting, Swivel 900 Elbow 6-6 ........................... 2 ....................•........ 2 51036 ................................. Switch Limit Body Only ................................... 1 .................•..•........ 1 51037 ................................. OffsetHeadLimitSwitch ................................. 1 ............................. 1 51039-002 ...•....•................. LimitSwitch,ArmlShort ................................. 1 .........•..........•........ 1 54589 ................................. Controller, Drive/Steer .................................... 1 .......•............•.. N/A 67939-015 .......................... Fuse, 15Amp ................................................... 1 ............................. 1 67940 ................................. FuseHolder ..................................................... 5 ............................. 5 52138 •................................ Solenoid24V ................................................... 1 ............................. 1 206-00001-00 ..................... Diode .............................................................. 9 ............................. 9 54438 ................................. Relay, 24V SPD T Bosch ................................... 1 ............................. 1 34547 ................................. Jumper ............................................................. 4 ....................•.. N/A 34542 ................................. Jumper ...................................................... N/A ............................. 1 55982-002 .......................... Decal Installation .............................................. 1 .....................•. N/A 55982-102 .......................... Decal, V2033XLEssentiais ............................... 1 .......... ~ ............ N/A 55982-001 .......................... Decal Installation ........................................ N/A ............................. 1 55982-101 .......................... Decal, V2033 Essentials .............................. N/A ............................. 1 55469 ................................. HoseKit .......................................................... 1 ............................. 1 55243 ................................. Spring-DeckLatch ......................................... 1 ............................. 1 55333 ................................. Charger ........................................................... 1 ..........................•.. 1 54910-102 .......................... Receptacle ................................ ~ ....................... 1 ............................. 1 54910-104 ....•..................... Mouming ......................................................... 1 ....................... N/A 51913 ................................. Operator,RedP-Pull ........................................ 1 ............................. 1 51914 ................................. Base, 1 NC Contact ......................................... 1 .....................•....... 1 52670 ................................. Operator, 3 PosRot ......................................... 1 ....................... N/A 34464 ....•............................ Base, NO/NC Contacts ................................... 1 ....................... N/A 52669 ................................. Operator,BlackP-Button ................................. 1 ....................... N/A 52672 ................................. Base, 1 NO Contact, ........................................ 1 ....................... N/A 69146 ................................. Operator, GreenP-Button ................................ 1 ....................... N/A 54913 ................................. Operator BlacklBlackDoubleP-Button ........... 1 ....................... N/A 52029 ................................. Base, 2 NO Contacts ........................................ 1 ............................. 1 50075 ................................. Switch ............................................................. 1 ............................. 1 67758 ................................. ToggleSwitch ............................................ N/A ............................. 1 52671 ................................. Operator, 3 Pos Key .................................. N/A ............................. 1

MANUAL 92350-003 JanuaIY 1997 SIN X935-97051

•

FIGURE C-How to Order Parts 1.

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

Stock

(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 92350·003 JanuaI}' 1997 SIN X935-97051

•

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

I

}CCOUNT# I NAME N F ADDRESS 0 R M CITY A T I PHONE 0 ( ) N CUST. PURCHASE ORDER NO. C U S T 0 M E R

PURCHASER

SALES ORDER # NAME

STATE

S H I P

ZIP

FAX

( I

ADDRESS T 0

iPHONE

FAX

(

(

)

ORDER DATE

I

I

STATE

PTY

)

REQUEST DATE

I

ZIP

)

SPECIAL MARKS & NUMBERS

SHIPPING INSTRUCTIONS

PART NUMBER

QTY.

DESCRIPTION

)

FOR ORDER STATUS PLEASE CHECK APPROPRIATE BOX BELOW

1

EMERGENCY

STOCK MANUAL 92350-003 JanUlUY 1997 SIN X935-97051

NOTES

•

FIGURE 1.1: Final Installation

14

5

2

1-----1

)

15 3

7

4

12 13

6

/_) MANUAL 92350-003 January 1997 SIN X935-97051

FIGURE 1.1: Final Installation • 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

PARTNUMBER

DESCRIPTION

M-V2033XL-01 ........... Final Installation V2033/XL .................................................... Ref. 55441 .......................... Arm Stack Installation .................................................................. 1 55478 .......................... Platform Assembly ...................................................................... 1 55467 .......................... Chassis Assembly ........................................................................ 1 55468 ..~........................ BellyPan Assembly ..................................................................... 1 54918 .......................... 110VExt. To Platform Installation .............................................. 1 55315 .......................... WiringInstallation ........................................................................ 1 54783 .......................... CableAssembly,EmergencyLowering ........................................ 1 ................................... Oil,HydraulicTellusT32 ........................................................ 8Gl. [NotUsed] ....................................................................................................................... . ................................... Nameplate, ScissorIdent............................................................. 1 55482 .......................... Cover,LHSide ........................................................................... 1 55483 .......................... Cover, RH Side ........................................................................... 1 54048 .......................... Latch, Door ................................................................................ 2 55317 .......................... Box Assembly, Upper Control ................................................... 1 55489 .......................... Box Assembly, Lower Control .................................................... 1 55469 .......................... HoseKit ..................................................................................... 1 55982 .......................... Decal Installation ......................................................................... 1 67837-007 .................... Tie,Nylon7 1/ 2 Black ............................................................... 10 34354 .......................... Holder,SafetyManual-BlkCaps .................................................. 1 67793 .......................... Clamp, 2.75 Dia. Cable ............................................................... 2 BOW31401 .................. Washer,Flat.25 IDx.63"OD ..................................................... 2 BOW34272 .................. Nut,Hex.25-20UNCNylonLock .............................................. 2 92350-001 .................... Operator'sManual ...................................................................... 1 A630-V2033 ................ OplMaintIPrtsManual ............................................................... 1 55866 .......................... Elec. Schematic ........................................................................... 1 55309 .......................... Hyd.Schematic ........................................................................... 1 55486 .......................... Dwg. V2033 Final Assembly ....................................................... 1 55469 .......................... Dwg. V2033 Hose Kit ................................................................ 1 I

- Indicates Items Not Shown

MANUAL 92350-003 1anuaIY 1997 SIN X935-97051

•

FIGURE 1.2: Final Installation V2033

20

12

.,1---.----7

)

21

1

14

2 13

) MANUAL 92350-003 January 1997 SIN X935-97051

FIGURE 1.2: Final Installation V2033 • 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 -36 -37 -38 -39

PARTNUMBER

DESCRIPTION

QIY

M-V2033-01 ................ Final Installation V2033 ........................................................... Ref. 55955 .......................... Chassis Assembly V2033 ............................................................. 1 55958 .......................... BellyPanAssembly ..................................................................... 1 BOW30055 .................. Bolt,.38-16 UNCx 1.25 Hex ...................................................... 2 BOW30057 .................. Bolt,.38-16 UNCx 1.75 Hex ...................................................... 2 BOW36703 .................. Washer, .37 ID .81 OD Gr 8 SAE Flat ........................................ 4 BOW34274 .................. Nut, 3/8-16 UNC Hex Lock ...................................................... 4 55962 .......................... ArmstackInstallation ................................................................... 1 54616-009 ....•............... Pin, Arm 20.38" .......................................................................... 2 54701 ..........•.•............. Block,Armstack.Nylatron ........................................................... 2 54616-008 .................... Pin, Arm26.62" .......................................................................... 2 55279 .......................... Block,Slide ................................................................................. 2 55981 .......................... Platform Assembly ...................................................................... 1 55846 .......................... WrringInstallation ........................................................................ 1 54783-002 .................... Cable Assembly, EmergencyLowering ........................................ 1 ................................... HydraulicOilTexacoHDZ32 ................................................ 8Gl ............................•...... Nameplate,ScissorIdent...................•......................................... 1 55758 ...•...................... CoverWeldment,RHSide .......................................................... 1 55759 .......................... CoverWeldment,LHSide .......................................................... 1 54048 .......................... Latch, Door ................................................................................ 2 55850 .......................... Box Assembly, Upper Elec.......................................................... 1 55869-001 .................... Box Assembly, Lower Elec......................................................... 1 BOW39002 .................. Bolt, 1/4-20 x 3/4 Gr 8 Hex Hd ................................................ 4 BOW31401 .................. Washer,.25 ID x .63 OD Flat. ..................................................... 4 BOW34272 .................. Nut, 25-20UNC Nylon Lock ..................................................... 4 55469 .......................... HoseKit ..................................................................................... 1 55982 .......................... DecalInstallation ......................................................................... 1 67837-007 .................... Tie, 71/2" Black Nylon ............................................................ 10 34354 .......................... Holder Assembly,SafetyManual ........................•......................... 1 67793 .......................... Clamp, 2.75 DiaCable ................................................................ 2 BOW31401 .................. Washer,.25IDx.630DFlat. ....................................................... 2 BOW34272 .................. Nut, 25-20UNCNylonLock ..................................................... 2 92350-001 .................... Operator'sManual ...................................................................... 1 A630-V2033-1 ............. Manual,OplMaintlParts ............................................................ 1 55843 .....•.................... Schematic,Electric ....................................................................... 1 55309 ..............•........... Schematic,Hydraulic ................................................................... 1 55953 .......................... Dwg, M-V2033-01 Final Assembly .............................................. 1 55469-DWG ............... Drawing,HoseKit ...................................................................... 1 04-0175-57 .................. CONDORGreenGJ-5 .......................................................... 4G1.

04-0081-57 ......•........... Primer .................................................................................... 4GL

- Indicates Items Not Shown

.)

MANUAL 92350-003 Januaxy 1997 SIN X935-970S1

•

FIGURE 2.1: Decal Insta11ation

21

) PARTIAL SECTION A APPLIES TO ALL MODELS

12

/0

r !

ARM STAND

o

(

o

o o

o o

18

o

o o

REF

0 0

0 0

0

0 -0

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

000 0 0

000

0

0

0 0 0 0 0 0 000 000 0

) MANUAL 92350-003 January 1997 SIN X935-97051

FIGURE2.1:DecalInstallation PART NUMBER

Ref *1

*13 14 15 16 17 18 19 20 ""21

55982 .......................... Decal Installation .................................................................... Ref. 55890 .......................... Decal V Upper Operator Instructions V2033 ............................... 1 55889 .......................... Decal VXL Upper Operator Intructions V2033 XL .................... 1 55894 .......................... Decal, V General Caution ........................................................... 1 54652-003 .................... Decal, GuardraiVChain Caution .................................................. 1 55963-800 .................... Decal, 250/800 Rated Load ........................................................ 2 55963-750 .................... Decal, 250/750 Rated Load ........................................................ 1 55944 .......................... Decal, 250RWL On Ext. XL ....................................................... 1 55480-002 .................... Decal, Lower Op Instruction ...................................................... 1 55480-001 .................... Decal,LowerControls ............................................................... 1 56303 .......................... Decal, U seArmstamd Caution .................................................... 1 54984-005 .................... Decal, Rear Bumper .................................................................... 1 66973 .......................... Decal, Elect. Hazard Keep Clear ................................................. 2 55871-001 .................... Decal,VUpperElectricaIBoxTop ............................................. 1 55856-001 .................... Decal, VXL Upper Control 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, CONDOR 3.45 x 23 ...................................................... 2 55984 .......................... Decal, V2033XL ......................................................................... 2 55941-017 .................... Decal, Condor "Bird" ................................................................. 2 53259 .......................... Tape, Non-Skid 6" Black ................................................... 1.50LF 66921 .......................... Coating,Non-SkidJetBlack ............................................... 025GL 55982-DWG ............... Dwg. V2033/XLDecalInstallation ............................................ 1 54984-006 .................... Decal, 110VExtention To Platform V2033XL ........................... 1 56302 .......................... Decal, Crushing Danger V2033XL .............................................. 1

31

51340 .......................... NameplateScissorsIndentification ........................................... Ref.

*

55982-102 .................... Decal Kit, V2033XLEssential ................................................. Ref. 55982-101 .................... Decal Kit, V2033 Essential ..................................................... Ref.

*2 *3 *4 ~"5

*6 *7 *8

*9 ""10 ""11 *12

)

QTY

DESCRIPTION

ITEM

*

- Indicates Items Not Shown Included In Essential Decals

'~Indicates

[[REF

r

w r

2 1/4 MARGIN NO NON-SLIP COATING

) PLANVIEW OF MODEL V2033

PARTIAL REAR VIEW OF MODELS V2033

MANUAL 92350-003 January 1997 SIN X935-97051

G

•

FIGURE 3.1: Chassis Assembly V2033XL

1-----1

1-----1

' I ,

' 3

, I

2 Pl

L__ ________ ~ I

,

----------~

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

2. FOR ITEMS IDENTifiED FINAL ASSY.

8

SEE HOSE KIT IN

3. ITEM 33, 55924, INCLUDES SPINDLE 55921, WHICH IS REOUIRED ON CHASSIS WLDMNT 55445.

2 PL INCLUDES: NUT, WASHER. COTTER PIN (SEE NOTE 3)

2 PL

27 SEE NOTE 1 TOP ViEW OF AXLE

) o

,------------------------1 ! BHL Y PAN FRONl WALL 0 I

i

!,

0

81368-40-40 2 Pl REf

I ,, I

o TOP VIEW OF CHASSIS WELDMENT

2 PL

TOP VIEW OF STEERING COMPONENTS 1.

LOCTITE ITEM 8 INTO ITEMS 4 &: 5.

MANUAL 9235Q.O03 JanuaI)' 1997 SIN X935-97051

)

FIGURE 3.1: Chassis AssemblyV2033XL 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 36 37 38

PART NUMBER

DESCRIPTION

QTY

55467 .......................... Assembly, Chassis V2033XL ................................................... Ref. 55445 .......................... Chassis Weldrnent ....................................................................... 1 34145 .......................... BushingR#81368 ....................................................................... 2 02219 .......................... Elbow, 90° M]04 F]04 ............................................................... 2 55496-003 .................... Knuckle Weldment,LHStr ......................................................... 1 55496-004 .................... Knuckle Weldment,RHStr ......................................................... 1 54776 .......................... ThrustWasher,Kingpin ............................................................... 2 55402 .......................... Retainer,Kingpin ........................................................................ 2 BOW39104 .................. Bolt, Hex Hd .50-13UNC x 1.00 Gr 8 ........................................ 2 54775 .......................... ConnectingArm,Steering ........................................................... 1 81368-01-08 ................ Bearing, .75"10 x 1.00"OD x .50"L ............................................ 4 BOW36708 .................. Washer,Flat.75 .......................................................................... 4 55111 .......................... Cylinder, 2.00"Dia./6/81 " Steer .................................................. 1 54035 .......................... Pin, Steering Cylinder .................................................................. 2 BOW36718-HD .......... Washer, Flat 3/4" SAE ................................................................. 2 BOW38230 .................. Pin, Cotter .125"Dia. x 1.25 ......................................................... 4 54644-001 .................... Motor, 11.9 Hyd. Wheel .............................................................. 2 BOW30109 .................. Bolt,Hex.50-13UNCx2.25 ....................................................... 8 BOW36605 .................. Nut, 1/r13 ................................................................................. 8 55302 .......................... HubAssembly,Drivew/Studs ................................................... 2 54779-Dwg ................. RearHubInstallationDrawing .................................................... 1 BOW38232 .................. Cotter Pin, .12 x 1.75L ................................................................ 2 54885-001 .................... Adapter, MOR08 FOR10 1.00 Lg ............................................... 1 54885-002 .................... Adapter, MOR08 FROiO 1.812Lg............................................. 1 54885-003 .................... Adapter, MOR08 FOR102.625 Lg............................................. 1 54885-004 .................... Adapter,MOR08FOR103.438Lg............................................. 1 36085 .......................... Fitting,Swivel900Elbow8-8 ..................................................... 4 54929 .......................... Tire&WheelAssembly(Tire&WhellNotSoldSeperately) ......... 4 91029 .......................... Nut,.50-20UNFWheelR#30288 ............................................. 10 54714 .......................... BrakeCylinder ............................................................................ 2 54796 .......................... Pin, Brake ................................................................................... 2 54795 .......................... Handle Weldment,BrakeRelease ................................................. 2 54779 .......................... Rear Hub Assembly .................................................................... 2 BOW30059 .................. Bolt, Hex .38-16UNC x 2.25 Gr 5 .............................................. 2 BOW30063 .................. Bolt,Hex.38-16UNCx3.25 ....................................................... 2 BOW36703 .................. Washer,Flat.38"lOx.81"OD .................................................... 4 BOW34274 .................. Nut,HexLock 3/ s-16UNC ........................................................ 4 02236 .......................... Elbow, 90 0M]04 M004 ............................................................. 6 55467-DWG ............... Chassis AssemblyD rawing .......................................................... 1

- Indicates Items Not Shown

) MANUAL 92350-003 January 1997 SIN X935-97051

8)

•

FIGURE 3.2: Chassis Assembly V2033

~S-:

2 PL-REf SEE NOTE 3

30

2 PL 2 PL

27 REF SEE NOTE 1 lOP VIEW DE AXl E

NOTES: 1. BRAKE RELEASE HANDLES (ITEM 31) MUST SI't1NG FREELY. DO NOT TIGHTEN ITEMS 35. 36. & 37 ANY MORE THAN SNUG FIT (2 PL).

2. FOR ITEMS IDENTIFIED fiNAL ASSY.

@

SEE HOSE KIT IN

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

o

I

BELLY PAN

FR~cNHT~~~ArL_L ~L-~-+____

o

)

o

81368-40-40 2 PL REF

__

L 2

2 PL

TOP VIEW OF CHASSIS WELDMENT

10 PL

2 PL

) TOP VIEW OF STEERING COMPONENTS NOTES: ,.

LOCTiTE ITEM 8 INTO ITEMS 4 &: 5.

MANUAL 92350-003 January 1997 SIN X935-97051

FIGURE 3.2: Chassis Assembly V2033 . ,

QTY

PART NUMBER

Ref.

55955 ......................•... Assembly, Chassis V2033 ........................................................ Ref. 55956 .......................... ChassisWeldInent ....................................................................... 1 34145 .......................... BushingR#81368 ....................................................................... 2 02219 .......................... Elbow, 90° M}04 F}04 ............................................................... 2 55496-003 .................... Knuckle Weldment,LHStr ........•................................................ 1 55496-004 .................... KnuckleWeldment,RHStr ......................................................... 1 54776 .......................... ThrustWasher,Kingpin ..........•........•.............................•............. 2 55402 .......................... Retainer,Kingpin ............................................................•........... 2 BOW39104 .................. Bolt, Hex Hd.50-13UNCx 1.00 Gr8 ........................................ 2 54775 .......................... ConnectingArm,Steering ........................................................... 1 81368-01-08 ................ Bearing, .75"ID x 1.00"OD x .50"L ..........................................•. 4 BOW36708 .................. Washer,Flat.75 .......................................................................... 4 55111 .......................... Cylinder,2.00"Dia./6/81" Steer .................................................. 1 54035 ........................•. Pin, Steering Cylinder .................................................................. 2 66110-075 .................... Washer, Flat 314 " SAE ................................................................. 2 BOW38230 .................. Pin, Cotter .125 "Dia. x 1.25 ......................................................... 4 54644-001 .................... Motor, 11.9 Hyd. Wheel .............................................................. 2 BOW30109 .................. Bolt,Hex.50-13UNCx2.25 ....................................................... 8 BOW36605 .................. Nut, l/r13 ................................................................................. 8 55302 .......................... HubAssembly,Drivew/Studs ................................................... 2 54779-Dwg ................. RearHubInstallationDrawing .................................................... 1 BOW38232 .................. Cotter Pin,.12x 1.75L ................................................................ 2 54885-001 .................... Adapter, MOR08 FOR10 1.00Lg ............................................... 1 54885-002 .................... Adapter,MOR08FR0101.812Lg............................................. 1 54885-003 .................... Adapter,MOR08FOR102.625Lg............................................. 1 54885-004 .................... Adapter,MOR08FOR10 3.438 Lg............................................. 1 36085 .......................... Fitting,SwiveI900Elbow8-8 ..................................................... 4 54929 .......................... Tire&Whee1Assembly(fire&WhellNotSoldSeperately) ......... 4 91029 .......................... Nut,.50-20UNFWheelR#30288 ............................................. 10 54714 .......................... Brake Cylinder ............................................................................ 2 54796 .......................... Pin, Brake ................................................................................... 2 54795 .......................... Handle We1dment,BrakeRelease ................................................. 2 54779 .......................... RearHubAssembly .................................................................... 2 BOW30059 .................. Bolt, Hex.38-16UNCx 2.25 Gr 5 .............................................. 2 BOW30063 .................. Bolt,Hex.38-16UNCx3.25 ....................................................... 2 BOW36703 .................. Washer,Flat.38"IDx.81"OD .................................................... 4 BOW34274 .................. Nut,HexLock 3/ s-16UNC ........................................................ 4 02236 .......................... Elbow, 90 0M}04 M004 ............................................................. 6 55955-DWG ............... Chassis AssemblyDrawing .......................................................... 1

1 2

3 4

5 6 7 8 9

)

DESCRIPTION

ITEM

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

- Indicates Items Not Shown

MANUAL 92350-003 January 1997 SIN X935-97051

•

FIGURE 3.3: Hose Kit

f-----l : I

~-----l

L _____ ~ BELLY PAN BACK WALL

C--)

:

I

--

LIFT CYLINDER

2

r;:;:;----------I TOP /\ , , ,

I I, ,

BELLY PAN : FRONT WALL

I, ,

~~T~M

=

=====J

12

RIGHT MOTOR

LEFT MOTOR

STEER

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

P1 VALVE ASSY

HYDRAULIC TANK

.3

) ELECTRIC MOTOR

MANUAL 92350-003 Jarwary 1997 SIN X935-97051 .

FIGURE3.3:HoseKit •

)

DESCRIPTION

ITEM

PARTNUMBER

Ref.

55469 .......................... Hose Kit V2033 ...................................................................... Ref. 66698-119.00 ............... Hose Assembly, #06 66645 J37 ST-ST ....•................................... 1 66044-151.00 ..............• Hose Assembly, #0467685J37ST-ST ........................................ 1 66702-019.00 ............... Hose Assembly, #1066137 J37 ST-ST ........................................ 1 66698-020.00 ............... Hose 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 J37 ST-ST ........................................ 1 66696-012.5 ................. Hose Assembly,#0466646J37ST-ST ........................................ 1 66696-012.5 ................. Hose Assembly, #04 66646 J37 ST-ST ........................................ 1 66696-012.5 ................. Hose Assembly, #04 66646 J37 ST-ST ........................................ 1 66700-026.00 .•............. Hose Assembly, #0666645 J37 ST-STJ ....................................... 1 66700-024.00 ............... Hose Assembly, #06 66645 J37 ST-STJ ....................................... 1 66700-026.00 ............... Hose Assembly, #04 66646 J37 ST-STJ ....................................... 1 66700-025.00 ............... Hose Assembly, #04 66646 J37 ST-STJ ....................................... 1 66043-028.00 ............... Hose Assembly, #0367684 J37 STJ-STJ ..................................... 1 66043-019.50 ............... Hose Assembly, #03 67684J37STJ-STJ ..................................... 1

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

- Indicates Items Not Shown

-)

) MANUAL 92350-003

Janwuyl997 SIN X935-97051

QTY

•

FIGURE 3.4: Lift Cylinder

I")

)

~~

r-

00

l=!w UO

~

«z

~w ~~

X w ~w

~'I

r<)i'.

'<tCX)

N n 1O:=

)

ITEM

PART NUMBER

Ref.

54705-001 .................... Cylinder,Lift .......................................................................... Ref. 54705-100 .................... Seal Kit ....................................................................................... 1 54705-101 .................... Castle Nut .................................................................................. 1 54705-102 .................... CastIronRing ............................................................................ 1 54705-103 ........·............ Piston (Steel) ............................................................................... 1 54705-104 .................... WearRing .................................................................................. 1 .................................... PolyPack (Included in Seal Kit 54705-100) ................................... 1 .................................... O-Ring (Included in Seal Kit 54705-100) ...................................... 1 .................................... Stop Tube (Included in Seal Kit 54705-100) ................................. 1 54706-105 .................... Jacket Assembly .......................................................................... 1 54705-106 .................... Piston Rod ................................................................................. 1 .................................... Polypack(IncludedinSealKit54705-100) ................................... 1 .................................... O-Ring (Included in Seal Kit 54705-100) ...................................... 1 54705-107 .................... GlandNut .................................................................................. 1 .................................... Rod Wiper (Included in Seal Kit 54705-100) ................................ 1 55221 .......................... FlowControlValve .................................................................... 1

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

DESCRIPTION

- Indicates Items Not Shown MANUAL 92350-003 lanU3I)' 1997 SIN X935-97051

QTY

)

FIGURE 3.5: Steer Cylinder

')

o

00 NZ

wo uo

I- W

tbrrl-Q:' 0::>-

«z

~_

0 "'-...0 i'-, 0...

o::w

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1-1-

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WX

IYW

I"")t[)

(Jli'-

rrjo ~N

)

PARTNUMBER

Ref.

55111 .......................... Cylinder,Steer ........................................................................ Ref. 55111-100 .................... Seal Kit ....................................................................................... 1 55111-101 .................... LockNut ..............................................................................•.... 1 ................................... Polypak (Included in Seal Kit 55111-100) ..................................... 2 ................................... O'Ring(IncludedinSealKit55111-100) ...................................... 1 55111-102 .................... Piston(Alum) ............................................................................. 1 55111-103 .................... JacketAssembly .......................................................................... 1 55111-104 .................... Piston Rod ................................................................................. 1 ................................... Polypak(TypeB) (Included in Seal Kit 55111-100) ....................... 1 ................................... O'Ring(IncludedinSealKit55111-100) ...................................... 1 55111-105 .................... GlandNut .................................................................................. 1 ................................... Rod Wiper (Included in Seal Kit 55111-100) ................................ 1 BOW32287 .................. Jam Nut 5/8-18 ......................................................................... 1 55111-106 .................... RodEnd .................................................................................... 1

1 2 3 4

5 6 7 8 9

)

10

11 12

- Indicates Items Not Shown

DESCRIPTION

QTY

ITEM

Revised January 1998 MANUAL 92350-003 January 1997

SIN X935-97051

•

•

FIGURE 3.6: Cylinder, Brake

I

EB I

7/16-20 O-RING PORT TYP

) tJ-•_ _ _ _ _ _ _ _ _ _ _ _ _ _

11-_4===~~~~_3._06_

10.18 EXTENDED _ _ _ _ _ 9.31 RETRACTED

QTY

ITEM

PARTNUMBER

Ref.

54714 .......................... Cylinder, 1.75Bx 1.13Rx.88 Stroke ........................................ Ref. 54714-100 .................... Seal Kit ....................................................................................... 1 54714-101 .................... Jacket Assembly .......................................................................... 1 54714-102 .................... Piston Rod ................................................................................. 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(Alum) ............................................................................. 1 .................................... O'Ring(IncludedinSealKit54714-100) ...................................... 1 .................................... Polypak(Type 'B') (Included in Seal Kit 54714-100) ..................... 1 .................................... O'Ring(IncludedinSealKit54714-100) ...................................... 1 54714-105 .................... GlandNut .................................................................................. 1 .................................... Rod Wiper (Included in Seal Kit 54714-100) ................................ 1

1 2 3 4

5 6 7 8 9

10 11

DESCRIPTION

I

-_-_-_-_-_-_---1-1:

- Indicates Items Not Shown MANUAL 92350-003

lanwuyl997 SIN X935-97051

)

FIGURE 3.7: Hub Motor Assembly . ,

10

)

9

1

1 6

1

4

1

1

1

1 17

3

10

11

1

)

DESCRIPTION

QTY

ITEM

PARTNUMBER

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

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 (11/4in Tapered) ......................................... 4 54644-103 .................... Key (For TaperedShaft) ............................................................. 1 54644-104 .................... Nut, Hex (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 f /8-14 Staggered Ports) ...................................... 1 54644-116 .................... Plug Assembly 7 /16-20UNF ......................................................... 1

- Indicates Items Not Shown

) MANUAL 92350-003 January 1997 SIN X935-97051

•

FIGURE 3.8: Hub Assembly, Rear Chassis Weldment Ref.

)

9

4

I

3

2

1

5 6 7

-) 11 12

10

ITEM

PARTNUMBER

Ref. 1 2 3 4 5 6

54779 .......................... Hub Assembly ........................................................................ Ref. 54779-109 .................... Hub ........................................................................................... 1 54779-101 .................... InnerCup ................................................................................... 1 54779-102 .................... InnerCone ................................................................................. 1 54779-106 .................... Seal ............................................................................................ 1 54779-103 .................... OuterCup .................................................................................. 1 54779-104 .................... Outer Cone ................................................................................ 1 BOW36718-fII) .......... Washer ....................................................................................... 1 BOW1802 ................... SlottedNut, 3/4"-16UNF ............................................................ 1 BOW38233 .................. CotterPin,.125"x2.00" ............................................................. 1 54779-105 .................... Dust Cap ................................................................................... 1 54779-107 .................... Stud ........................................................................................... 5 54779-108 .................... StudNut .................................................................................... 5

7

8 9

10 11 12

DESCRIPTION

- Indicates Items Not Shown MANUAL 92350-003 January 1997 SIN X935-97051

QTY

)

FIGURE3.9:TubeKit •

ITEM

PARTNUMBER

Ref. -1 -2 -3 -4

55397 55072 55067 55047 55050 55048 55324 55051 55298 55076 55064 55063

-5 -6 -7

-8 -9

-10 -11

DESCRIPTION

QTY

.......................... TubeKit ................................................................................ Ref. .......................... TubeAssembly,M2 .................................................................... 1 .......................... TubeAssembly,M1 .................................................................... 1 .......................... Tube Assembly, M3 Bulkhead ..................................................... 1 .......................... TubeAssembly,M3 .................................................................... 1 .......................... TubeAssembly,CylVenttoT .................................................... 1 .......................... TubeAssembly,B ....................................................................... 1 .......................... Tube Assembly, Brakes to T ........................................................ 1 .......................... Tube Assembly, TtoFilter ........................................................... 1 .......................... TubeAssembly,S2 ..................................................................... 1 .......................... TubeAssembly,Sl ..................................................................... 1 .......................... TubeAssembly,L ....................................................................... 1

- Indicates Items Not Shown

)

) MANUAL 92350-003 Januaty 1997 SIN X935-97051

",

--.-'~

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

§

F'L

4. FOR ITEMS IDEN TIFIED 5. EST. WT.~ 706 Ibs.

E9 E9

2 PL

4 PL

SEE CABLE KIT.

+

+

SOd

CHARGER BA TTERY

RED

CK

SOd

Szt-l

SZl-l

NVrO~:I1

NVrOdl

CK

BLK

-

CK

5

4

~3N

3

CK CK

2

5

TROJAN

TROJAN

T-125

T-125

POS

PL

CK 6

~K SEE NOTE 4

+

POS

+

FIGURE 3.10: Belly Pan Assembly . , PARTNUMBER

Ref.

55468 .......................... BellyPan Assembly V2033XL ................................................. Ref. 55958 .......................... Belly Pan Assembly V2033 ...................................................... Ref. 55481 .......................... BellyPanWeidmentV2033XL .................................................... 1 55786 .......................... Belly Pan Weldment V2033 ......................................................... 1 54989 .......................... MotorlPumpAssembly .............................................................. 1 55379 .......................... ValveInstallation ......................................................................... 1 55297 .......................... TankWeldment,Hyd.................................................................. 1 50316 .......................... BreatherFiller .................................................................•........... 1 52049 .......................... Gauge,FluidLevel ...................................................................... 1 04699-08 ..................... Plug,SocketHex.50NPT ...................................................... ~ ... 1 02806 .......................... Straight,MJ10MP12 ......................................................•........... 1 33430 .......................... Ftlter •......................................................................................... 1 67408 .......................... -Filter Element ........................................................................... 1 00324 .......................... Elbow, 90° MJ08 MP12 ............................................................. 1 02430 .......................... Straight,MJ04MB04 .................................................................. 3 02431 .......................... Fitting, Straight MJ06 MB06 ........................................................ 2 02303 .......................... Elbow, 90 0 MJ06MB06 .............................................................. 2 00345 .......................... Tee,MJ06MJ06MB06 ............................................................... 1 00334 .......................... Nut,Bulkhead04 ........................................................................ 5 00336 .......................... Nut, Bulkhead 06 ........................................................................ 5 02662 .......................... Elbow, 90° MJ06 M006 ............................................................ 2 55398 .......................... Cable Kit (See Note 4) ................................................................ 1 04674 .......................... Elbow, 90° MJ10M008 L ......................................................... 1 02407 .......................... Tee,MJ04MJ04MP)4 ................................................................ 1 55333 .......................... Charger Mod.115V/25A ............................................................ 1 52138 .......................... Soienoid24V .............................................................................. 1 55334 .......................... Jumper Assembly, 12LG Wire ................................................... 1 52627 .......................... Battery,6VTrojan Tl25-WT ....................................................... 4 55505 .......................... Angle, Battery Tie Down 22" ...................................................... 2 55506 .......................... J-Bolt, Battery Hold Down ......................................................... 2 BOW36726 .................. Washer,.31IDSplitLock ............................................................ 3 BOW30055 .................. Bolt,Hex.38-16UNCx 1.25 ....................................................... 3 BOW30057 .................. Bolt,Hex.38-16UNCx1.75 ....................................................... 2 BOW31433 .................. Washer, .38 x .81"OD Flat SAE Gr 5 .......................................... 5 BOW34274 .................. Nut,HexLock 3/ g "-16UNC ....................................................... 5 BOW30037 .................. Bolt,Hex.31-18UNCx3.00 ....................................................... 3 BOW30029 .................. Bolt, Hex.31-18UNC x 1.00 ....................................................... 4 BOW31432 .................. Washer,Flat.31"IDx.68"OD .................................................... 4 BOW34273 .................. Nut,LockHex 5/16"-18UNC ...................................................... 4 BOW30003 .................. Bolt,Hex.25-20UNCx.875 ....................................................... 4 BOW31401 .................. Washer,Flat.25"IDx.63"OD .................................................... 8 BOW34272 .................. Nut,Hex.25-20UNCNylonLock .............................................. 4 55397 .......................... Tube Kit (See Note 3) ................................................................. 1 04185 .......................... Fitting,BulkheadTee .................................................................. 2 BOW34323 .................. Nut,.25-20UNCWing .............................................................. 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

DESCRIPTION

QTY

ITEM

- Indicates Items Not Shown

MANUAL 92350-003

Janlllll)'l997 SIN X935-97051

TK 9

l

LEFT

BACK

SIDE PI

r-___~

S"ILD~E~L______________~'-______________ ~3

SI '---+~S2

GI

MI

M2

~K SEE NOTE 3

o

-~:':---+~~~t--rs~-L~~__®~__

I

3 PL

@

TK

7

HK TANK BELL Y PAN

BELLY PAN FRONT WALL

2 PL

FIGURE 3.10: Be11yPanAssembly •

ITEM

PARTNUMBER

Ref.

55468 .......................... Belly Pan Assembly V2033XI.. ................................................. Ref. 55958 .......................... Belly Pan Assembly V2033 ....••....................•.•......................... Ref. 55481 .......................... BellyPanWeldmentV2033XI.. .•.........................•........................ 1 55786 .......................... Belly Pan Weldment V2033 ......................................................... 1 54989 .......................... MotorlPumpAssembly .............................................................. 1 55379 .......................... ValveInstallation ....................•.................................................... 1 55297 .......................... TankWeldment,Hyci.................................................................. 1 50316 ........................•. BreatherFiller ............................................................................. 1 52049 .......................... Gauge,FluidLevel ...........•.......................................................... 1 04699-08 ..................... Plug,SocketHex.50NPT .......................................................... 1 02806 .......................... Straight,MJ10MP12 .................................................................. 1 33430 .......................... Filter .......................................................................................... 1 67408 .......................... -Filter Element ........................................................................... 1 00324 .......................... Elbow, 90° MJ08 MP12 .......................................•..................... 1 02430 .......................... Straight,MJ04MB04 ...........•..........................................•........... 3 02431 .......................... Fitting,StraightMJ06MB06 .................................................•...... 2 02303 .......................... Elbow, 90 0 MJ06 MB06 .............................................................. 2 00345 .......................... Tee, MJ06 MJ06 MB06 ............................................................... 1 00334 .......................... Nut,Bulkhead04 ........................................................................ 5 00336 .......................... Nut, Bulkhead 06 ...........•............................................................ 5 02662 .......................... Elbow, 90° MJ06 M006 ............................................................ 2 55398 .......................... Cable Kit (See Note 4) ................................................................ 1 04674 .......................... Elbow, 90° MJ10M008 L ......................................................... 1 02407 .......................... Tee, MJ04 MJ04MP)4 ................................................................ 1 55333 .......................... ChargerMod.115V/25A ............................................................ 1 52138 .......................... Soienoid24V .............................................................................. 1 55334 ........................ ;. Jumper Assembly, 12LG Wire ................................................... 1 52627 •......................... Battery, 6VTrojan T125-WT ...........................................•........... 4 55505 .......................... Angle, Battery Tie Down 22" ...................................................... 2 55506 .......................... J-Bolt, BatteryHoldDown ......................................................... 2 BOW36726 .................. Washer,.31IDSplitLock ............................................................ ·3 BOW30055 .................. Bolt, Hex.38-16UNC x 1.25 ....................................................... 3 BOW30057 .................. Bolt, Hex .38-16UNC x 1.75 ...............................•....................... 2 BOW31433 .................. Washer, .38 x .81"OD Flat SAE Gr 5 .......................................... 5 BOW34274 .................. Nut,HexLock 3/ s "-16UNC ....................................................... 5 BOW30037 .................. Bolt,Hex.31-18UNCx3.00 ....................................................... 3 BOW30029 .................. Bolt, Hex.31-18UNC x 1.00 ....................................................... 4 BOW31432 .................. Washer,Flat.31"IDx.68"OD .................................................... 4 BOW34273 .................. Nut, Lock Hex 5116"-18UNC •....•...•..........•................................• 4 BOW30003 .................. Bolt,Hex.25-20UNCx.875 ....................................................... 4 BOW31401 .................. Washer,Flat.25"IDx.63"OD .................................................... 8 BOW34272 .................. Nut,Hex.25-20UNCNylonLock .............................................. 4 55397 .......................... Tube Kit (See Note 3) ................................................................. 1 04185 .......................... Fitting,BulkheadTee .................................................................. 2 BOW34323 .................. Nut,.25-20UNCWing .............................................................. 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

)

DESCRIPTION

- Indicates Items Not Shown

MANUAL 92350-003 lanllllI)'l997 SIN )(935-97051

QTY

. , FIGURE 3.11: Motor & Pump Assembly

)

5

G

G

IlIl

m

000000000 000000000 000000000 000000000 '0 0 0 0 0 0 0 0 0 000000000 O~O~O~O

6

)

PART NUMBER

Ref. 1

54989 .......................... Motor/PumpAssembly .......................................................... Ref. 54761 .......................... Duplex Pump & Parts (See Page 45) ........................................... 1 54761-101 .................... Seal Kit (pump) .......................................................................... 1 BOW30029 .................. Bolt,Hex.31"-18UNCx 1.00" ................................................... 4 .................................... Tag Nails .................................................................................... .

BOW31444 .................. Washer,Flat S/16" •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4 54759 .......................... 24 Volt Motor (See Page 46) ...................................................... 1 54989-100 .................... Gasket ........................................................................................ 1 54760 .......................... ReplacementCoupling ................................................................ 1 [NotUsed] ...................................................................................................................... 1

2 3 4 5 6 7 8

DESCRIPTION

QTY

ITEM

- Indicates Items Not Shown

) MANUAL 92350-003 January 1997 SIN X935-97051

FIGURE 3.12: Pump Assembly •

SECTION A-A 9

10

18

17

6

13

1

7

12

HYDRAULIC SCHEMATIC 8

INLET PORT 16 3/4-16 SAE

-)

)

ITEM

PARTNUMBER

Ref.

24

23

4

11

OUTLEr PORTS 9/16-18 SAE

DESCRIPTION

20

QTY

1

54761 .......................... DuplexPump & Parts ............................................................ Ref. 54761-100 .................... Seal Kit ....................................................................................... 1 54761-103 .................... Gear Housing ............................................................................. 1

2

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

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

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

54761-108 .................... DrivePin .................................................................................... 1 ........................................................................................................................................ . ................................... Oil Seal (in seal kit) ...................................................................... 1 54761-112 .................... DriveShaft ................................................................................. 1 ................................... LeePlug ..................................................................................... 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 .................... Shear Pin .................................................................................... 1 ................................... Plastic Plug ................................................................................. 1 ... ........................ ........ Gasket (in seal kit) ....................................................................... 1 54761-111 .................... Woodruff Key ............................................................................ 1 ........................................................................................................................................ . ................................... Plastic Plug ................................................................................. 1 ........................................................................................................................................ .

22

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

23 54761-110 .................... CreascentRing ............................................................................ 1 24 54761-104 .................... Gear Housing ............................................................................. 1 - Indicates Items Not Shown MANUAL 92350-003 Janu<uy 1997 SIN X935-97051

•

FIGURE 3.13: Motor 24VDC Assembly

-l-----NAMEPLATE

j

15

)

) MANUAL 92350-003 January 1997 SIN X935-97051

FIGURE 3.13: Motor 24VDC Assembly

QTY

PARTNUMBER

Ref. 1

54759 .......................... Motor, 24VDCAssembly ....................................................... Ref. ................................... Complete Stator Assembly .......................................................... 1 NSS ............................. Complete Terminal Assembly ..................................................... 2 ................................... Screw Hex fill Cap 3/g"-16 ....................................................... 2 ................................... Jam Nut, Hex 3/g"-16 ................................................................. 2 ................................... Jam Nut, Hex 3/g"-16 ................................................................. 2 ............................. ...... Insulator ..................................................................................... 4 ...................... ............. Insulator ..................................................................................... 2 ................................... Lock Washer,Split 3/ g" ............................................................... 2 ................................... Lock Washer, Ext. TTH3/g" ....................................................... 4 ................................... Field Coil Assembly .................................................................... 1 ................................... FieldPole ................................................................................... 4 ................................... Screw, BTTN fill Socket, 3/g"-16 x 5/g" ..................................... 8 ................................... Field Coil Terminal ..................................................................... 1 ................................... Loctite,222 .................................................................................. . ................................... PulleyCover ............................................................................... 1 ................................... Screw, Socket fill #10-32 x1.00" ............................................... 4 54759-117 .................... CompleteArmatureAssembly .................................................... 1 54759-118 .................... Fan ............................................................................................. 1 54759-119 .................... Bearing,Pulley ............................................................................ 1 54759-120 .................... Bearing,Comm .......................................................................... 1 ................................... Complete Comm Cover Assembly ............................................. 1 54759-122 .................... Complete Brush Ring Assembly .................................................. 1 54759-123 .................... Brush Spring ............................................................................... 8 54759-124 .................... BrushAssembly .......................................................................... 2 ................................... Screw, RH Slotted #10-32 x 3// ................................................. 4 ................................... Nut, Hex #10-32 ........................................................................ 4 ................................... Washer Bearing Spring ................................................................ 1 ................................... Screw, Hex fill #10-32 x 2.00" .................................................. 4 54759-129 .................... Brush Inspection Cover ............................................................... 1 ................................... Screw, PH fill #10-32 x 1_3// .................................................. 1 ................................... Nut, Square #10-32 .................................................................... 1 ........................... ........ Insulator ..................................................................................... 1 ................................... Screw, RH Slotted 1//-20 x 3/g" ................................................. 2 ................................... Lock Washer, Ext. TTHI// ....................................................... 2 54760 .......................... Coupling Assembly .................................................................. Ref

2 3 4

5 6 7 8

9 10 11 12 13 14 15 16 17 18 19 20 21

)

DESCRIPTION

ITEM

22 23 24 25 26 27 28 29 30 31 32 33 34 35

NSS -Not Sold Separately - Indicates Items Not Shown

) MANUAL 92350-003 JanU3I}' 1997 SIN X935-97051

G

•

FIGURE 3.14: Valve Installation

3

REAR VIEW

)

) LEFT END VIEW MANUAL 92350-003 January 1997 SIN X935-97051

FIGURE 3.14: Valve Installation •

')

G2 CREEP

o o o

) RIGHT END VIEW

)

ITEM

PART NUMBER

Ref. 1 2 3 4 5 6 7 8

55379 55296 54892 02525 02448 00458 04579 04682 04003

DESCRIPTION

QTY

.......................... Valve Installation ..................................................................... Ref. .......................... Valve Assembly .......................................................................... 1 .......................... Valve,LoadControl ................................................................... 2 .......................... Straight,M]04M004 ................................................................. 3 .......................... Straight,M]06M006 ................................................................. 5 .......................... Straight,M]08M008 ................................................................. 1 .......................... Elbow, 90° M]06 M006 LL ...................................................... 1 .......................... Tee,M]04M004M]04 .............................................................. 1 .......................... Nut, Cap #04 ............................................................................. 2

- Indicates Items Not Shown

MANUAL 92350-003 JanUaIY 1997 SIN X935-97051

•

FIGURE 3.15: Valve Assembly

A

8

I

fit

~

§ 12

A

B

RIGHT END VIEW

FRONT VIEW

= =

)

= c

LEFT END VIEW A- A

BACK VIEW 8-B

SERVICE PARTS:

l J

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

NOTES: 1. SEAL ALL OPENINGS WITH THREADED PLUGS. REF: 7/16-204 PL; 9/16-186 PL: 3/4-16 1 PL

MANUAL 92350-003 JanuaI)'1997 SIN )(935-97051

FIGURE 3.15: Valve Assembly . ,

QTY

ITEM

PARTNUMBER

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

55296 .......................... Valve Assembly ...................................................................... Ref. 55337-001 .................... Manifold,Valve .......................................................................... 1 54646-004 .................... Valve,Drive ............................................................................... 1 54646-001 .................... Valve, Steer ................................................................................. 1 54646-005 .................... Valve,Select ................................................................................ 1 54639 .......................... Cartridge, 2 Way No Spool Valve ............................................... 2 54852-052 .................... Orifice, 0.052 DiaHF 10 ............................................................ 1 54641 .......................... Cartridge,4WayNoSpoolValve ............................................... 1 54634 .......................... Cartridge,FlowDividerValve .................................................... 1 54890 .......................... Cartridge,Dir.ActReliefValve ................................................... 2 54640 . ... ...•.... ......... ..... Cartridge, Check Valve ............................................................... 1 54889 .......................... Cartridge, Flow Control Valve .................................................... 1 54622 .......................... Cartridge, Needle Valve .............................................................. 1 54638 .......................... Cartridge, Sequence Valve ........................................................... 1

DESCRIPTION

- Indicates Items Not Shown

.)

MANUAL 923S0-003 JanU3IY 1997 SIN X93S-970S1

•

FIGURE 3.16: Charger115V125AMod.

11

BlK BA TTERY CHARGER

~--RRmED----__~ - - 24

)

DESCRIPTION

QTY

ITEM

PART NUMBER

Ref. 1 2

55333 .......................... Charger, 115V125AMod. ...................................................... Ref. 54908 .......................... Charger,115V160HZ-25A/24VDC ........................................... 1 BOW23065 .................. Ring Terminal, 12Ga. 3/8 Stud ................................................... 2

- Indicates Items Not Shown

) MANUAL 923S0-003 Janruuy 1997 SIN X93S-970S1

FIGURE 3.17: Charger 115V/25A Mod.

14

BU<

BATTERY CHARGER 22 1/2 _

RED

EB

-J

ITEM

PART NUMBER

Ref. 1 2

55901 .......................... Charger, 115V125AMod . ...................................................... Ref. 54908 .......................... Charger, 115V/60HZ-25A/24VDC ........................................... 1 BOW23065 .................. Ring Terminal, 12Ga. 3/8 Stud ................................................... 2

DESCRIPTION

- Indicates Items Not Shown

) MANUAL 92350-003 Januaxy 1997 SIN X93S-970S1

QTY

G

. , FIGURE 3.18: Charger 115V160HZ-25A124VDC

(

I~====::::"

®

~~H 11'1YlLll.'\1

~

~'ii'1I© ~~rrnr

W©lo.'ii'

II?~

.1

~v-Electrlcal825 W.4tASt. Lincoln. NE 68522 USA ACYOLTS

IlERn

MODEl

[iliJ

[!QJ

1179701

ACAMPS

PHASE

SERIAL NO.

IT]

IT]

DCVOlTS

©IHJLi\IFl@ll:1i'l

IU\'i"i'imfC&'P£Cri"if "CELLS.RIE.COHNECTEO

l..EA°M~~~~~:'':Tr~~'1.

U,$.'AT.NO.'.7i4,$05

c::EJ

M.8R.I"AT.NO.',Al14,t5S

[KJ

W. GR.PAT.NO.2.a51,ne .lA-rAN PAT. NO.S3U3I1n,

DCAMI"S

'''.PAT.NO.2,203,1U

) RING

I

10 I I I I I

#12 AWG, 2 PL

~o

III

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

~I

AMMETER, 0-30 AMP

®

I

§] V

®8®

~I@

II II

~

I I I I I

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

®

MANUAL 92350-003 Januruy 1997 SIN X935-97051

~ ~

~

c::==::::J c::==::::J c::==::::J c::==::::J ~ c::==::::J c::==::::J ~ c::==::::J c::==::::J c::==::::J ~ c::==::::J ~ c::==::::J ~ c::==::::J ~ c::==::::J c::==::::J c::==::::J ®

®I I

\~ I I

\E

VENTILATION LOUVERS ON BACK SIDE

)

FIGURE 3.18: Charger 115V160HZ-25A124VDC . ,

ELECTRIC nMER BLACK RED GREEN TRANSFORMER

FAN RED or WHITE

+ TO SA TTERIES

BLACK

2

BLACK

FAN

WHITE

-

.GREEN WIRE NO T USED ON SOME MODELS.

QTY

ITEM

PART NUMBER

DESCRIPTION

Ref.

54908 ..........................

54908-101 ....................

54908-102 ....................

54098-103 ....................

54908-104 ....................

54908-105 ....................

54908-106 ....................

54908-107 ....................

54908-108 ....................

54908-109 ....................

54908-110 ....................

Charger,115V/60HZ-25A/24VDC ....................................... Ref. Transformer Assembly HeatsinkAssembly, with Diodes Ammeter Electronic Timer Assembly Capacitor,6.0MFD,660VAC

Fuse Assembly Case Assembly Bushing, 7W-2, Insulator For Cordset Cordset,DC,75",NoPlug ACReceptacle

- Indicates Items Not Shown

) MANUAL 92350-003 JanuaIY 1997 SIN X93S-970S1

CABLE FROM LOWER CONTROL BOX TO UPPER CONTROL BOX

CABLE FROM LOWER CONTROL BOX TO HYDRAULIC VAL YES

,.-V-V--

COLOR GRN BlU BlU BlK ORN ORN/alK WHT alK WHT/BlK BLK WHT GRN BlK REO BlK REO

# I 2

•

[,- 6 [,- 7

[,- 8 V-- IDA V-- 80 V-- IIA V-- 12 16

r-

[,-

CIRCUIT DESCRIPTION GROUNO rORWARD DRIVE VALVE REVERSE RIGHT STEER VALVE lEn uP PLArrORM SElEC T VALVE rAST ORIVE SPEEO DECElERA TlON VALVE CREEP DRIVE SPEED VALVE POSITRAcnON VALVE SIGNAL HORN OPTION SPARE

~

19

•

,---- 6

ill:

Q§§~~I'N"H

4$P~~t.t bS~TEIIIoI

#8C=Y.1",H MOTION HSD=WHT TRAVEL H9=WH T DESCEND

~--.j.,p;.-F--~II

P

I'=GRN

WELD ON STUD AT CHASSIS

0

11=GRN

OPTIONAL 16GA/2C 67295-035

'----'--T<.:.::='-----' STROBE LIGHT OPTION

J

.

'-'-_---''-!L::9_=-''WH''-'...T_ _--' VALVE ON CYL

~[

i

rJ iJ rGkfl'PL

@

@ @ DRIVE

u

@

@ @ SELECT

@@

~[J [j

18D=WHT/BlK

~J

CABLE FROM lOWER CON TROl BOX

rv

r-~~ r-

II=GRN

SENSOR opnON

a=

SIGN l

l=G N l=ORN

GROUND GROUND

=8LK 58=alU

o

III--,"m

CONTACTOR

POWER POWER

fl0A-BLK opnONAl 16GA/8C 67295-024 CABLE rROM lOWER CON TROL BOX, RErtR TO STANDARD CABLE SHOWN BELOW

'7=ORNIBLK HllA=BlK/WHT SPARE-RED 116=REO/BLK

OPMN l SIGNAL HORN SIGNAL

HI6=RED/BlK #i=GRN

1

Ie

0

SIGNAL HORN OP TlON

I=GRN

GROUND

5B-BlK

POWER

2 PL

IS

"

18

,.

21

19

18

20 2Pc

CONNECTOR & CABLE SUB-ASSV IS INCLUDED IN ARM INSf.

5' SLOPE

@

.PL

16 19 20

20

:-h

@

'( :t-LtJ

f/4=BLU/BLK

:- -,

0

STEER

@@

9 10 11 12

ClRCUI T DESCRIP TlON GROUND-SPARE, Ir NO OPnONS FORWARD DRIVE POWER TO UPPER CONTROLS REVERSE DRIVE OPTION BA TTER V GAGE lEn STEER RIGHT STEER UP PLATI'ORM DOWN PlA rrORM r AST DRIVE SPEED CREEP DRIVE SPEED POSITRAcnON

BELOW ARE LISTED CONDUCTORS IN CABLE THAT IS PART or CERTAIN opnONS. (REr opnONAL 16GA/16C 67295-003) , . - - 13 GRN WHT SLOPE ALARM OPTION ,.-OVERRIDE LOW VOLT OPTION RED WHT ,--- 15 " INDICA TE lOW VOL T BLU/WHT OPTION , . - - 16 BLK RED SIGNAL HORN OPTION

L f..J

[SiSiD r-

ALARM OPTIONS

7 8

L I--'~

2J

1\)

.¥8=WHT 12=BlU

CID

,---,---,---,.-,.-,.--

I

"-

#I=GRN 16-0RN

1\ POS (+)

"

----=,--,..Jj

I. 20 21 2 PL

112=GRN/BlK

COLOR GRN BLU RED BlU/BlK REO BlK ORN ORNIBLK \\!-iT \\!-iT Blk BlK BlK/\\!-iT GRN/BLK

2

,---- 3 ,---,---- 5

,) 0

*

r-- I 10

o

CONTACTOR

STANDARD CABLE rROM LOWER CON TROl BOX

NOTES: I. SEE: 5'918-DWG rOR IIOV EXT 2. THIS DWG SUPERCEDES 54916.

FIGURE3.19WiringInstallation . , PART NUMBER

Ref. 1 2 3

55315 ......................•... WiringInstallation .........................................•.....................•... Ref. 55331 .......................... Jumper Assembly 3" LgWire ...................................................... 6 55330-001 .................... Jumper Assembly21 1/ 2" Lg Wire ............................................... 1 55330-002 ................•... JumperAssembly24" LgWire .................................................... 1 55330-003 .................... Jumper Assembly14 1/ 2 " Lg Wire ............................................... 1 55328 ..•....................... Switch Assembly, Chassis Limit .................................•..•.............. 1 67295-037 ...................• -Cable, 16Ga.l4 Conductor SJO ..................................... 1.85LF 51036 .......................... -SwitchLimitBodyOnly ........................................................... 1 51037 .......................... -Offset Head Limit Switch .............................................•........... 1 51039-002 ...........•........ -Limit Switch Arm, Short ............................................................ 1 67114-003 .................... -Strain Relief 1/2"NPT .37/.5 .......................................•....•...... 1 55868 .......................... Spacer, .5"OD x #10 ID x .5L Nylon ......................................... 2 BOW31148 .................. Screw, Round Hd #lO-32UNF x 2 ............................................. 2 BOW31233 .................. Nut, Hex Keps #10-32 ............................................................... 2 67837-006 .................... Tie, Nylon 6" Black ..................................................................... 1 55222 .......................... Cover, Chassis Elec. Terminal ..................................................... 1 34552-008 .................... TerminalStrip ............................................................•....•........... 1 BOW31130 .................. Bolt, Round Hd #8-32UNC 1/2 " •••••••••••••••••••••••••••••••••••••••••••••••• 2 BOW31232 .................. Nut, Hex Keps #8-32UNC ........................................................ 2 54952 .......................... Support Weldment, Cable ...............................................•........... 1 BOW34980 .................. Pin, Roll.125 x 1.250 .................................................................. 1 BOW34575 .................. Bolt, Carriage .25-20UNC x .75L ....................................•........... 2 54926 .......................... Tray, Extension Cable ................................................................. 1 BOW30002 .................. Bolt,Hex.25-20UNCx.75 ........................................................ 3 BOW36780 .................. Nut,Hex.25-20UNCNylonLock .............................................. 9 BOW31444 .................. Washer,Flat.25"IDx.63"OD .................................................. 12 BOW32606 .................. Clamp, Wire Loom 1" Dia ...................................•..................... 3 67281-005 .................... Wrapping, 3/4" Black/Spiral ................................................. 66LF. 55329 .......................... Cylinder Harness Assembly ......................................................... 1

4

5

6

7 8 9

)

QTY

ITEM

10 11 12 13 14 15 16 17 18 19 20 21 22

23

DESCRIPTION

- Indicates Items Not Shown

) MANUAL 92350-003

Jamruyl997 SIN )(935·97051

•

FIGURE 4.1: Box Assembly-Lower Control

o

o

o

o

3

4

I I I I I I

o

III III 111

ill ~I

fUSE

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 92350-003

January 1997 SIN X935-97051

FIGURE 4.1: Box Assembly-Lower Control •

P ART NUMBER

Ref. 1 2 3

55489 •..............•.......... BoxAssembly-LowerControl ...........................................•.. Ref. 55488 .......................... Box,Mach.LowerControl ......................................................... 1 55029 .......................... Decal, Box Elec. T ags ................................................................. 1 51913 .......................... Operator,RedP-Pull ...........................•...................................... 1 51914 .......................... Base + lNCContact ............•.................. ,,~:: ........................... 1 52670 .......................... Operator, 3 Pos. Rot (Key Switch 52671) .. ~ .. 8..~Q.~9..I~ .. 1 52029 .......................... Base + 2 NO Contacts ............................................................... 1 50075 .......................... Switch, (R.efPIN 67760) ........................................•...........•....... 1 54438 .......................... Relay, 24V SPDTBosch ...................................................•.......... 1 206-00001-00 ............... Diode ................................................................•....................... 9 67114-013 ..............•..... StrainRelieflNPT.62/.75 ...........................•............................. 1 67114-008 ... ...... .......•... Connector, Strain Relief...... ........ .............. ............ ............ ...... ..... 1 67114-009 .................... StrainRelief,3/4"NPT.62/.75 .................................................... 2 67124-003 .................... Locknut,l"NPT ........................................................................ 1 67124-002 .................... Locknut,3/4NPTConduit ..........................•............................... 3 67123-003 .................... Seal, Connector Elect 1" .......................•.•.................................... 1 67123-002 .................... Seal, Connector Elect. 3/4" ............................. ~ ............................ 3 34542 .......................... Jumper ....................................................................................... 4 67837-006 ....•............... Tie, Nylon 6" Black ..................................................................... 8 BOW31430 .................. Washer,Flat#10ID ................................................................... 1 BOW31129 .................. Screw,SlotRoundHd8-32UNCx 3/g " •••••••••••••••••••••••••••••••••••••• 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 Cond.16AWG Type SO ..................................... 9.50LF. 67295-004 .................... Cable, 12 Conductor 16Ga .................................................... 5LF. 34552-016 .................... Termina1Strip ............................................................................. 2 67295-022 .................... Cable, 3 Conductor 12AWG ........................................... 5.50LF. 67940 .......................... Holder,Fuse ............................................................................... 1 67939-015 .................... Fuse, 15Ga 1/4" x 1-1/ 4".............................................................. 1 58282 .......................... Wire, 12 GaBlack ......................•........................................... 4LF. 58300 .......................... Wire, 16 Ga Black .................................................................. lLF. 66720-001 .................... Disconnect, STA-KON Female ................................................... 6 BOW23087 .................. Terminal,FemalePush-On.250W ............................................... 3 67960-006 .................... Terminal,Ringl016-14AWG ..................................................... 2 BOW23024 .................. Ring, Tongue 16-14 Ga 1/4Stud ..........•....................................... 1 BOW23025 .................. Terminal,RingTongue 16-14Ga ................................................ 1 BOW18578 .................. Terminal,PiggybackR67963 ...................................................... 1 BOW23087-2 .............. Terminal,FemalePush-On.250W ............................................... 2 55489 .......................... Dwg.BoxAssembly,LowerControl ...................................... Ref.

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

A626-2633 ...................

A309-2633 ...................

A310-2633 ...................

67295-003 ....................

DESCRIPTION

QTY

ITEM

Low Volt AlarmlInterrupt ..................................................... Ref. MotionAlarm ........................................................................ Ref. StrobeLight ........................................................................... Ref. XL Models 16ga/16cond ...................................... ~ ................ Ref.

- Indicates Items Not Shown MANUAL 92350-003 Jarnwy 1997 SIN X935·97051

•

FIGURE 4.1: BoxAssembly-LowerControl

i---------------------------------r-------------d:-----l I

50 1

A

"DOWN"

5G

@o

8

"UP"

12 GA

w

o

'"

SG 9

5£

w

9 PL

3

~

2

12 GA

m

o

1

0&

)

12 GA

72 PL

58

224 PL

_______ j ________

234 PL

L-----

244 PL

3 _ 9 __O

_________

J

TO MOTOR CONT.i£TOR"-SEE SHEEr 113

. - - - - - - - - - - - - - - -- - - - - - - - - - - - - -

SEE SHEET 63

- --

I

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

NOTES: 1. THIS SHEET SHOWS "STANDARD", SEE SHEET 3 FOR 0 2. CONNECT "RED/BLK" TO SPARE, AS SMWN . .3. ALL WIRING TO BE 16 GA. EXCEPT CIRCUlfS .3,5, 8( 5[ 4. SEE WIRING DRAWING FOR COLOR TO CIRCUIT NUMBER

L ________________________________ J

i:~=--~~~~~~h'~hl~~--0NEtI_.w:,,11IQIB"

BOX ASSY.

) MANUAL 92350-003 lanuaIy 1997 SIN X935-97051

FIGURE 4.1: BoxAssembly-LowerControl

ITEM

)

)

PART NUMBER

DESCRIPTION

QTY

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

55489 .......................... Box Assembly- Lower Control .............................................. Ref. 55488 .......................... Box,Mach.LowerControl ......................................................... 1 55029 .......................... Decal, Box Elec. Tags ................................................................. 1 51913 .......................... Operator, Red P-Pu 11 ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••.. 1 51914 .......................... Base + iNC Contact ................................................................. 1 52670 .......................... Operator,3 Pos. Rot (KeySwitch52671) ..................................... 1 52029 .......................... Base + 2NO Contacts ............................................................... 1 50075 .......................... Switch, (RefP /N 67760) ............................................................ 1 54438 .......................... Relay,24VSPDTBosch .............................................................. 1 206-00001-00 ............... Diode ........................................................................................ 9 67114-013 .................... StrainRelieflNPT.62/.75 ......................................................... 1 67114-008 .................... Connector,StrainRelief............................................................... 1 67114-009 .................... Strain Relief, 3/4NPT .62/.75 ...................................................... 2 67124-003 .................... Locknut, 1" NPT ........................................................................ 1 67124-002 .................... Locknut, 3/4NPT Conduit .......................................................... 3 67123-003 .................... Seal, Connector Elect 1" .............................................................. 1 67123-002 .................... Seal, Connector Elect. 3/ / •••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 3 34542 .......................... Jumper ....................................................................................... 4 67837-006 .................... Tie,Nylon6"Black ..................................................................... 8 BOW31430 .................. Washer, Flat #10 ID ................................................................... 1 BOW31129 .................. Screw,SlotRoundHd8-32UNCx 3 /g" ...................................... 1 BOW31232 .................. Nut, Hex Keps #8-32UNC ........................................................ 1 BOW31124 .................. Screw, Round Hd #6-32 x 1/2Lg ................................................ 4 BOW31231 .................. Nut, Hex Keps #6-32 ................................................................. 4 BOW31428 .................. Washer,Flat#6 .......................................................................... 4 67295-024 .................... Cable, 8 Condo 16AWG Type SO ..................................... 9.50LF. 67295-004 .................... Cable, 12 Conductor 16Ga .................................................... 5LF. 34552-016 .................... TerminalStrip ............................................................................. 2 67295-022 .................... Cable, 3 Conductor 12AWG ........................................... 5.50LF. 67940 .......................... Holder,Fuse ............................................................................... 1 67939-015 .................... Fuse, 15Ga 1// x 1-1/4" .............................................................. 1 58282 .......................... Wire, 12GaBlack .................................................................. 4LF. 58300 .......................... Wire, 16 GaBlack .................................................................. 1LF. 66720-001 .................... Disconnect,STA-KONFemale ................................................... 6 BOW23087 .................. Terminal, FemalePush-On.250W ............................................... 3 67960-006 .................... Terminal, 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,PiggybackR67963 ...................................................... 1 BOW23087-2 .............. Terminal, FemalePush-On.250W ............................................... 2 55489 .......................... Dwg.BoxAssembly,LowerControl ...................................... Ref.

51 52 53

A626-2633 ................... LowVoltAlarmlInterrupt ..................................................... Ref. A309-2633 ................... MotionAlarm ........................................................................ Ref. A310-2633 ................... StrobeLight ........................................................................... Ref. 67295-003 .................... XL Models 16ga/16cond ....................................................... Ref.

- Indicates Items Not Shown MANUAL 92350-003 January 1997 SIN X935-97051

G

fit

FIGURE 4.1: BoxAssembly-LowerControl

o

,Ill :j : I

I

20"

I

BOX

I

I

I

INSIDE BOX 2 PL

I

I

I

o

o

I

I

I

I

I

fcl~

o

END OF STRAIN REiJEF TY?

38" CABLE SHEATH

CABLE 16GA/8C (REF) TO MOTOR CONTACTOR/ 5" SLOPE SENSOR OPTION

(REF)

67964-002 5" SLOPE OPTION

(REF)

67964-002 5" SLOPE OPTION (REF)

(REF)

67960-006 5" SLOPE OPTION

MANUAL 92350-003 JanuaIY 1997 SIN 'X935-97051

BOW23025

(REF)

5" SLOPE OPTION

67964-002 5" SLOPE OPTION

)

FIGURE 4.1: BoxAssembly-LowerControl •

)

PARTNUMBER

Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 2425 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

55489 .......................... BoxAssembly-LowerControl .............................................. Ref. 55488 .......................... Box,Mach.LowerControl ......................................................... 1 55029 .......................... Decal, Box Elec. Tags ................................................................. 1 51913 .......................... Operator,RedP-Pull ................................................•................. 1 51914 .......................... Base + lNCContact ................................................................. 1 52670 .......................... Operator, 3 Pos. Rot (Key Switch 52671) ...............•.................... 1 52029 .......................... Base + 2 NO Contacts ............................................................... 1 50075 .......................... Switch, (R.efP/N 67760) ............................................................ 1 54438 .......................... Relay, 24VSPDTBosch .............................................................. 1 206-00001-00 .•............. Diode ........•............................................................................... 9 67114-013 .................... Strain Relief 1 NPT .62/.75 ......................................................... 1 67114-008 .................... Connector,StrainRelief............................................................... 1 67114-009 .................... Strain Relief, 3/..NPT .62/.75 ...................................................... 2 67124-003 .................... Locknut,l"NPT ................•....................................................... 1 67124-002 .. ,. ................ Locknut,3/.. "NPTConduit ........................................................ 3 67123-003 .................... Seal, Connector Elect 1" ..............................................•............... 1 67123-002 .................... Seal,ConnectorElect. 31/ .......................................................... 3 34542 .......................... Jumper ....................................................................................... 4 67837-006 .................... Tie, Nylon 6" Black ..................................................................... 8 BOW31430 .................. Washer,Flat#10ID ................................................................... 1 BOW31129 .................. Screw, Slot RoundHd 8-32UNCx 3/g" •••••••••••••••••.•••••••.••.•.•••.••• 1 BOW31232 .................. Nut, Hex Keps #8-32UNC ........................................................ 1 BOW31124 .................. Screw, RoundHd #6-32 x II/Lg ............................................... 4 BOW31231 .................. Nut, Hex Keps #6-32 ................................................................. 4 BOW31428 .................. Washer,Flat#6 .......................................................................... 4 67295-024 .................... Cable,8 Cond.16AWG Type SO ..................................... 9.50LF. 67295-004 .................... Cable, 12 Conductor 16Ga ............................................... ,.,.. 5LF. 34552-016 .................... TerminalStrip ............................................................................. 2 67295-022 .................... Cable, 3 Conductor 12AWG ,.,.,.,.,.,.,. .. ,. ...... ,. ............ ,. ... 5.50LF. 67940 .. ,.,. ... ,..,.,. .......... Holder,Fuse ,.,..,. ........... ,. .. ,. .... ,. .... ,. ....... ,. .. ,. .. ,..,..,. ..... ,.,..,. .... ,. .. 1 67939-015,. ...... ,.,. .. ,.,.,. Fuse, 15Ga II.." x 1-1/4" ,.,.,.,. ...... ,. ............. ,.,.,.,.,. .... ,. ... ,. .. ,. .... ,. .. 1 58282 ,.,.,.,.,. ........ ,. .... ,. Wire, 12 Ga Black .......... ,. .............................. ,.,. .... ,.,.,.,.,.,. .... 4LF. 58300 ... ,.,. .. ,.,.,.,. .... ,.,.. Wire, 16 Ga Black .......... ,.,. .. ,. .............................. ,. ....... ,. ....... lLF. 66720-001 ,.,. .... ,. .. ,.,. .... Disconnect,STA-KONFemale ................................................... 6 BOW23087 .................. Terminal,FemalePush-On.250W .................. ,. .. ,. .............. ,.,. ..... 3 67960-006 .. ,. ........... ,. ... Terminal, Ring 10 16-14AWG ...... ,. .... ,. .......... ,.,. .. ,. .......... ,. ... ,. .... 2 BOW23024 ............ ,. .... Ring, Tongue 16-14 Ga II.... Stud ..,.,. .... ,.,. .............. ,. ........ ,. ........ 1 BOW23025,. ........... ,. ... Terminal, Ring Tongue 16-14 Ga ...... ,.,. .. ,. .. ,.,.,.,. .. ,.,.,. ................ 1 BOW18578 ........ ,. ........ Terminal,PiggybackR67963 ............. ,. ............. ,.,. .... ,. ................ 1 BOW23087-2 .............. Terminal,FemalePush-On.250W .................. ,.,.,. .............. ,. ....... 2 55489 .. ,. .......... ,.,. ........ Dwg.BoxAssembly,LowerControl ........ ,. ............................ Ref.

51 52 53

A626-2633 ...................

A309-2633 ..... ,.,. .. ,.,. .. ,.

A310-2633 .. ,. ...............

67295-003 ................ ,. ..

DESCRIPTION

QTY

ITEM

Low Volt AlarmlInterrupt .. ,. .... ,. .... ,. .. ,. .... ,. ........................ ,.. Ref. MotionAlarm ....... ,. ... ,..,. .. ,. ..... ,. ..... ,. ...... ,..,. .. ,. ...... ,.,.,. .......... Ref. StrobeLight ....................................... ,. ...... ,. .......................... Ref. XL Models 16gal16cond ............ ,. ................ ,. ........ ,.,. ........... Ref.

- Indicates Items Not Shown MANUAL 92350-003 JanuaI)' 1997 SIN Xl/35-97051

•

FIGURE 4.1: Box Assembly- Lower Control

i---------------------------------r--------------5

:

t~cJf\b

:

I

I

12GA

,odf'l

5D

~

1

-----l

IZ GA

1

"OOWN"

~

5G

"uP"

~::-,2GA

12 GA

@

5G

~

5E

5E

N2:,

!

'-b-------~Jr---------~,------~-5-8--;5B

234 Pl

I

244 PL

_ _ _ _ _ _ _ _ _ -----1 _ _ _ _ _ _ _ _ _ _ _ _ _

I--------r---- 1-------- f - - - -

SEE SHEET #3

1----

!.1

LOW VOLT oPTION

5.3

STROBE LIGHT QPnON

,~,'c<i'-,G"A----)

i2~ ~:~ ETC.

16 GA

SO

@

L.?_

50

""'---~==ilt~cn~

16

~---

(~~O!~~ __ _ ~CONTACTOR

VALVES

SEE SHEET #3

o

38 39

O _________

J

(REF) 1 EA. BOW18578 (REF) 1 EA. 80W2.3087 5' SLOPE OPTION

SEE SHEET #3

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

I NOTES: 1. THIS 5HEE T SHOWS ALL OPTIONS. SEE SHEEr 2 FOR "STANDARD",

2. CONNECT "RED/BLK~ TO SPARE, AS SHOW, IF NO ALARM OPnON. CONNECT "RED/BLK" TO CIRCUIT 8e FOR MonON ALARM OPTION. CONNECT "RED/BLK TO CIRCUIT 9 FOR DESCEND ALARM OPTION. CONNECT "RED/BLK~ TO CIRCUIT 80 FOR TRAVEL ALARM OP"TION. 3. ALL WIRING TO BE 1E. GA. EXCEPT CIRCUITS ,3,5, &: 50 A;5 MARI\ED. 4. IF LOW VOLT OPTION IS USED, THEN 00 NOT USE JUMPER BETWE£N 8A AND 88 N

5. SEE Vv1RtNG ORAW1NG FOR COLOR TO CIRCUIT NUMBER TABLE.

51

LOW VOLTAGE BATTERY PROTECTION opnON

RESET GROUND

L _____________ : ::: ________________ ~

MANUAL 92350-003

Januatyl997 SIN X935-97051

)

FIGURE 4.1 Box Assembly- Lower Control

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 36 37 38 39 40 51 52 53

PART NUMBER

DESCRIPTION

QTY

55489 .......................... BoxAssembly-LowerControl .............................................. Ref. 55488 .......................... Box, Mach. Lower Control ......................................................... 1 55029 .......................... Decal, Box Elec. T ags ................................................................. 1 51913 .......................... Operator ,RedP-Pull .................................................................. 1 51914 .......................... Base + 1 NCContact ................................................................. 1 52670 .......................... Operator, 3 Pos. Rot (Key Switch 52671) ................................... 1 52029 .......................... Base + 2 NO Contacts ............................................................... 1 50075 .......................... Switch, (RefP/N 67760) ............................................................ 1 54438 .......................... Relay,24VSPDTBosch .............................................................. 1 206-00001-00 ............... Diode ........................................................................................ 9 67114-013 .................... Strain Relief 1 NPT .62/.75 ......................................................... 1 67114-008 .................... Connector,StrainRelief ............................................................... 1 67114-009 .................... StrainRelief,3//NPT.62/.75 .................................................... 2 67124-003 .................... Locknut, 1" NPT ........................................................................ 1 67124-002 .................... Locknut, 3// NPT Conduit ........................................................ 3 67123-003 .................... Seal, Connector Elect 1" .............................................................. 1 67123-002 .................... Seal, Connector Elect. 3// .......................................................... 3 34542 .......................... Jumper ....................................................................................... 4 67837-006 .................... Tie, Nylon 6" Black ..................................................................... 8 BOW31430 .................. Washer, Flat#10ID ................................................................... 1 BOW31129 .................. Screw, Slot RoundHd 8-32UNC x 3/g" •••••••••••••••••••••••••••••••••••••• 1 BOW31232 .................. Nut, HexKeps#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 Cond.16AWG Type SO ..................................... 9.50LF. 67295-004 .................... Cable, 12 Conductor 16Ga .................................................... 5LF. 34552-016 .................... TerrninalStrip ............................................................................. 2 67295-022 .................... Cable, 3 Conductor 12AWG ........................................... 5.s0LF. 67940 .......................... Holder,Fuse ............................................................................... 1 67939-015 .................... Fuse, 15Ga 1// x 1-1/4" .............................................................. 1 58282 .......................... Wire, 12 GaBlack .................................................................. 4LF. 58300 .......................... Wire, 16GaBlack .................................................................. lLF. 66720-001 .................... Disconnect,STA-KONFemale ................................................... 6 BOW23087 .................. Terminal,FemalePush-On.250W ............................................... 3 67960-006 .................... Terminal, RingJO 16-14AWG ..................................................... 2 BOW23024 .................. Ring, Tongue 16-14 Ga 1// Stud ................................................ 1 BOW23025 .................. Terminal, Ring Tongue 16-14Ga ................................................ 1 BOW18578 .................. Terminal,PiggybackR67963 ...................................................... 1 BOW23087-2 .............. Terminal,FemalePush-On.250W ............................................... 2 55489 .......................... Dwg.BoxAssembly,LowerControl ...................................... Ref. A626-2633 ...................

A309-2633 ...................

A310-2633 ...................

67295-003 ....................

Low Volt AlarmlInterrupt ..................................................... Ref. MotionAlarm ........................................................................ Ref. Strobe Light ........................................................................... Ref. XL Models 16ga/16cond ....................................................... Ref.

- Indicates Items Not Shown MANUAL 92350-003 Iammy 1997 SIN X935-97051

8)

. , FIGURES.l:ArmstackAssembly

~~.,~~--~--~=~.,

~-

_____ - - - - - - - - - - - - - - - ___

14 15

-----

--___

SEE NOTE 2

~3

--___ ----r-- - -----<:::::"'-_ .... ___ .~

---------~_--

--

___ -

SEENOTE2~3~::~ ----

___ -

-

----

--______

F\\

~-----

'

,-

~-./(

14 15

2 PL

- -..::::::::.- -

---, ---- --

14 15

- - ___

14 15

---~:.----..:::::::---

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

-":::::::::':.-

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

- - - - - - -13

-~

-....-:::::.....--_

____ - - - - - - - - -

\

----

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

-::----

---:>::-

- --- - -

---~--

- -

)

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

2 PL

- - _____~19 30 2PL

NOTES: 1.

TOTAL EST. WT.= 1090 LBS.

2.

ITEM 13 TO BE ON UPHILL SIDE OF ROUND TUBE. ITEMS 14 & 15 TO BE ON DOWNHILL SIDE OF ROUND TUBE.

3.

THIS OWG SUPERCEDES 55282.

) MANUAL 92350-003

Janwnyl997 SIN X935-97051

FIGURE5.1:ArmstackAssembly • 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 36 37 38 39

PART NUMBER

DESCRIPTION

QTY

55441 .......................... ArmstackAssembly ................................................................ Ref. 55418 .......................... Armstack Weldment + Brg/Pin .................................................. 1 55418-001 .................... Arm Weldment, Lower Outer ..................................................... 1 55418-002 .................... Arm Weldment, Lower Inner ...................................................... 1 55418-003 .................... Arm Weldment, Left Middle Outer ............................................ 1 55418-004 .................... Arm Weldment, Right Middle Outer ........................................... 1 55418-005 .................... Arm Weldment,Middle Inner ..................................................... 1 55418-006 .................... Arm Weldment, Upper Outer ..................................................... 1 55418-007 .................... Arm Weldment, Upper Inner ...................................................... 1 81368-007 .................... Bearing, 1.50"ID x 2.50"L x 1/8 W ........................................... 14 54616-002 .................... Shaft, Arm Pivot 6 3//Lg ........................................................... 4 54616-001 .................... Shaft, Arm Pivot 18" Lg ............................................................. 5 67281-005 .................... Wrapping, 3// Black/Spiral .............................................. 2.83LF. 66388-001 .................... Collar, 1 1/ 2 " Shaft .................................................................... 14 BOW30037 .................. Bolt,Hex.31-18UNCx3.00 ..................................................... 11 BOW31432 .................. Washer,Flat.31"IDx.68"OD .................................................. 21 BOW34273 .................. Nut,LockHex 5/16"-18UNC .................................................... 15 55327 .......................... Harness, Main Control ................................................................ 1 67295-017 .................... Cable, 3 Conductor 12 Ga ................................................... 39LF. 67998-001 .................... Screw, Thread Frmng.. 38-16 x 1.0 Lg ........................................ 2 BOW32606 .................. Clamp, Wire Loom 1"Dia .......................................................... 9 BOW9977 ................... O-Ring, .375"ID x .50"OD ......................................................... 1 BOW30000 .................. Bolt,Hex.25-20UNCx.50 ........................................................ 2 BOW31401 .................. Washer,Flat.25"IDx.63"OD .................................................... 2 BOW30035 .................. Bolt,Hex.31-18UNCx2.50 ....................................................... 2 BOW30036 .................. Bolt,Hex.31-18UNCx2.75 ....................................................... 4 55083 .......................... ManifoldAssembly, Lift Cylinder ................................................ 1 54569 .......................... Cable Bracket, Holding Valve ...................................................... 1 54798 .......................... Nut, 10-32UNF Coupling ........................................................... 1 54705 .......................... Cylinder,ArmstackLift ............................................................... 1 34145 .......................... Bushing, (R#81368) .................................................................... 4 BOW36780 .................. Nut,Hex.25-20UNCNylonLock .............................................. 8 54616-004 .................... Shaft, ArmPivot6.50"Lg............................................................ 1 55027 .......................... Pin Weldment, Lift Cylinder ........................................................ 1 55279 .......................... Block,HDPESlide ..................................................................... 2 54616-009 .................... Shaft,ArmPivot20.38"Lg.......................................................... 2 54701 .......................... Block,ArmstackNylatron ........................................................... 2 54616-008 .................... Shaft,ArmPivot26.62"Lg.......................................................... 2 54582 .......................... Block, UHMWPEBearing .......................................................... 2 02236 .......................... Elbow, 90° MJ04 M004 ............................................................ 1 02662 .......................... Elbow, 90° MJ06 M006 ............................................................ 1

- Indicates Items Not Shown

) MANUAL 92350-003 January 1997 SIN X935-97051

, J

4 PL

115 1/2

7

~ 132

.1

e '"r.I ~

GJ

~

~

!":'"

~ ~

~

~

6

5 PL

5

RIGHT SIDE VIEW

m cr

~

FIGURES.l:AnnstackAssembly •

)

QTY

ITEM

PARTNUMBER

Ref.

55441 .......................... ArrnstackAssembly ................................................................ Ref. 55418 .......................... Arrnstack Weldment + Brg/Pin .................................................. 1 55418-001 .................... Arm Weldment,Lower Outer ..................................................... 1 55418-002 .................... ArmWeldment,LowerInner ...................................................... 1 55418-003 .................... Arm Weldment, Left Middle Outer ............................................ 1 55418-004 .................... Arm Weldment, Right Middle Outer ........................................... 1 55418-005 .................... Arm Weldment,MiddleInner ..................................................... 1 55418-006 .................... ArmWeldment,UpperOuter ..................................................... 1 55418-007 .................... Arm Weldment, Upper Inner ...................................................... 1 81368-007 .................... Bearing, 1.50"ID x 2.50"L x 1/8 W ........................................... 14 54616-002 .................... Shaft, Arm Pivot 6 3/ /Lg ........................................................... 4 54616-001 .................... Shaft, Arm Pivot 18" Lg ............................................................. 5 67281-005 .................... Wrapping, 3// Black/Spiral ............................................. , 2.83LF. 66388-001 .................... Collar, 1 1/ 2 " Shaft .................................................................... 14 BOW30037 .................. Bolt,Hex.31-18UNCx3.00 ..................................................... 11 BOW31432 .................. Washer,Flat.31"IDx.68"OD .................................................. 21 BOW34273 .................. Nut,LockHex s/16"-18UNC .................................................... 15 55327 .......................... Harness, Main Control ................................................................ 1 67295-017 .................... Cable, 3 Conductor 12 Ga ................................................... 39LF. 67998-001.. .................. Screw, Thread Frmng.. 38-16x 1.0Lg ........................................ 2 BOW32606 .................. Clamp, Wire Loom l"Dia .......................................................... 9 BOW9977 ................... O-Ring, .375"ID x .50"OD ......................................................... 1 BOW30000 .................. Bolt, Hex .25-20UNC x .50 ........................................................ 2 BOW31401 .................. Washer,Flat.25"IDx.63"OD .................................................... 2 BOW30035 .................. Bolt,Hex.31-18UNCx2.50 ....................................................... 2 BOW30036 .................. Bolt,Hex.31-18UNCx2.75 ....................................................... 4 55083 .......................... ManifoldAssembly,LiftCylinder ................................................ 1 54569 .......................... Cable Bracket, Holding Valve ...................................................... 1 54798 .......................... Nut, 10-32UNF Coupling ........................................................... 1 54705 .......................... Cylinder,ArmstackLift ............................................................... 1 34145 .......................... Bushing, (R#81368) .................................................................... 4 BOW36780 .................. Nut,Hex.25-20UNCNylonLock .............................................. 8 54616-004 .................... Shaft, ArmPivot6.50"Lg............................................................ 1 55027 .......................... Pin Weldment,LiftCylinder ........................................................ 1 55279 .......................... Block,IIDPESlide ..................................................................... 2 54616-009 .................... Shaft,ArmPivot20.38"Lg.......................................................... 2 54701 ........... :.............. Block,ArmstackNylatron ........................................................... 2 54616-008 .................... Shaft,ArmPivQt26.62"Lg.......................................................... 2 54582 .......................... Block, lJI-IMWPEBearing .......................................................... 2 02236 .......................... Elbow, 90° M]04 M004 ............................................................. 1 02662 .......................... Elbow, 90° M]06 M006 ............................................................ 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 33 34 35 36 37 38 39

DESCRIPTION

- Indicates Items Not Shown

) MANUAL 92350-003 January 1997 SIN X935-97051

. , FIGURE 5.1: ArmstackAssembly

4 PL

5 PL

8

10

-----------~-----------~ 10 PL

12

SEE NOTE #1

SECTION C-C Scale= 1:3

2 PL

SEE

SECTION 8-8 Scole= 1: 3

2 PL

9

2 PL 12 SEE NOTE #1

SECTION A-A Scale= 1: 3

MANUAL 923 50-003 January 1997 SIN X935-97051

FIGURE 5.1: ArmstackAssembly • ITEM

PART NUMBER

Ref.

55441 .......................... Annstack.Assembly ................................................................ Ref. 55418 .......................... Annstack Welchnent + Brg/Pin .................................................. 1 55418-001 .................... Arm Weldment, Lower Outer ..................................................... 1 55418-002 .................... ArmWelchnent, Lower Inn er ...................................................... 1 55418-003 .................... Arm Weldment, Left Middle Outer ............................................ 1 55418-004 .................... Ann Weldment, Right Middle Outer ........................................... 1 55418-005 .................... ArmWeldment,MiddleInner ..................................................... 1 55418-006 .................... Arm Welchnent, Upper Outer ..................................................... 1 55418-007 .................... Arm Welchnent, Upper Inner ..................•................................... 1 81368-007 .................... Bearing, 1.50"ID x2.50"L x 1/8 W ........................................... 14 54616-002 .................... Shaft, Arm Pivot 6 3/ 4"Lg .....................•..................................... 4 54616-001 .................... Shaft, Arm Pivot 18" Lg ............................................................. 5 67281-005 .................... Wrapping,3/4 "Black/Spiral .............................................. 2.83LF. 66388-001 .................... Collar, 1 1/ 2" Shaft .................................................................... 14 BOW30037 .................. Bolt,Hex.31-18UNCx3.00 ......•.............................................. 11 BOW31432 .................. Washer,Flat.31"IDx.68"OD .................................................. 21 BOW34273 .....•............ Nut,LockHex 5/ 16-18UNC ..................................................... 15 55327 .......................... Harness, Main Control ..............................•................................. 1 67295-017 .................... Cable, 3 Conductor 12 Ga ................................................... 39LF. 67998-001 .................... Screw, Thread Frmng..38-16 x 1.0 Lg .......................................• 2 BOW32606 .................. Clamp,WireLooml"Dia .......................................................... 9 BOW9977 ................... O-Ring,.375"IDx.50"OD ......................................................... 1 BOW30000 .................. Bolt,Hex.25-20UNCx.50 ........................................................ 2 BOW31401 .................. Washer,Flat .25"IDx.63"OD .................................................... 2 BOW30035 .................. Bolt,Hex.31-18UNCx2.50 ....................................................... 2 BOW30036 .................. Bolt,Hex.31-18UNCx2.75 •...................................................... 4 55083 .......................... ManifoldAssembly,LiftCylinder ................................................ 1 54569 .......................... Cable Bracket, Holding Valve ...................................................... 1 54798 .......................... Nut, 10-32UNF Coupling ........................................................... 1 54705 .......................... Cylinder,ArmstackLift ............................................................... 1 34145 .......................... Bushing, (R#81368) .................................................................... 4 BOW36780 .................. Nut,Hex.25-20UNCNylonLock .............................................. 8 54616-004 .................... Shaft, Arm Pivot 6.50"Lg............................................................ 1 55027 .......................... Pin Welchnent, Lift Cylinder ........................................................ 1 55279 .......................... Block,lIDPESlide ..................................................................... 2 54616-009 .................... Shaft, ArmPivot20.38"Lg.......................................................... 2 54701 .......................... Block,ArmstackNylatron ........................................................... 2 54616-008 .................... Shaft,ArmPivot26.62"Lg......................•................................... 2 54582 .......................... Block, lJ1-Th1WPEBearing .......................................................... 2 02236 .......................... Elbow, 90° M]04M004 ............................................................ 1 02662 .......................... Elbow, 90° M}06M006 ............................................................ 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 33 34 35 36 37 38 39

DESCRIPTION

- Indicates Items Not Shown

) MANUAL 92350-003

Janwuyl997 SIN X935-9705\

QTY

G ~ .....

CJ

~

U1

~

§ ~

~ p;-

r

a-: ()

~

ft;:t>

CAVITY FOR PARKER FVIOIS VALVE CARTRIDGE REF. CONDOR #55221

en

REF FOUR BUSHIN(, 34145

g CJ

o::c=

~ ~----------------------r--i

I

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -+--

I

I __ I _______________________ L ~

FIGURE 5.2: ArmstackLift Cylinder Assembly •

ITEM

PARTNUMBER

DESCRIPTION

Ref.

54705 .......................... ArrnstackLiftCylinder Assembly ............................................ Ref. 54705-100 .................... Seal Kit ...........................................................................•.............

54705-101 .................... CastleNut .........................................................•..........................

54705-102 .................... Cast Iron Ring ............................................................................. .

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

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

54705-105 .................... Jacket Assembly ........................................................................... .

54705-106 .................... Piston Rod .................................................................................. .

54705-107 .................... GlandNut ................................................................................... .

55221 .......................... FlowControlValve,LiftCylinder ........•........................................

QTY

- Indicates Items Not Shown

) MANUAL 92350-003 JanU3l}' 1997 SIN )(935-97051

----'-,-'

CD FIGURE 5.3: Manifold Assembly c=--=r==-,

(

,

[QJ JL

11

II

---\®;T

I I

-'Zf;" ' ) ITEM

PARTNUMBER

DESCRIPTION

Ref. 1 2 -3

55083 .......................... Manifold Assembly ................................................................ Ref. 54596-001 .................... Manifold, Lift Cylinder ............................................................... 1 54635-001 .................... Valve, 2WNCSPCL Cartridge ................................................... 1 00417 .......................... Plug,M004 ................................................................................ 1

QTY

- Indicates Items Not Shown

) MANUAL 92350·003 Janruuy 1997 SIN X935-97051

SECTION A-A SAE-6 a-RING PORT SAE-4 a-RING PORT

VALVE CAVITY PER CHART

LINE PORT

GAUGE PORT

..JB

FROM CAVllY SPOTFACE

~ O-RING DETAIL

SEE 0- RING DE' AlL CYLINDER PORT

. , FIGURE 6.1: Platform Installation

2

o

o

3

o o o

o

o

o

) 10

o

o

o

) MANUAL 92350-003

Janwuyl997 SIN X935-97051

FIGURE 6.1: Platform Installation . ,

PARTNUMBER

Ref.

55478 .......................... Platform Installation ................................................................ Ref. 54598 .......................... Platform Weldment .................................................................... 1 55474-001 .................... ToeboardWeldmentLH ............................................................ 1 55474-002 .................... ToeboardWeldmentRH ............................................................ 1 54682 .......................... MountWeldment,Ext.DeckRoller ............................................ 4 54689 .......................... Roller, Ext. Deck ........................................................................ 4 55476 .......................... DeckWeldment,Ext.................................................................. 1 55267 .......................... HandraiIWeldment,Ext.Deck .................................................... 1 55241 .......................... LatchAssembly,.62-11UNCMount ........................................... 1 55473 .......................... Handrail W eldment, Side ............................................................. 2 55470 .......................... Gate, Lift Up ............................................................................. 1 55471 .......................... Plunger, Latch ............................................................................. 2 55243 .......................... Spring,DeckLatch ..................................................................... 2 55244 .......................... Finger Ring,DeckLatch .............................................................. 2 BOW36702-HD .......... Washer, .313, .813 "OD x .344"ID x .10 ...................................... 8 BOW2548 ................... S-Hook ...................................................................................... 1 164-00013-00 ............... Chain2l0 ......................................................................... 2.50LF. 50286 .......................... ChainSnap ................................................................................. 1 BOW34273 .................. Nut,LockHex 5/16"-18UNC .................................................... 34 BOW36718-HD .......... Washer, Flat 3// SAE ................................................................. 4 BOW30002 .................. Bolt,Hex.25-20UNCx.750 ..................................................... 12 BOW30008 .................. Bolt,Hex.25-20UNCx2.00 ....................................................... 6 BOW31444 .................. Washer,Flat.25"IDx.63"OD .................................................. 16 BOW36780 .................. Nut,Hex.25-20UNCNylonLock ............................................ 18 BOW30027 .................. Bolt,Hex.31-18UNCx.75 ...................................................... 18 BOW34602 .................. Bolt, Carr .31-18UNC x 1.25 .................................................... 16 BOW31432 .................. Washer,Flat.31"IDx.68"OD .................................................. 52 55207 .......................... Plug,Dome ................................................................................ 2 55563 .......................... BracketWeldment,LockMount .................................................. 1

1 2 3 4

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

)

QTY

ITEM

22 23 24 25 26 27 28

DESCRIPTION

- Indicates Items Not Shown

~ ~

~'"

0

0 0

0

0

0

0

0

c6 MANUAL 92350-003 January 1997 SIN X935-97051

0

0

0

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0

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0 0

0

0 0

0 0

0 0

0

0 0

0

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0

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0

0 0

0

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0

0

0

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0

0

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0

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0

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•

This page intentionally left blank

)

) MANUAL 92350-003 January 1997 SIN X935-97051

FIGURE 6.2: 110 Volt Extension To Platform •

GRE N -LOCA TED AT RIGHT REAR

WHITE OF PLATFORM-NOT ILLUSTRATED

BLACK

2

:3 PL -LOCA TED UNDER PLATFORM

REF. CABLE IS INCLUDED IN ARMSTACK AT CHASSIS

12

REF. LEFT

GOLD SCREW

FRONT OF CHASSIS

GREEN SCREW

11

SILVER SCREW

PARTNUMBER

Ref.

54918 .......................... 110VoltExtensionToPlatform{Option) ............................... Ref.

1 2 3 4

5 6 7 8 9

-)

10 11 12 13

66357 ..........................

55019 ..........................

66358 ..........................

67114-003 ....................

67124-001 ....................

67123-001 ....................

BOW31105..................

BOW31233 ..................

BOW32603 ..................

52710 ..........................

55036-001.. ..................

BOW34272 ..................

DESCRIPTION

QTY

ITEM

Receptacle, Ground Fault ............................................................ 1 OutletBox,Platform .................................................................. 1 Cover, Weatherproof .................................................................. 1 Strain Relief1/2"NPT .371.5 ........................................................ 1 Locknut, 1/2"NPTStrainRelief .................................................... 1 Seal, Connector Elect. 1/2" •••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1 10-32 x .75 Slotted Pan Head, Machine Screw.............................. 2 Nut, Hex Keps #10-32 ............................................................... 2 Clamp, WireLoom.50 ............................................................... 4 Plug,110Volt ............................................................................. 1 Grommet, 1/2" II) 1/4 X 13 / 16" Dia. Grv ..................................... 1 Nut,HexLock.25"-20UNC ....................................................... 4

- Indicates Items Not Shown MANUAL 923S0'()03

Janwuyl997 SIN X93S-970S1

. , FIGURE 6.3: Upper Control Box Assembly

17

35 REF'

I I

"" LOWER

II

"I I

II

"

I

"

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I

I : L_U ____'I

I", I' I,

l ___________________________ l

) MANUAL 92350·003

Janrnuyl997 SIN )(935·97051

FIGURE 6.3: Upper Control Box Assembly •

)

PARTNUMBER

Ref. 1 2

55317 .......................... Upper Control Box Assembly ...•............................................. Ref. 54587 ..................•....... Box, Upper Control ........................................................•.......... 1 5~ .. 5.19.7.g.~.......... Contr.BMS4RM9071 W/RG5 + Lever ...................................... 1 54589-100 .................... -Boot ......................................................................................... 1 51913 .......................•.. Operator-Push Pull ..................................................................... 1 51914 .......................... Contact BlockNC ...................................................................... 1 52670 .......................... OperatorSelector ...•.............•..................................................... 1 34464 .......................... ContactBlockNO-NC .............................................................. 1 52669 .......................... Operator Black Pushbutton .•....................................................... 1 52672 ............•............. Contact Block 1 NO .................................................................. 2 69146 .........•................ Operator, Green Pushbutton ....................................................... 1 54913 .......................... Operator-BlacklBlackD\JaISwitch ........................................... 1 52029 .......................... BlockContact2NOw/Base ...................................................... 1 54910-104 .................... MountingBase-AGPanel .......................................................... 1 54910-102 .................... Recep. Screw Term. #1-16 ......................................................... 1 67837-006 .................... Tie, Nylon 6.00" Black ................................................................ 5 BOW31125 .................. Screw, SlottedPan#06-32UNF x .62" ........................................ 4 BOW31231 .................. Nut,'Hex Keps #6-32 ................................................................. 4 55012 .......................... Insert, Control Box Plastic ..•........................................................ 2 58300 .......................... Wire, 16GaBlack ................................................................... 8LF. 54976-001 .................... Decal, UpperControIBox .......................................................... 1 54976-002 .................... Decal, Upper Control Box .......................................................... 1

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 31 32 33 34 35 36 37

DESCRIPTION

QTY

ITEM

A620-2633 ................... BatteryConditionIndicator(Option) ....................................... Ref. A353-2633 ................... Slope Alarm (Option) ............................................................. Ref. A626-2633 ................... Low Volt AlarmlInterrupt (Option) ....................................... Ref. A304-2633 ................... Signal Horn (Option) .............................................................. Ref.

- Indicates Items Not Shown

) MANUAL 92350-003

Janwuyl997 SIN X935-97051

r

,-----------------, I

OPTIONAL SLOPE ALARM

...

Z

511I

13

SEE NOTE I

...

18 I

r-- ---- --- --- --- ---- --- -l-- - - - - - - - - -Jl - - - - - - - - - - - - - LID (FLIPPED OPEN)

----i

LEFT SIDE

I

OPTIONAL

BATTIERY

INDICATOR

OPTIONAL LOW VOLTAGE OVERRIDE SIIHCH

o>< "'I

JA

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VIEW OF INSIDE OF BOX

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1-+----I---+-I~'4T.:iI~~~

NOTES: 1. CONNECT CIRCUIT" AS REOUIRED BY OPTIONS. 2. CIRCUITS 1, 5, 13, 14, 15, & 16 ARE FOR OPTIONS.

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WACO, TEXAS

BOX ASSY MDD263.3 UPPER CNTRL

lIft.t

55317 I:I.~

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2 Or:' 2

FIGURE 6.3: Upper Control Box Assembly

PARTNUMBER

Ref. 1 2

55317 .......................... UpperControlBoxAssembly ................................................. Ref. 54587 .......................... Box, Upper Control ................................................................... 1 54589 .......................... Contr.BMS4RM9071 W IRG5 + Lever ...................................... 1 54589-100 .................... -Boot ......................................................................................... 1 51913 .......................... Operator-PushPull ..................................................................... 1 51914 .......................... Contact BlockNC ...................................................................... 1 52670 .......................... OperatorSelector ....................................................................... 1 34464 .......................... ContactBlockNO-NC .............................................................. 1 52669 .......................... Operator Black Pushbutton ......................................................... 1 52672 .......................... Contact Block 1 NO .................................................................. 2 69146 .......................... Operator, Green Pushbutton ....................................................... 1 54913 .......................... Operator-BlacklBlackDualSwitch ........................................... 1 52029 .......................... BlockContact2NOw/Base ...................................................... 1 54910-104 .................... MountingBase-AGPanel. ......................................................... 1 54910-102 .................... Recep. Screw Term. #1-16 ......................................................... 1 67837-006 .................... Tie, Nylon 6.00" Black ................................................................ 5 BOW31125 .................. Screw, SlottedPan#06-32UNF x .62" ........................................ 4 BOW31231 .................. Nut, Hex Keps #6-32 ................................................................. 4 55012 .......................... Insert, ControlBoxPlastic ........................................................... 2 58300 .......................... Wire, 16Ga Black ................................................................... 8LF. 54976-001 .................... Decal, Upper Control Box .......................................................... 1 54976-002 .................... Decal, UpperControIBox .......................................................... 1

3 4 5 6 7 8 9 10

11

)

12 13 14 15 16 17 18 19 20 31 32 33 34 35 36 37

DESCRIPTION

QTY

ITEM

A620-2633 ................... BatteryConditionIndicator(Option) ....................................... Ref. A353-2633 ................... Slope Alarm (Option) ............................................................. Ref. A626-2633 ................... Low Volt AlarmlInterrupt (Option) ....................................... Re£ A304-2633 ................... Signal Hom (Option) .............................................................. Ref.

- Indicates Items Not Shown

MANUAL 92350-003

Januaxyl997

SIN X935·97051

G

•

FIGURE 7.1: Travel Alarm (Option)

QTY

ITEM

PART NUMBER

DESCRIPTION

Ref. -1 -2 -3 -4

A301-2633 ...................

80188-024 ....................

67295-035 ....................

BOW23027 ..................

55036-001 ....................

TravelAlarm .......................................................................... Ref. WobbulatorandSpeaker ............................................................. 1 Cable, 16Ga.l2 Conductor S]O ............................................. 2LF Terminal 6 Stud 16/14Ga. Spade ............................................... 4 Grommet, 1/2"ID 1// x 13/16 "Dia. Grv ...................................... 1

- Indicates Items Not Shown

)

) MANUAL 92350-003 Januruy 1997 SIN X935-97051

FIGURE 7.2: MotionAlarm (Option)

QTY

ITEM

PART NUMBER

Ref.

A309-2633 ................... MotionAlarm ........................................................................ Ref. 80188-024 .................... WobbulatorandSpeaker ............................................................. 1 67295-035 .................... Cable, 16Ga.l2Conductor SJO ............................................. 2LF BOW23027 .................. Terminal 6 Stud 16/14Ga. Spade ............................................... 4 55036-001. ................... Grommet, 1/2"ID 1// x 13/16"Dia. Grv ...................................... 1 206-00001-00 ............... Diode ........................................................................................ 2

-1 -2 -3

-4 -5

DESCRIPTION

- Indicates Items Not Shown

)

) MANVAL92350-003 lanuaIy 1997 SIN X935-97051

G

•

FIGURE 7.3: Strobe Light (Option)

REF. RIGHT SIDE VIEW OF PLATFORM

4 3 PL

3

2

)

ITEM

PARTNUMBER

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

A310-2633 ................... Strobe Light ........................................................................... Ref. 58395 .......................... Light Amber Strobe 12-72 VDC ............................................... 1 BOW31400 .................. Washer,Flat #10 ....................................................................... 3 BOW31144 .................. Screw, Slot Rnd. #10-32UNF x .50 ............................................ 3 55400 .......................... Mount -Strobe Light 14" .......................................................... 1 BOW34001 .................. Bolt, Hex .25-20UNC x 1.00 ..................................................... 2 BOW31432 .................. Washer, Flat .31 ID x .68 OD .................................................... 2 BOW36780 .................. Nut,Hex .25-20UNCNylonLock ............................................. 2 67295-035 .................... Cable, 16Ga.l2 Conductor SJO .......................................... 50LF 52672 .......................... Base + 1 NO Contact ZB2BZ101 ............................................. 2 58259 .......................... Wire, 18Ga. Black-Bulk .......................................................... 1LF

DESCRIPTION

QTY

)

- Indicates Items Not Shown

MANUAL 92350-003 January 1997 SIN X935-97051

FIGURE7.4DescendAlarm(Option) •

ITEM

PARTNUMBER

Ref.

A312-2633 ................... DescendAlarm ....................................................................... Ref. 80188-024 .................... WobbulatorandSpeaker 24V .................................................... 1 67295-035 .................... Cable, 16Ga.l2 Conductor 5JO ............................................ 2LF BOW23027 .................. Terminal 6 Stud 16/14Ga. Spade ............................................... 4 55036-001 .................... Grommet, 1/2"ID 1// x 13/16 "Dia .............................................. 1 34542 .......................... Jumper ....................................................................................... 1

-1 -2 -3 -4 -5

DESCRIPTION

- Indicates Items Not Shown

MANUAL 92350-003 January 1997 SIN X935-97051

QTY

•

FIGURE 7.5: Slope Alarm (Option)

QTY

ITEM

PART NUMBER

Ref. -1

A353-2633 ................... Slope Alarm ........................................................................... Ref. 32002 .......................... Slope Sensor 2-Axis ................................................................... 1 BOW30002 .................. Bolt, Hex .25-20UNC x .750 ..................................................... 2 BOW31432 .................. Washer, Flat .31 ID x .68 OD .................................................... 2 67295-024 .................... Cable, 8 Conductor 16AWG Type SO .................................. 7LF BOW23003 .................. Terminal Ring #6796022-18 #10 Stud ...................................... 2 34644 .......................... Alarm ......................................................................................... 1 58259 .......................... Wire, 18Ga.Black-Bulk .......................................................... 2LF

-2 -3 -4 -5 -6 -7

DESCRIPTION

)

- Indicates Items Not Shown

)

) MANUAL 92350-003 J anuaI)' 1997 SIN X935-97051

FIGURE 7.6: Hour Meter (XL-Option) . ,

8

2 PL

88=WHT #1 =8LK

#1 =8LK

88=WHT

REFERENCE MOTOR CONTACTOR

)

)

QTY

ITEM

PARTNUMBER

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

A619-2633 ................... Hour Meter ............................................................................ Ref. 80027 .......................... Meter, Hour 4/40VDC ............................................................ 1 67840-001 .................... Bracket, Gage Mounting ............................................................. 1 BOW30003 .................. Bolt,Hex .25-20UNCx.875 ...................................................... 2 BOW31401. ................. Washer, Flat .25 ID x .63 OD .................................................... 4 BOW36780 .................. Nut,Hex .25-20UNCNylonLock ............................................. 2 67295-035 .................... Cable, 16Ga.l2 Conductor SJO ............................................ 6LF BOW23087 .................. Coupler - R#67963 16-14 Female ............................................... 2 67960-006 .................... Terminal Ring - 16-14 #10 Stud ................................................. 2 67837-004 .................... Tie,Nylon-4"Black ..................................................................... 4

DESCRIPTION

- Indicates Items Not Shown

MANUAL 92350-003 JanuaIY 1997 SIN X935-97051

•

FIGURE 7.7: Battery Condition Indicator (XL-Option)

ITEM

PART NUMBER

Ref.

A620-2633 ................... BatteryConditonIndicator ...................................................... Ref. 37716 .......................... Meter, 24VBattery ..................................................................... 1 37993 .......................... MeterGuard .............................................................................. 1 58300 .......................... Wire, 16Ga.-Black .................................................................. 2LF 67963-001 .................... Coupler - 22-18 Male ................................................................. 2

-1 -2 -3 -4

DESCRIPTION

QTY

- Indicates Items Not Shown

)

) MANUAL 92350-003 JanUllI)'l997 SIN X935-97051

FIGURE 7.8: Low-Voltage Warning Interrupt (XL-Option) •

-)

QTY

ITEM

PART NUMBER

Ref.

A626-2633 •.................. Low-Voltage Warning Interrupt .............................................. Ref. 54169 .......................... LowVoltageInterrupt 24V ......................................................... 1 54967-104 .................... Operator,BluelliumPushbutton ................................................. 1 55902 .......................... Base + NO/NCContactw!24VBulb ....................................... 1 58259 .......................... Wire, 18Ga. Black-Bulk .......................................................... 6LF 54935 .......................... Decal-LowVoltWarning/Override .......................................... 1 BOW31141 .................. Screw, SlottedRnd. #10-24 x 2.00 .............•............................... 2 BOW31288 .................. Nut, Hex #10-32 ....................................................................... 2 BOW31430 .................. Washer, Flat #10 ID .................................................................. 4

-1 -2 -3 -4

-5 -6 -7

-8

DESCRIPTION

- Indicates Items Not Shown

)

) MANUAL 92350-003 JanwuyJ997 SIN X935-970SJ

•

FIGURE 7.9: Larger BatteriesIPOS (XL-Option)

) MANUAL 92350-003

Jamruyl997 SIN X935-97051

SELF-PROPELLED ELEVATING WORK PLATFORM

MODEL V2033XL, V2033 Serial Number X935-97051

VENDOR SECTION

SHIPPING ADDRESS

MAILING ADDRESS

TIME CONDOR

TIME CONDOR

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

WACO, TEXAS 76702-1447

P.O. Box 21447 (254) 420-5200

) MANUAL 92350·003 January 1997 SIN X935·97051

(

c

CONDOR® MODEL V2033XL, V2033 VENDOR SECTION

TABLE OF CONTENTS

CONTROLLER .................................................................................................. OEM CONTROLS CHARGER ................................................................................................ LESTER ELECTRICAL OPEN CIRCUIT TRANSFORMER TEST ....................................................................................... .

2000 SERIES MOTOR ............................................................................................... CHAR-LYNN

)

)

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LENGTH

TO

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20 AvG

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C

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20 AVG 22 A\lG

• 12'

52-NU ROCK£R-C

22 AWG 22 A\lG

12' 12"

ROCKER-NO

22 AWG 22 AWG

2 112'

S2-C TB-3 TB-l

TB--4 TB-5 R(JCI<ER-C P. B po. B t B - 6

PER PERC rORM .33

BurIO" MICRO (LErT)

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MI CROSY ITCH , I

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(LEFT;

WHITE 'w'HT/RED

wHT/BLU wHT/YEL

BOTTOM MICRO

WHT/GRN

TOP MICRO WHT/BLK

o

WHT/RED

C1 ) (2)

BLACK

(3)

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MARKrNG.

REV A CHANGED WIRES TO MICRO'S PER PECR FORM #33

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CONTROL s. INC.

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SYSTEM DrAG~AM FOR CALAVAR FOR BMS4RM9071

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1/27/95

Rrv. A 5/18/95

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(LEFT~

(RIGHT)

MOUmNG DIMENSIONS

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AUX

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RIGHT

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CDNTRCl..S. INC. SI-lCL TON. CONNECTICUT 060484

MECHANICAL ASSEMBLY AND DIMENSION DETAIL FOR CALAVAR

12/16/94

DD DATE

12/12/94

R£Vo

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~DR~A~_H~~D~D__~A089-6316-54 CI-ECKED (0- K. D~G.

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,. J lH H't utI I N',ERT

(

OWNERS MANUAL

24 Volt Fully Automatic Battery Charger Model 17970 Specifications: ACSupply

DC Output

Battery Specifications

120 Volts 8 Amps 60 Hertz Single-Phase

24 Volts 25 Amps Tapering to 8 amps

Use only on 24 volt. 12 cell. series connected wet lead acid systems. 180-305 ampere-hour (20 hr. rate)

oIkteiv-1v-ElectriCa! 625 West A St. Lincoln, NE 68522 USA

) F01532 A

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SAVE THESE IMPORTANT INSTRUCTIONS READ AND FAMILIARIZE YOURSELF WITH THIS ENTIBE MANUAL BEFORE INSTALUNG OR OPERATING THE -~C.HARGER. FOLLOW ALL INSTRUCTIONS ON THE BATTERY CHARGER, AND BATTERY POWERED EQUIp·

pENT. THIS MANUAL CONTAINS IMPORTANT SAFETY AND OPERATING INSTRUCTIONS FOR THIS BATTERY . CHARGER.

A

LOOK FOR THIS SYMBOL TO POINT OUT SAFETY PRECAUTIONS. IT MEANS BECOME ALERT· YOUR SAFETY IS INVOLVED. IF YOU DO NOT FOLLOW THESE SAFETY INSTRUCTION, PERSONAL INJURY OR PROPERTY DAMAGE CAN OCCUR. SAVE THESE IMPORTANT INSTRUCTIONS. to ensure superior battery performance and life. A patented electronic circuit turns the charger on and off automatically.

When the battery has reached its maximum state of charge, the circuitry will turn the charger off.

IMPORTANT SAFETY INSTRUCTIONS 1. SAVE THESE INSTRUCTIONS· This manual contains important safety and operating instructions for battery charger Model 17970.

2. Before using battery charger. read all instructions and cautionary markings on (1) battery charger. (2) battery, and (3) product using battery.

CAUTION: TO REDUCE RISK OF INJURY, CHARGE ONLY LIQUID ELECTROLYTE (WET) LEAD ACID RECHARGE· ABLE BATTERIES. OTHER TYPES OF BATTERIES MAY BURST CAUSING PERSONAL INJURY AND DAMAGE.

RECEIVING AND INSTALLATION When the charger is received, check for possible in transit damage. If any damage is found, it should be reported as a claim to the carrier.

A

Proper installation of the charger is important in order to achieve good charger performance and to prevent damage to the charger and batteries. The charger should be located in a clean. cool. dry, and well ventilated area To permit free air flow for convection cooling, allow three inches minimum between the charger and any wall and six inches between the charger and other equipment. Position the charger on a foundation of stone, brick, concrete or grounded metal.

DANGER: TO REDUCE THE RISK OF FIRE. DO NOT USE THE CHARGER NEAR FLAMMABLE MATERIALS OR VAPORS.

3. Do not expose charger to rain or snow.

4. Use ot an attachment not recommended or sold by the battery charger manufacturer may result in a risk of fire, electric shock, or injury to persons.

S. To reduce risk of damage to electric plug and cord, pull by plug rather than cord when disconnecting charger.

Make sure cord is located so that it will not be stepped on, tripped over, or otherwise subjected to damage or stress.

An extension cord should not be used unless absolutely necessary. Use of improper extension cord could result in a risk of fire and electric shock. If extension cord must be used, make sure: a. Pins on plug of extension cord are the same number, size, and shape as those of plug on charger b. Extension cord is properly wired and in good electrical condition. c. Wire size is large enough for ac ampere rating of charger.

S. Do not operate charger with damaged cord or plug - replace it immediately.

9. Do not operate charger if it has received a sharp blow. been dropped, or otherwise damaged in any way; take it to a qualified service center.

10. Do not disassemble charger; take it to a qualified service center when service or repair is required. Incorrect reassembly may result in a risk cif electric shock or fire.

11. To reduce risk of electric shock, unplug charger from a live outlet or disconnect AC power to the outlet betore attempting any maintenance or cleaning. Turning off controls will not reduce this risk.

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AC INPUT AND GROUNDING INSTRUCTIONS

A CAUTION: TO REDUCE RISK OF ELECTRIC SHOCK

OR FIRE, DISCONNECT POWER TO RECEPTACLE BEFORE INSTALLING OR REMOVING UNIT. This battery charger must be connected to a 120 Vac. 60 hertz, 1 phase AC power source which is properly installed and grounded in accordance with the National Electrical Code (U.S.) and all local codes and ordinances.

GROUNDING INSTRUCTIONS· Charger should be grounded to reduce risk of electric shock. Charger is equipped with an electric cord having an equipment-grounding conductor. The installed plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances.

A

DANGER: NEVER AlTER AC CORD OR PLUG IF IT WILL NOT FIT OUTLET. HAVE A PROPER OUTLET INSTAlleD BY A QUAUFIED ELECTRICIAN. IMPROPER CONNECTION CAN RESULT IN A RISK OF AN ELECTRIC SHOCK. -A-

INTRODUCTION

COIIeROF~~

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This battery charger is a self-regulating charger with a minimum of moving parts, designed for long, trouble free service. Built-in ,ne voltage compensation produces a consistent output when ~e AC supply voltage varies by as much a 10% from nominal. . Convection cooling maximizes the reliability and minimizes any maintenance costs. ONLY LIQUID ELECTROLYTE (WET) LEAD ACID BATTERIES should be recharged with this charger -2-

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-C-

-8-

j(i)"l

ADAPTER

~

6:1 ~

~~I~"'·~. 'i' l~i~ 'Zl GROUND

~

GROUNDING IoIEAHS

OF CIROUNOED 0U1l.ET BOX

lII.ADe GADUNDED

oun.ET

NOTE: Use of an adapter shown in figures B and C is not permitted in Canada.

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This banery charger is for use on a nommai 120 volt circuit and has a grounding plug, which looks like the adapter Iilustrated in figure A. A temporary adapter, which looks like the adapter illustrated in figures Band C. may be used to connect this piug ~l a two-pole receptacle as shown in figure B if a properly . grounded outlet is not available. The temporary adapter should be used only until a properly grounded outlet can be installed by a qualified electrician.

4. Monitor the ammeter for correct charge current. The initial charge current should range between approximately 25 amps. If the batteries have not been discharged. or the AC supply voltage is lower than 120 volts. the initial charge rate may be less. If the batteries have been excessively discharged, or AC supply voltage is higher than 120 volts. the initial charge rate may be more than 25 amps.

5. Charge current will gradually taper to approximately 8 amps depending on the age and condition of the batteries. Charger turns off automatically and the "CHARGE COMPLETEff light will glow when battery is fully charged. Charge time varies with battery size and depth of discharge. Allow 12-14 hours for normal charging. Severely discharged batteries may require more time to be properly charged and equalized.

6. After the charger has turned off. disconnect the DC output plug from the battery (if required) and the AC supply cord from outlet.

A DANGER: BEFORE USING ADAPTER AS ILLUSTRATED. BE CERTAIN THE CENTER SCREW OF OUTLET PANEL PLATE IS GROUNDED. The green-colored rigid ear or lug extending from adapter must be connected to a properly grounded outlet. If necessary, replace original outlet cover plate screw with a longer screw that will secure adapter ear or lug to outlet cover plate and make ground connection to grounded outlet.

EXTENSION CORD REQUIREMENTS Always use a three conductor No. 14 AWG (1.5mm) heavy duty cord with ground, properly wired, in good electrical condition and keep it as short as possible. Make sure the pins on the plug of the extension cord are the same number. size and shape as the AC plug of the battery charger. The use of an improper extension cord could result in a risk of fire or electric shock. Locate all cords so they will not be stepped on, tripped over or otherwise subjected to damage or stress.

MAINTENANCE INSTRUCTIONS The battery charger requires minimal maintenance. It should be kept clean and all connections are to be tightly secured.

In the event of intermittent operation, examine and tighten. if necessary. all connections. BE SURE THE CHASSIS IS SECURELY GROUNDED. If any problems cannot be resolved consult a qualified service center.

DC OUTPUT This battery charger is designed to produce a 24 volt dc output 'with an initial charge current of 25 amps. ONLY 24 VOLT. 12 );ELL. SERIES CONNECTED. 180 TO 305 AMP-HOUR, LIQUID-ELECTROLYTE (WET) LEAD-ACID BATTERIES SHOULD BE USED. The charge current will decrease gradually to about 8 amps as the battery reaches full charge and will remain there until the charger turns off. As the battery ages the charge current may no longer decrease to the 8 amp finish current. Liquid electrolyte batteries will normally be charged to 2.5 volts per cell.

OPERATING INSTRUCTIONS 1. Connect AC supply cord to a properly grounded 120 volt, 60 hertz. single phase outlet.

2. Connect the DC output plug to batteries (if required). The black wire must be connected to battery negative (-). and the red or white wire to battery positive (+). Make sure all connections are clean and tight.

3. The charger will start after a short delay as indicated by the "CHARGING" light. transformer hum and the ammeter movement.

WARNING: LEAD ACID BATTERIES GENERATE GASES WHICH CAN BE EXPLOSIVE. CHARGE ONLY IN WELL VEN· TlLATED AREAS. DO NOT DISCONNECT CHARGER DC OUT· PUT TERMINALS FROM BATTERY WHEN CHARGER IS ON. THE RESULTING ARCING AND BURNING COULD CAUSE THE BATTERY TO EXPLODE. KEEP SPARKS, FLAME, AND SMOKING MATERIALS AWAY FROM BATTERY.

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If the charger must be stopped. always disconnect the AC supply cord from its outlet before disconnecting the DC output terminals from the battery.

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Observe the following battery maintenance procedures to obtain good performance and maximum cycle life.

1. Always observe the following personal safety precautions when working with lead acid batteries: a. Someone should be within range of your voice or close enough to come to your aid when you work near a battery. b. Have plenty of fresh water and soap nearby in case battery acid contacts skin. clothing or eyes. c. Wear complete eye protection and clothing protection. Avoid touching eyes while working near battery. d. If battery acid contacts skin or clothing. wash immediately with soap and water. If acid enters eye. immediately flood eye with running cold water for at least ten minutes and get medical attention. e. NEVER smoke or allow a spark or flame in the vicinity of batteries. f. Be extra cautious to reduce risk of dropping a metal tool onto battery. It might spark or short-circuit battery or other electrical part that may cause explosion. g. Remove personal metal items such as rings. bracelets. necklaces, and watches when working with a lead acid battery. A lead acid battery can produce a short-circuit current high enough to weld a ring or the like to metal, causing a severe burn. h. NEVER charge a frozen battery.

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DANGER: TO REDUCE RISK OF ELECTRIC SHOCK, ALWAYS DISCONNECT THE AC SUPPLY CORD FROM ITS OUTLET AND THE DC OUTPUT CORD FROM THE BATTERY BEFORE ATTEMPTING ANY MAINTENANCE (CHANGING FUSES, ETC.) OR CLEANING OF THE BAT· TERY OR BATTERY CHARGER.

2. New batteries should be given a full charge before their first use because it is difficult to know how long batteries have been stored.

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3. Limit use of new batteries for first five cycles. New batteries are not capable of their rated output until they have been discharged a number of times. not excessively discharge batteries. Excessive discharge can cause polarity reversal of individual cells , resulting in complete failure shortly thereafter. Limited use of new batteries will minimize the chance of cell reversal.

5. CHECK THE LEVEL OF THE ELECTROLYTE IN CONVENTIONAL LIQUID ELECTROLYTE LEAD ACID BAITERIES MONTHLY. MAINTAIN THE PROPER ELECTROLYTE LEVEL BY ADDING DISTILLED OR PURIFIED WATER WHEN NECESSARY. Electrolyte levels lower during discharge and rise during charge. Therefore. it is mandatory that water be added to cells ONLY when they are fully charged - do not overfill. Old batteries require more frequent additions of water than new batteries.

6. Keep tops of batteries clean and dry to prevent excessive self discharge. Keep battery terminals reasonably tight.

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4.

5.

6.

TROUBLE SHOOTING 7.

FOR SAFE AND EFFICIENT TROUBLE SHOOTING. READ THIS TROUBLE SHOOTING GUIDE COMPLETELY BEFORE BEGINNING ANY TESTS.

Ii.

CAUTION: DO NOT OPERATE THE CHARGER IF IT IS DAMAGED OR APPEARS TO BE MALFUNCTIONING. PERSONAL INJURY OR DAMAGE TO THE CHARGER OR BATTERIES MAY RESULT. DO NOT DISASSEMBLE THE CHARGER. TAKE IT TO A QUAUFJED SERVICE AGENT WHEN SERVICE OR REPAIR IS REQUIRED. INCOR· RECT REASSEMBLY MAY RESULT IN A RISK OF ELEC· \ TRIC SHOCK OR FIRE. ~ determine if a charger malfunction eXists, eliminate the problems not associated with the charger in the sections below.

If the problem can not be resolved, contact a qualified service center.

1. CHARGER D0ES NOT TURN ON a. Battery is not connected to charger. b. Charger is not plugged into a live AC outlet.

WARNING: IF THE AC OR DC PLUG OR RECEPTACLE IS BROKEN, TWISTED, BENT OR LOOSE AND DOES NOT MAKE GOOD ELECTRICAL CONTACT, HAVE IT RE· PLACED BY QUAUFIED SERVICE PERSONNEL IMMEDIATEL Y. DO NOT USE THIS CHARGER IN THIS CONDITION AS FIRE OR PERSONAL INJURY CAN RESULT_

Ii.

c. DC fuses blown.

2. CHARGER REMAINS AT HIGH RATE a. The charger is connected to a battery pack with a system voltage lower than specified. b. Battery amp-hour capacity is greater than specified for charger. c. One or more of the batteries in the battery pack has reversed polarity.

3. CHARGER TURNS OFF EARLY a. The DC cord was accidentally disconnected from the battery during charge. b. The battery has been allowed to sulfate. Charge the battery at least once every three days when the ) equipment is lightly utilized. Once sulfation is allowed to take place it may be partially reduced by returning, temporarily, to daily charging.

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c. AC circuit is not live (power outage or circuit breaKer blownl.

CHARGER DOES NOT TURN OFF a. The charger is connected to a battery with an amp-hour capacity greater than specified. b. The charger is connected to a battery pack with a system voltage higher or lower than specified. c. New batteries (5 cycles or less), cold batteries or over discharged batteries may require an extended charge time to achieve full charge.

CHARGER FUSE BLOWS (OR CIRCUIT BREAKER) a. AC fuse blows when wrong AC power supply is used.

BUILDING AC LINE CIRCUIT BREAKER OR FUSE BLOWS a. A "weak" fuse or circuit breaker is protecting the circuit. Connect the charger to another outlet on a different circuit. If the charger operates properly, have a qualified electrician inspect and test the Original circuit. b. The circuit is overloaded. Connect the charger to another outlet on a different circuit.

EQUIPMENT RANGE DECREASING a. The electrolyte level in conventional liquid electrolyte lead-acid batteries was allowed to drop below the too of the battery plates. Add distilled water to JUST .

COVER THE TOPS OF THE PLATES immediately upon discovery and fill to the proper level with distilled water at the completion of the very next charge cycle. Battery capacity lost in this manner is permanent and is not recovered with additional charge cycles. b. Use of the equipment before the batteries have been fully charged and the charger turns off. This shortens battery life and hastens the onset of reduced daily range. Battery capacity lost in this manner is permanent and is not recovered with additional charge cycles. c. This is the normal wear out process for all types of deep-cycle motive power batteries.

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WIRING DIAGRAM

ELECTRONIC TIMER

block red green-

TRANSFORMER

red or white

,

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

147

TO BATTERIES

3

block

2 AMMETER

block

DIODE

4

ton white ,120 Voc INPUT

I

CAPACITOR

I

*Green wire not used 1~~_________-___o_n__s_o_m__e__m_o_d_e_ls___________________________________________________

PARTS LIST FOR LESTRONIC II CHARGER MODEL 17970 TYPE 24LC2S-SET 120 VAC 60 Hz PART NO,

DESCRIPTION

232788 161058 16354S 163698 183208 023908 020288 232828 08776S 043288

CA8E A88EMBLY TRANSFORMER ASSEMBLY HEATSINKASSEMBLY, WITH DIODES AMMETER ELECTRONIC TIMER ASSEMBLY CAPACITOR, 6.0 MFD, 660 VAC BUSHING, 7W-2, IN8ULATOR FOR CORDSET CORDSET, DC, 75", NO PLUG FUSE ASEMBLY AC RECEPTACLE

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Limited Warrantv .

Lester Electrical warrants each new Lester Battery Charger for defects in material and workmanship for a period of two years from the date of manufacture of the complete unit. Repairs can be made at the Lester factory. To do so send the defective unit with transportation charges prepaid to: Lester Electrical 625 West "An Street Lincoln, NE 68522 U.S.A. Attention: Repair Department For repairs made at other than the Lester factory, Lester will provide only the replacement parts. Defective parts should be sent with transportation charges prepaid to the Lester factory at the previously mentioned address.

If the"unit or parts are found in the reasonable judgment of Lester to be defective in· material or workmanship, repair, or replacement will be made by Lester without charge for parts or labor. Repair or replacement will be at the discretion of Lester, with replacements being made using current models or parts performing the equivalent function. Labor charges other than those incurred at the Lester factory are not covered under this warranty. All expenses associated with delivering defective items to the Lester factory and the expense of returning repaired or replaced items from the Lester factory to the owner will be paid for by the owner. All warranty work accomplished at the Lester factory will be completed within a reasonable time after receipt of defective items.

This warranty does not cover any semiconductor parts, such as diodes, which are vulnerable to electrical overloads beyond the control of Lester. Warranty on parts not manufactured by Lester, which include, but are not limited to, timers and ammeters is limited to the period specified in the original manufacturer's warranty.

This warranty does not cover any charger that has been subject to misuse, neglect, negligence, or accident, or operated in any way contrary to instructions speCified on the charger case and in the owner's manual. No claim of breach of warranty shall be cause for cancellation of the contract of sale of any Lester charger. Lester assumes no responsibility for loss of time, inconvenience, or other damage, consequential or otherwise, resulting from a defective charger. All implied warranties (including merchantability) are limited in duration to the two years from date of manufacture warranty period.

Some states do not allow the exclusion or limitation of incidental or consequential damages: or limitations on how long an implied warranty lasts, so the above limitations may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

Lester's obligation under this warranty is strictly and exclusively limited to the repair or replacement of defective items. Lester issues this warranty in good faith and with full confidence in the workmanship and quality of Lester products.

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OPEN CIRCUIT TRANSFORMER TEST Failure of the transformer can be the result of natural aqinq • ) . premature shorting of adjacent coil turns or overheating damage. The most common cause of transformer overheating and premature burn-out is the result of misuse. connecting the charger to a battery system of lower voltage than specified on the charger. Darkening of all the transformer secondary coil windings is an indication of possible overheating damage. ! DANGER

HIGH VOLTAGE; With the charger operating, the charger capacitor voltage can be as high as 660 Volts AC. Use extreme caution when working near the capacitor terminals.

To test transformers used in chargers of different output voltages than 36 Volt as covered in manual, Form 00910, the transformer coil AC voltages are: Charger Nameplate Vol t,:!qe VDC

Number of Lead-Acid Battery Cells in Series

VN

-)

No Load Open Circuit Transformer Secondary Coil e~_I~§i_~Qli~g~~

Resonant Capacitor Connected

...,...,.

______________________ _ Resonant Capacitor Disconnected '.)2 = '.)1 X 2/3

-'-'

~~

17 to ....._.

12

54 to 66

36 to 44

36

18

83 to 97

55 to 65

48

24

110 to 130

73 to 97

12

6

24

..:.,/

to

...,~

Use the equations to calculate approximate test voltages for other systems.

The readings are approximate and transformer failure is indicated when measured voltages are significantly lower than those calculated in the table. DC voltages measured at the charging leads are about 1/2 the transformer test voltage amounts.

Transformer secondary voltage measurements made with the resonant capacitor connected can occasionally result in noticeably higher readings than expected. No-load transformer instabilities and peculiar wave shapes can increase these voltage readings. This is particularly true when using digital meters, as several models get confused with other than pure sine wave AC or pure ripple-~ree DC.

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PROPER CARE OF MOTIVE POWER BATTERIES Motive power battenes are suclectea to severe deep cycte duty on a dally basIs. Althougn these oattenes are designed to Withstand SUCr1 duty the following precautions must be observed to cctaln 0000 certormance ana' maximum cycle life.

A CAUTION: Always wear protective eye shields and clothing when working with batteries.

Batteries contain acids which can cause bodily harm. Do not put wrenches or other metal objects across the battery terminal or battery top. ArCing or explosion of the battery can result. ,. When installing new batteries be sure the polarity of each battery and overall oatterl paCK is correc:. Due to the electrlcai cl1arac!enstics at this charger it is possible to improperiy hook uo the batteries and not blow the fuse wnen charging. 8attery ana/or charger damage can result 2. New batteries should be given a full charge before their first use because it is difficult to know how long the batteries have been stereo.

3. Umit the use at new batteries for the first 20 cycles.

New batteries and oleer battenes that have been in storage are not cacable aT their rated outcut until they have been discharged ana chargeo a number oltimes.

5.

6.

7.

8.

4. Sulfation results when batteries in storage are not

maintained in a charged ac:ive state. Internal self discharge can bring about the start at thIS condition in as little as three days in warm temperatures. Batteries

9.

atlowea to Sit unmatnralned in storage selt discharge. suttate to vanous degrees ana lose caoaclty.

Reoeatea charging 'Hlil generally result in the recovery oi most oi the oattery·s capaCity. though some permanent loss can be exCected.

DO NOT EXCESSiVELY OISC;;ARGE THE BATTE;='IES. Excessive disc~arge can cause polarity reversai of individual cells resuiting 10 complete failure shortly thereatter. Heavily discharging (Over 60%) new batteries before they have been broken in (approximately 20 cycles) can cause permanent cell damage. resulting in reduced energy capacity and shortened life.

Maintain the proper electrolyte level by adding water when necessary. Never allow the electrolyte level to fall below the top of the battery plates. Electrolyte levels fall during discnarge and rise during charge.

Therefore. to prevent the overilow of electrOlyte when charging. it is mancatory that water be added to cells AFTE;=' they have been fully charged. DO NOT OVERFILL Old batteries reouire more frequent additions of water than dO new batteries.

When the temperature falls below 65 degrees F. the battenes should be piaced on charge as soon atter use as pOSSible. Cold battenes require more time to fully recnarge.

The toes of the battenes and battery hold-downs must be kept clean ana cr'.' at all times to orevent excessive self discharge ana :Iow of current between the battery posts ana frame.

Follow all operatinc instructions. cautions. and warnings as specified in ~hjs manual. on the charger. and in your vehicle owners manual.

TROUBLE SHOOTING GUIDE TO BE ABLE TO USE THE TROUBLE SHOOTING GUIDE SAFELY AND EFFECTIVELY IT IS IMPORTANT TO READ THIS GUICE COMPLETELY BEFORE BEGINNING ANY TESTS. ~ CAUTION: REPAIRS BY QUALIFIED PERSONNEL

A DANGER: HIGH VOLTAGE - With the charger on. the internal charger capacitor voltage is ONLY. NOTE: Modifying this charger for approximately 650 volts. use other than that tor which it was intended. repairs by persons not qualified, or not using original equipment A CAUTION: ALWAYS UNPLUG THE ELECTRICAL replacement parts will void the warranty CORDS FROM THE AC OUTLET AND and Lester liability.

THE BATTERIES BEFORE ATTEMPTING ANY REPAIRS TO THE CHARGER. ~ CAUTION: DO NOT DISASSEMBLE THE CHARGER. TAKE IT TO A QUALIFIED SERVICEMAN WHEN SERVICE OR REPAIR IS AWARNING: Do not operate the charger if it is malREQUIRED. Incorrect assembly may functioning. Personal injury or property result in a risk of electric shock or fire. damage could result.

The Lestronic II battery charger is a reliable. automatic charger designed for long, trouble-free service. If a malfunction should develop. identify the symptom and follow the associated test procedures.

MALFUNCTION SYMPTOM SECTION CHARGER DOES NOi iURN ON A. Relay does not Close. No Tra:1sformer Hum and Ammeter Does Not Register.

B. Relay Closes But No Transformer Hum and Ammeter Does Not Register.

C. Relay Closes and Transformer Hums But Ammeter Does Not Register.

D. E!ectronic iimer Kit Replacement Instructions.

2

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CHARGER FUSE BLOWS A. Single Fuse Link Blows B. Both Fuse Links Blow

SECTION 3 AMMETER i1EADS 30 AMPS FOR MORE THAN 30 MINUTES 4 CHARGER OUTPUT IS LOW

5

CHARGER TURN OFF MALFUNCTIONS A. Charger Turns Off Too Soon.

B. Charger Does Not Turn Off. C. Charger Runs Too Long But Does Turn Off.

6

AC LINE FUSE OR CIRCUIT BREAKER BLOWS

7

TRANSFORMER SHORT OR BURN-OUT

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SECTION 1 -

CHARGER DOES NOT TURN ON ~~arge!" CC OUIcut connecter must ce ::,,::ec::-:: to :r.e :::atter!es !n crcer to turn tne charger cn ...!. :Ime -:e!ay oi 2 :a 5 seconas is crovlded to ailow acec:.;a:e :ir.":e :0 maKe 3 sec:.;re connection ceiore the c~ar;er :L;r~s ~n. ;".i~er tnlS ame ae!ay the power relay c:cses 3::: an 3Lc:::::e ··c::c:<· should be heara.

When :r.e re!ay ·::oses. ;"C ccwer IS s<.Jcciied to the transformer :::r:r..c,·! c:::::. !f cceratlng :::r-:ceriy tt1e transformer snoulc ~t..~ 3::: :t:e 5mr."!e!er sr.cwc Inclcate rne charge rate. If :~e :.-2.,;::: ::::es ~c: ::..;rr: cn oroceny reier to Part A. a or C rer seec::lc :es, or:::cec:Jres. :n normal -:cerar::n :r:e

PART A -

RELAY DOES NOT CLOSE. NO TRANSFORMER HUM AND AMMETER DOES NOT REGISTER. CheCK to ce sure !he oower sueeiy cord is securely connec~ec to a iive oL;tlet CheCK the DC auteut connector ana the batter! c::::lnec~or tor damage. dirt or corrosion that wouid prevent a gooo e!ec!rlcal connection.

A

WARNING: 11 the plug or receptacle is broken. twisted. bent or loose and does not make good electrical contact. have it replar:ed by a qualified serviceman immediately. DO NOT USE THIS CHARGER IN THIS CONDITION AS FiRE OR PERSONAL INJURY CAN RESULT. Then cisocnnec::ne Dower sueciv cord from its outlet.

With tlie DC .Jutcet connec~or stl·1I connec~ed to the battery connecter. measure the vOltage at the battery connec:or uSing a suitaoie DC voitmeter as snown in Figure 1.

The Eiectronlc Timer Kit may be bypassed in order to veriiy that a malfunction eXists. First disconnect the cnarger cower SUCCIY cord from its outlet ana the DC output connector irom the batter! connector. Place a Jumper wire oetween terminals #1 and #3 to bypass the E:ec:ronlc Ti~er Kit as snown In Figure 2 and Figures 6 and 7.

The power sucety cord is now connected directly to the primary transl0rmer coil ana the transformer should hum when the power sueeiy cord is connected to a live outlet.

The charger oeeration may be checked by first connec~­ ing the DC outout connec~or to the battery connector. anc then connec:mg the power supply cord to an outlet If normal cnarging current is indicated on the ammeter the ElectrOniC Timer Kit :s detective and must be replaced.

A

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 bypassea. a continuity cneck of the cnarger AC circuit is necessary.

Disconnect me power suoeiy cora from Its outlet and the DC output connec:or irom the battery connector and.

With a sUltaole continUity tester. cneck the circuit across the power sueeiy cord prongs as snown in Figure 2.

With the Elec~onic Timer Kit bypassed. the CIRCUIT SHOULD BE COMPLETE.. If the Circuit is not comolete.

Individually check the continuity of the power SUPPlY cord. primary transformer coil and all connections.

PART B -

FIGURE 1 Battery DC Voltage Test

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 twoprong 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 c!1arger. utility light. or other electrical appliance to the outlet to verify the presence of AC power.

If AC power is present. disconnect the power supply cord from its outlet and the DC output connector from tne battery connector. Bypass the Electrontc Timer Kit as described in Section 1. Part A. and with a suitable continuity tester check the circuit across the power supply cord prongs as shown in Figure 2. With the Electronic

The voltage reading shOuld be the same as the battery terminal voltage and must be between 24 and 50 volts DC in order to c:ose the relay. If the DC voltage is within the above limits. remove the charger cover and verify thatthe charger is properly wired and you read the same voltage (24 to 50 Vec: insJ(:;e the charger wnere the white and black wires of ~he DC core attacn. (Fig. 4 and wiring diagram Fig. 8.; If the battery DC voltage measured inside the charger is now below the above limits or not present the DC plug or corcset has an internal break and must be replaced. If the c:larger is wired correctly and a satisfactory battery DC voltage is measured inside the charger. a malfunction in the Electronic Timer Kit has probably occurred. Due to its complexity. do not attempt to make field repairs to any part of the E!ectronic Timer Kit If a malfunction· eXists. simaiv remove-the entire Electronic Timer Kit and repiace it 'with a new one. Refer to Part D-"E!ectronlc Timer Kit Replacement"-for correct procedure.

FIGURE 2 Charger AC Circuit Continuity Test (Transformer removed for clarity)

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Timer Kit bvoasseo. the CIRCUIT SHOUl!) BE CC:"l?LET2. if the Circuit IS comCle,e. re!er to :ne wlrlnc =Iagram In Figure a. ana c~ec:-< :r.e relay wiring ane all connections. If tne ClrCUlt is net comOle!e. cnecl< tne wiring ot the cower suooiy core. trans:ormer pnmarf cOil leaas ana the EiectronJc Timer r<it. if the cnarger IS wlrea correC:ly. inaivldually cneci< :r:e c::~~nUlty oi the cewer sue ply cord. transformer primary COil and relay.

connector. ana checl< the charger fuse. If a fuse link is Olown. reier to SectIon 2 - "Charger Fuse Slows" for :urtner tests. If tt1e fuse cnecks gooo. use a low voltage continUity tester to penorm the following tests: 1. Connect the tester leads to the Charger DC output

connector as snown in Figure 3. and note the reaaIng. Reverse the tester leads and check the output connector again. The circuit should be complete In oniy one direction. If the circuit does not conduct in t!!lher cirection ana the fuse is good. individuaily cneCK the continUIty of the DC output cord. ammeter. diOdes. and ail connections. If the circuit conducts in beth direc!lons. a "short" exists in the Charger DC CirCUIt First Check the DC output cord tor a "short" between the two wires. It is more likely ttlat one or both diodes have "shorted." Refer to Section 2 "Charger Fuse Slows·' for continuity test at diodes.

PART C -

RELAY CLOSES AND TRANSFORMER HUMS BUT AMMETER DCES NOT REGISTER If the relav c!oses ana the transiormer nums. the cnarcer AC cirCUit and E:ectronlc Timer Kit are functioning prcoeny. If the ammeter does ne: regiSter. a fault in the charger DC cirCUit eXists ane a continUity cnecl< must Oe performea. Disconnect the power suepty core trom Its Qutle! ana the DC output co~nec:or from the bar:ery

2. If the charger DC circuit test is good. a check of the capacitor is necessary. Disconnect the power supply cord from its outlet ana the DC output connector trom 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 breal<. Using an ohmmeter. set the scale to R X 10K ohms and test the capacitor as follows: GOOD CAPACITOR-When the ohmmeter leacs are connected to the capacitor terminals. the meter needle jumps to mid-scaie and rapidly moves to high resistance (x).

FIGURE 3 Charger DC C.jntinuity Test

) CAPAcrroR COIl. (SecONOAAY COlI.

PRIMARY COIl.

UNDERNE.O.THI

SLACK WIRE --~ OF DC CORD

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FIGURE 4 Electronic TImer. Kit Wiring

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OPEN CAPAC:TOR-When me onmme!er leads are cennec!eO to the capacitor terminals. the meter neeole does not move ana stays at nlgn resistance (xl.

A bulge In the toe of the capac:ter may be visible if the cacacltor has failed "Open'" SHORTED CAPAClTOR-When tl1e ohmmeter leads are connected to the capacitor terminals. the meter neeale jumps immediately to zero ohms and remains there.

If the capacitor is "Open" or "Shorted" it must be reolaced.

A

C~UTION: Use only a 6 Mfd. 660 volt AC rated

capaCitor for replacement (Part No. 02390S1. The use of a different value capaCitor may result in improper charging, capacitor failure. transformer burnout. and/or battery damage.

3. If ~he charger DC circuit and capacitor check good. a test of the transformer is necessary. Refer to Section i - "Transtormer Short or Burn-Out" for test proceat.:res.

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PART D - ELECTRONIC TIMER KIT REPLACEMENT The E:ectronlc Timer Kit should alwavs be replaced as a complete assemcly. The tools reauired are a Phillips head screwdriver. 3/8" and" 132" wrenches. and pliers. No soldering is required. To replace the kit follow the step-by-step procedures listea below. .

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

2. Disconnect the green. black. and red wires of the Electronic TImer Kit as shown in Figure 4. Then remove the black and white leads of the power supply cord and both primary transformer coil leads from the Eiec:ronic Timer Kit terminal tabs. The Kit can be removed by removing the three mounting screws on the Charger front panel. Save ail hardware for reassemcly.

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

FIGURE 5 Diode Continuity Test

either transformer ;Jrimarv lead to terminal #2. ar.a the remaining ;Jnmary iead to terminal #3.

Connect :he OlacK leaa of the oower sue Ply cord te termInal ~, on the ::ectrenic Timer Kit and the whIte leac of the power sucely cord to terminal #2.

Connec! tl1e red wire of the E!ectronic Timer Kit along With tl1e wnlte leac of the DC cora to the Heat SinK Assemelv. Connec: the black wire at the Eiectronlc Timer Kit along With the black leaa of the DC cord :0 the ammeter post. 00 not allow the ammeter post to turn when tigntenmg the nut. Reconnect the green wire of the Electronic Timer Kit along with the transformer seconcary !ead to the diode lead terminal.

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

4. Reelace the charger cover and cneck the Electronic Timer Kit for proper operation as follows: a. With the DC outout connector disconnected from the battery connector. insert the power suecly cord intO an outlet. The relav on the ElectrOnic Timer Kit shouid not close. A DC voltmeter c:::nnec:ed across the DC output connector Should indicate zero VOltS. b. Disconnect tne power sueply cord from its outlet ana connect the DC outeut connecter to the battery connector. The relay on the Electronic Timer Kit shouid close with an audible "click" after a twO to five second delay. c. If the Electronic Timer Kit does not ocerate as (a) and (b) above. reter to the wiring diagram in Figure 8 and check to be sure the charger is wired correctly. If the Electronic Timer Kit operates property. the charger is ready for use. Always monitor the first charge cycle to verify that the charger is turning off properly.

SECTION 2 - CHARGER FUSE BLOWS The charger fuse ass em ely 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 recnfier diode to provide protection for the transformer in the event of a diode faiiure. Visually inpsect and electncaily test the fuse to determine it one or both fuse links are blown and refer to Pan A or Pan 8 for test procedures. LOCATE AND CORRECT CAUSE OF TROUBLE BEFORE REPLACING BLOWN FUSE. DO NOT attempt to repair the fuse link as inadequate protection wiil result PART A - SINGLE FUSE LINK BLOWS This condition is normaily caused by a shan circuit failure of one diode. The fuse link wiil blow when the charger DC output connector is connected to the battery connector. regardless of whether the power supply cord is connected to an outlet To check the diodes. disconnect the power supply cord from its outlet and the DC output connector from the battery connector. and then disconnect one transformer secondary coil lead tram the diode terminal. Using a low voltage continuity tester. connect one tester lead to the diode mounting plate and the other tester lead to a diode terminal as shown in Figure 5.

Note the reading and then reverse the tester leads and check each diode again. If a diode conducts current in both directions. it is "shorted" and the complete Heat Sink Assembly with Diodes (Part No. 096535) must be replaced.

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On rare occasions a slngie fuse linK mav melt due to excessive neat. This can oe causea bv a ioose Internal fuse connection. ChecK all :hree iuse connections Inside. :he charger to be sure they are Clean and tight. The proper torque on the fuse connector nuts is 20 InchPounas (23 Cm-Kg).

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PART B - BOTH FUSE LINKS BLOW This is normally caused l:ly a reverse oolarlty connection between tne c!1arger DC cutout connector and the battery connector. ChecK the oatter/ pack anc oattery connector to be sure they are wired In the correct polarity. If possible checK the voltage and polanty at the battery connector with a DC voltmeter. Also. check the cnarger DC outout connector for the correct polarity. The white wire ShOUld be connected to the pOSitive (-+oj contact. and the black wire to the negative H contact. If a reverse pOlarity connection is mace between the charger ana battenes. both fuse linKs wlil blow regardless of whether the power supply cora is connectea to an outlet AnOther cause for both fuse links blowing is the short ClrC:.!lt failure of both diodes. Although this is rare. it may occ:.!r as the result of a lightning stnke at the charging location. ExceSSive heat due to a loose connectlon may also cause both fuse links to melt. Refer to Part A "Single Fuse LlOk Blows" for trouole-shOoting procedures.

SECTION 3 - AMMETER READS 30 AMPS FOR MORE THAN 30 MINUTES This high outout condition is caused by misuse. connecting the charger to an incorree: battery system whiCh is lower than 36 vOits. A common error is to instail one or more of the 6 volt batteries in a 36 volt battery paCK reverse polarity. Using a suitaole DC voltmeter test to be sure all batteries in a battery pack are correctly wired. and also test the battery pack voltage at the charging connector. After charging for 30 minutes at this excessive rate the measured on charge voltage should rise to 34 to 38 volts DC for a 36 voit system. Voltage measurements_ while Charging, lower than this indicate an incorrect or failed battery paCK that must be corrected betore using the charger. & CAUTION: DO NOT connect the charger to battery packs which are not 36 volt systems_ This misuse will cause overheating and transformer bum-out will result.

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

& CAUTION: Do not use Ihe 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 -

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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

wlil rise. the lower the iinlsh charge rate wlil be beiore the Electronic Timer terminates cnarglng.

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

PART A - CHARGER TURNS OFF TOO SOON Check to oe sure the oower suoely cord is securely connected to a live outlet. ii the power suoply outlet is live proceed with the next step.

To determine if the charger did shut off too soon. disconnect and reconnect the cnarger D.C. outcut connector.

This Will restart the charger. Observe cnarger output on the ammeter.

1. The ammeter needle jumos smartly to between 20 and 25 amos and then tapers below 14 amps within 15 minutes. This indicates that the battenes were truiy charged. The apoarent short charging time is in response to the batteries' ability to accept charge and the electronic timer is pertorming properly.

2. The ammeter needle jumps smartly to between 20 and 25 amps. but does not taper below 14 amps within 15 minutes. It the battenes have been properly maintained and chargee regularly, this generaily indicates that the batteries were not fully cnargea. If possibie. use a hydrometer to check the specific gravity of several battery cells. If !he specific gravity readings are more than 30 poims (.030) lower than normal full charge readings. the electronic timer has malfunctioned and the complete Electronic TImer Kit must be rep lac ea. Refer to Section 1. Part D-"Electronic TImer Kit Replacement." for correct procedure.

If the batteries have not been used or charged regularly. they may be sulfated and will not produce their full capacity. Repeated cycles (at least 5) of a light discharge followed by a full charge will generally result in the recovery of most of the battery's capacity.

Do not interpret this reduced battery capacity as being caused by the charger turning off too soon. The charger is working properly if. after several charge cycles. the battery caoacity 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 resuits in a finish charge rate higher than 10 amps and less time is required to fully charge the batteries. Do not interpret this shorter charging time and reduced battery capacity as being caused by the charger turning off too soon. The battery is aging naturally and the charger is working properly. When the batteries will no longer pertorm as required they should be replaced.

PART B - CHARGER DOES NOT TURN OFF New batteries with ali good celis 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 tha~ 8 amperes. and less time will be required for the batteries to reach fuil charge. At a finish charge rate of 8 amperes or less the charge time should not exceed 18 hours. At a finish charge rate greater than 8 amperes the charge time should ,not exceed 14 hours.

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If the cnarger remains on longer than the scecliied maximum time. cneck to see it the charger turns on immediately when the D.C. output cord is connected without the normal two to five secono 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 compiete Electronic Timer Kit must be reolaced.

Refer to Section 1. Part D - "E!ectronic TImer Kit Replacement." for correct procedures.

If the 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 in Figure 4. The charger will NOT turn off if the green wire is loose or disconnected. If the green wire is securely connected. the E:ectronic Timer has malfunctioned and the complete Eiectronic Timer Kit must be replaced.

If a precision digital type D.C. voltmeter is available. a test to verify that the Electronic Timer has malfunctioned can be made. Connect the charger to the batteries and

115 Yac N'Ur

allow to charge normaily. After the charge rate has taperea to its lowest POlOt. measure the battery terminal voltage using a D.C. voltmeter capable of reading in incrementS at .001 VOltS. Continue charging and check the battery vOltage reading every hour. If the battery voltage increases jess than .012 volts. or if the battery voitage decreases cetween successive hourly readings. the charger should turn off. If the charger does not turn off. the Eiectronic Timer has maifunctioned and the complete ElectrOnic Timer Kit must be replaced.

PART C -

CHARGER RUNS TOO LONG BUT DOES TURN OFF

In the event at A.C. power interruption when the charger is on. the charger Will automatically restart when A.C. power is restored. This power outage can make the apparent cnarge time seem longer than the actual charge time. To check tor A.C. power interruPtions plug an electric clock into the same outlet to whiCh the A.C. cord is connected. Charge normally and note any time difference between the test clock time and the actual time.

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FIGURE 6 Transformer Coil Voltage Test (without capacitor)

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FIGURE 7 Transtormer Coil Voltage Test (with capacitor)

B..ECmONC" KIT

_ TODCPUXI IlATlEl'IES

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FIGURE 8 Charger Wiring Diagram.

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SECT10N 6 -

AC LlNE FUSE OR CIRCUIT BREAKER BLOWS if this oC:::.Jrs wnen the charger Dower sUDDly cora is connec,ea to an outlet. without the DC outout connec,or connec:ea to the banery connecter. the c:"1arger power' suooly cora may be Shorted, Disconnec: the power suoPly cora from Its outlet ana the DC outout connector from the battery connector. then C!1eck to oe sure the E:ec:ronlc Timer Kit is NOT bypassed. With a suitable continUity tester check the CirCUit across the power suooly cora orongs as Shown In Figure 2. THE ClRCUIT SHOULD NOT 8E COMPLETE. If the CirCUit IS complete. check the relay contacts to "le sure they are open ana have not weloed c!osea. If the relay contacts are ooen. the power supply cord IS shorted and must oe replacea.

If the power suo ply cord checks good the transformer cOils may be snorted. Refer to Section 7 - "Transtormer Short or Burn-Out" for test proceaures.

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SECTION 7 - TRANSFORMER SHORT OR BURN OUT Failure of the transformer can be the resuit of naturai aClnc premature shorting of adjacent coil turns or Dverneatlng ciam~ age. The most common cause of transformer overheating and premature burn-out is the result of misuse. connecting the cnarger to a battery system OT lower vOltage than specified on the Charger. (See Section 3) Darkening of all the transformer seconaarv COil winoinos is an indication of DOSSIOle overneating oamace. A low or comolete lack oi outout 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. aisconnect the power suo ply cord from its outlet and the DC outout connector from the· battery connector. Then disconnect the tra.nsformer secondary coil leads #1 and #4 from the diode !erminals and disconnect the transformer capacitor coil leaas from the capacitor terminals. Use care when disconnecting the capacItor lead so the wires do not break.

DANGER-HIGH VOLTAGE: With the charger operating, the charger capacitor voltage is approximately 650 volts AC. Use extreme

caution wnen Working near the capacitor terminals. in oraer to 300ly AC ::lower directly to the transformer primary COil :r.e ;;:iec:ronlc Timer Kit must De oypassea.

Refer to Section 1. ?3rt A for bypass orocedures, With the E:ec:ronlc Timer r<it bypasseo ana taKing care tor personal saierv. connect the power sUDpiy cord to an Outlet. If the AC line fuse or CIrCUIt breaKer blows, the transformer IS snortea Internally ana must be replaced. If thIS does not occur. C!1ecx the transformer seconaary and caoacltor Call vOltages as snown In Figure 6. uSing a SUitable AC voltmeter. If the measured voltages are suostantlally lower than those snown. the transformer IS snortea Internally ana must be replacea.

If the transformer secondary Call voltage and capacitor coil voltage c!1eck gOOd. disconnect the power suo ply cord from ItS outlet. Check the caoac:tor to be sure its rating is 6 Mfd. 660 VOltS AC. and then carefully reconnect the capaCitor cOllleaas to the capacitor terminals. Then. taking care for personal safety. reconnect the power supply cord to an outlet and measure the transformer secondary voltage again. The correct voltage reading IS snown in Figure 7, if the transformer secondary voltage reading is the same as measured with the capaCitor disconnected. trom Figure c. the caoacltor may be open. the caoac:tor COil may be ooen or the caoac:tor coil terminalS may not be maKing prooer electricai contact Refer to Section 1. Part C. item 2 for caoacltor test proceaures. If the voltage readings are correct. both the transtormer ana capacitor are good. refer to Section 1, Part C. item 1 for further tests of the DC circuit If it should become necessary to reclace 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 usea on these wires that is intenaed for use on aluminum. such as Alcoa ~807 solder With Alcoa #69 flux. If the'se materials are not available locally. contact the Lester fac:ory,

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NO. 7-124

Eaton ~) Hydraulics . Division

2000 Series Char-Lynn-ID Motors

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006

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2

Valve

Pin HOrn,

Balancing Ring

Shaft Face Seal Bearing and Shaft Ass'y

Back-up Washer Bearing Housing

Geroler

Valve Plate

Tie

Bolt

I

Valve

Seal Splined Drive C)

Wear Plate

Key

Inner Face Seal

Shaft Seal

~1 Plug

Spring

Exclusion Seal

Valve Drive

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Case Drain Plug Seal

Tools required for disassembly and reassembly.

Torque wrench 500 Ib-in[57Nm] capacity 12-16[300-450] * breaker bar 9/16 socket Small screwdriver 6-8x1/4[150-200x6,5] blade 3/16 allen wrench .

Press *Unless indicated otherwise, measurements are given in inches[mm]. **Shaft seal installation tool **Bullet for 1 diameter shafts The following tools are not necessary for disassembly and reassembly, but are extremely helpful.

Alignment studs (2)

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5/16[8 1

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rAPprox.1/2[13]

Ii ii iii iii il 3/8[9,5] Dia. Steel Rod

3/8-24 UNF

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Grind Flat Spots on Each Side ** Available--by special order © Copynght 1985 Eaton Corporation

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Disassembly

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Cleanliness is extremely important when r2pairing hydraulic motor. Work in a clean area. Before dis· connecting the lines, clean the port area of the mo· tor thoroughly. Use a wire brush to remove foreign material and debris from around the exterior joints of the motor. Check the shaft and keyslot. remove all nicks, burrs or sharp edges that might damage the bearing housing seals when installing the shaft and bearing assembly. Before starting the disassembly procedures, drain the oil from inside the motor.

2

Remove 4 bolts from motor.

Figure 3

3 Lift valve housing straight up. If done carefully the pins, springs, balance ring assembly, and valve will remain on the valve plate.

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Figure 1 1 Place the motor in a vise with the output shaft down. Clamp across the mounting flange of the motor not the housing. Excessive clamping pressure will cause distortion. When clamping, use some protective device on the vise, such as special soft jaws, pieces of hard rubber or board.

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Case

Seal - - "

Plug

.1 __ Drain

Although not all drawings show the motor in a vise, we recommend that you keep the motor in the vise during disassembly and reassembly.

Follow the clamping procedures explained throughout the manual.

Figure 4

4 Carefully remove 3[76] diameter seal from valve housing.

5 Remove case drain plug-with seal, from valve housing.

6 Remove 2 pins and 2 springs from balance ring assembly, see Fig. 5.

) Tie Bolts Figure 2

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Disassembly

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15 Remove me 3 [76] diameter seal from wear plate, see Fig. 7.

Wear /Plate

Bearing Housing

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Inner Face Seal Balance Ring Figure 5 7

Remove balance ring assembly.

8 Remove inner and outer face seals from balance ring.

9

Shaft Face Seal

Remove the valve.

Figure 8 16 Remove the wear plate.

17 Remove the shaft face seal from the wear plate.

18 Remove the 3 [76] diameter seal from bearing housing.

Bearing Housing

\ ) Shaft & Bearing Assembly

Figure 6 10

Remove the valve plate.

11 Remove the 3(76) diameter seal from valve plate.

12

Figure 9 19 You may need a press to remove shaft and bearing assembly from bearing housing. (Key must be removed before removing shaft.)

Remove the valve drive.

Bearing Housin g ---.....

Back·up Washer Figure 10

Figure 7 )

13 Remove the Gercler. Be sure to retain the rol· lers in the outler ring if they are loose.

14

Remove the drive.

20 Use a small screwdriver to remove shaft seal, back-up washer and exclusion seal from bearing housing, see Fig. 10. Do not damage bore of housing.

Nota: Individual parts of shaft and bearing assembly are not sold separately. Replace as a unit.

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Check all mating surfaces. Replace any parts that have scratches or burrs that couid cause leakage.

Clean all metal parts in clean soivent. Blow dry wl(n air. Do not wipe dry with cloth or paper towel be· cause lint or other matter can get in the hydraulic system and cause damage. Do not use a coarse grit or try to file or grind these parts. Check around the keyway and chamfered area of the shaft for burrs, nicks or sharp edges that can damage the seals when reassembling the bearing housing.

Note: Lubricate all seals (prior to installation) with petroleum jelly such as Vaseline. Use new seals when reassembling this motor. Refer to parts list (6·129) for proper seal kit number.

21 Use a press to install exclusion seal in outer bore of bearing housing. Lip of seal must face outward. See Fig. 11. I f a press is not available use a plastic or rubber hammer, being careful not to damage or cock seal in the bore.

Shaft Face

5

Re'assembly 26 AI ignment studs can be very helpful in reassembl y of the motor. See special tool listing page 2. If you use studs. install 2 studs diagonally opposed in the bearing housing.

27 I nstall the shaft face seal in the wear plate as shown in Fig. 11. Do not distort seal.

28

I nstall the wear plate, see Fig. 11.

29 Apply a light film of petroleum jelly to the 3[76J diameter seal and install seal in the wear plate.

30

I nstall the drive into the output shaft.

31 Align the notch on the outside of the Geroler with the notch on the wear plate. I nstall the Geroler against the wear plate. Be sure to retain the rollers in the outer ring if they are loose.

Shaft Shaft Seal

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Seal

Wear Plate Back-up Washer

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\"~~~~~I[~__-seal Shaft & Searing Ass'y

Exclusion Seal

32

I nstall the valve drive in the Geroler.

Note: I nstallation at this time involves 3 steps in the timing of the motor. Timing determines the direction of rotation of the output shaft. Timing parts include: 1. Geroler 2. Valve 0 rive 3. Valve Plate 4. Valve

Rotate Valve Clockwise 112 tooth max. to Engage \ Spline CQ

Figure 11

22

Place back-up washer into seal bore. Place shaft seal onto installation tool and press seal into seal bore of the housing.

23

Clamp housing in vise, see Fig. 1.

24 Place protective bullet (see note below) over shaft. Apply petroleum jelly to inside diameter of dust and shaft seal. You may need a press to install shaft and bearing assembly. Do not distort shaft seal. Damage to this seal will cause leakage.

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Note: Bullet for 1" shafts, available-by special order. Use tape over other shafts to prevent cutting the seals.

25 Apply petroleum jelly to the 3(76] diameter seal. Install seal into the bearing housing.

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Anyone of 6 Ports open to Outside of Valve Figure 12 Timing Alignment Timing Step H= 1-Locate the largest open pocket in the Geroler and mark it on the outside edge of the Geroler.

33 Apply a light film of petroleum jelly to the 3 (76] diameter seal. Install seal in groove of valve plate.

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6

Reassemblv

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34 Align the notch on the outside of the valve plate with the notch on the Geroier as shown In Fig. 12.

Timing Step FI= 2- Locate the slot opening in the valve plate which is in line with the largest open pocket of the Geroler.

Timing Step FI= 3- Locate anyone of the side openings of the valve and align this opening with the open slot of the valve plate that is in line with the largest open pocket of the Geroler. I nstall the valve by rotating it clockwise until the spline teeth engage (1/2 spline tooth max. ). This will provide the proper rotation when pressurized as shown in Fig. 13.

Imp-ortant: Install face seals in the positions shown in Fig. 15. or the motor will not operate properly.

Do not force or bend the face seals. Any damage to these seals will affect the operation of the motor.

Pin Notch

Balance Ring Figure 15

38 Align pin notches in balance ring with pins in bore of valve housing. I nstall balance ring assembly in valve housing.

Clockwise Rotation Balance Ring -

-)

Counter Clockwise - - - - Rotation

Housing

Figure 13 Figure 16 Valve Housing

Pin & Spring

N~ Seal

Alignment Studs ~

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35 Install 2 springs and 2 pins in the holes located in the bore of the valve housing, c:;s shown in Fig. 14.

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36 Apply a light film of petroleum jelly to the 3[76] diameter seal. Install seal in the valve housing.

37 Apply petroleum jelly to inner and outer face seals. I nstall seals on balance ring as shown in Fig. 15.

39 Insert your finger through port of valve housing. Apply pressure to side of balance ring as shown in Fig. 16. Hold ring in position until valve housing is in place against valve plate. See Fig. 17.

Note: After installing the valve housing on the valve plate check for proper placement. Push down on the valve housing. You shou Id get a sl ight spring action.

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Reassembly 40 Install the tie bolts. If you use alignment studs, install 2 bolts opposite the studs. Finger tighten the bolts. Remove the alignment studs and replace with the 2 remaining bolts. Torque all 4 bolts alternately to 450 Ib·in [50Nm].

41 Install seal on case drain plug then install in valve housing. Torque to 50 Ib·in[6Nm].

Figure 18

Wheel Motor On wheel motors, a different bearing housing is used, see Fig. 19. Other than this the parts are the same as the standard motor and the same disassembly and reassembly procedures apply.

) Exclusion Seal

Seal Figure 19

Shaft Face Seal

Bearingless Motor This motor is the same as the standard motor without the shaft/bearing assembly, and bearing housing.

The mounting flange replaces the bearina housing, see Fig. 20. Follow same disassembly and reassembly procedures as rear section of standard motor.

Figure 20

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