Condor T40 & T46J Operation, Service & Parts Manual - PDF DOWNLOAD

OPERATION, SERVICE

AND PARTS MANUAL MODELS T40 & T46J " BOOM-SUPPORTEDELEVATINGWORKPLATFORM Beginning With Serial Number P-ll X-0026 15

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OPERATOR'S MANUAL MODELS T40 & T46J BOOM-SUPPORTED ELEVATING WORK PLATFORM Beginning With Serial Number P-l1 X-002615

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MANUAL 92376-001 JUNE 1998

i INTRODUCTION

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

THIS MANUAL MUST BE RETAINED ON THE UNIT AT ALL TIMES.

Do not attempt to operate 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 and safety. The various decals attached to this machine contain vital information.

Read the decals before operating this machine.

It is YOUR RESPONSIBILITY to follow safe procedures while operating the CONDOR®. The manufacturer of this unit 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 the safety of all personnel when making decisions regarding the unit's intended use.

It is also YOUR RESPONSIBILITY to understand and obey all federal, state, and local regulations regarding the safe operation and use of aerial work platforms. A copy of the ANSIISIA A92.5-1992 Manual of Responsibilities is attached for your use.

TIME CONDOR Corporation reserves the right to modify, improve, add, andlor 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 UNIT WITHOUT PRIOR WRITTEN APPROVAL FROM THE MANAGEMENT OF TIME CONDOR Corporation

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

MANUAL 9237EHlO1 JUNE 1998

TABLE OF CONTENTS

•

INTRODUCTION ........................................................................................................................................ i TABLE OF CONTENTS ............................................................................................................................. 1 I. SAFETY ................................................................................................................................................. 3 A. Safety Symbols .......................................................................................................................... 3 B. Safety Rules .............................................................................................................................. 4 C. Safety Decals .......................................................................................................................... ,. 8 II.

MACHINE OPERATION ................................................................................................................ 12 A. B. C. D. E.

Primary Machine Components ................................................................................................ 13 Range Of Operation ................................................................................................................ 14 GroundControls ...................................................................................................................... 16 Platform Controls .................................................................................................................... 22 Start Up Procedures ................................................................................................................ 29 1. Shift Check ......................................................................................................................... 29 2. Machine Start Up ............................................................................................................... 30 3. Ground Operation and Checks ........................................................................................... 31 4. Platform Operation and Checks ......................................................................................... 33 5. Cold Weather Operation ..................................................................................................... 37 E. General Operation .......................................................................................................................... 37 1. Boom Operation ................................................................................................................. 37 2. Drivers and Steering ........................................................................................................... 38 3. Braking ............................................................................................................................... 38 4. Gas Engine Operation ......................................................................................................... 39 5. Diesel Engine Operation ..................................................................................................... 39 F. Shut Down Procedures ........................................................................................................... 40 III. MOVING FROM JOB SITE TO JOB SITE ....................................................................................... 40 A. Unloading ....................................................................................................................................... 40 B. Loading .......................................................................................................................................... 41 C. Tie Down ....................................................................................................................................... 41 D. Towing Procedure ......................................................................................................................... 41 IV. EMERGENCY PROCEDURES ....................................................................................................... 43 V.

MACHINE SPECIFICATIONS ........................................................................................................ 48

ANSI/SIA 92.5-1992 MANUAL OF RESPONSIBILITIES

MANUAl92376-OO1 JUNE 1998

•

SAFETY SYMBOLS

This manual contains important infonnation on the safe use of your CONDOR T Series. Your failure to read, understand and follow all safety rules, warnings and instructions will unnecessarily expose you and others to dangerous situations. For your safety and the safety ofthose around you, you must operate your aerial platfonn as instructed in this manual.

You the operator, are the single most important factor for safety when using any piece of equipment. Learn to operate your work platfonn in a safe manner.

To help you recognize important safety infonnation, we have identified warnings and instructions that directly impact on safety with following signals:

& DANGER "DANGER" INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY. TmS SIGNAL WORD IS LIMITED TO THE MOST EXTREME SITUATIONS.

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WARNING

"WARNING" INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY.

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CAUTION

"CAUTION" INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT IS ALSO USED TO ALERT AGAINST UNSAFE PRACTICES, AND FOR PROPERTY-DAMAGEONLY SITUATIONS.

One final note: The best method to protect yourself and others from injury or death is to use common sense. If you are unsure of any operation, don't start until you are satisfied that it is safe to proceed.

MANUAL 92376-001 JUNE 1998

.SAFETY RULES AND PRECAUTIONS

.& DANGER • ELECTROCUTION HAZARD!! THIS MACHINE IS NOT INSULATED!!

Maintain safe clearance from electrical lines and apparatus. You must allow for machine sway (side to side movement) when elevated, and electrical line movement.

This machine does not provide protection from contact with or proximity to an electrically charged conductor.

You must AVOID CONTACT between any part of the machine, or its load, and any electrical line or apparatus carrying up to 300 volts.

You must maintain CLEARANCE OF AT LEAST 10 FEET (3.05 M) between any part of the machine, or its load, and any electrical line or apparatus carrying over 300 volts up to 50,000 volts. One foot (30.5 cm) additional clearance is required for every additional 30,000 volts.

DEATH OR SERIOUS INJURY will result from contact with, or inadequate clearance from, any electrically charged conductor.

• Read and understand all safety and control information found on the machine and in this manual before operating the unit.

• Only trained, competent personnel should operate the aerial work platform.

• Be aware of all Government and Local rules which may apply to this machine and its safe operation.

• Approved safety belts must be worn at all times when operating the unit from the platform. In addition, approved headgear and other protective equipment must be worn as required. (In the U.S.A., OSHA approved equipment is required. For other countries, the appropriate equivalent government body should be consulted.)

• NEVER fasten safety belt to an adjacent structure while on the work platform.

• Make sure that entry gate to platform is secured before operating unit from the platform.

• DO NOT block the foot switch or any function control in the operating position.

• DO NOT exceed the platform capacity of the unit in any configuration. Review the section titled "MACHINE SPECIFICATIONS", later in this manual, regarding this model's capacities and dimensions.

MANUAL 92376-001 JUNE 1998

SAFETY RULES AND PRECAUTIONS (Continued)

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DANGER

• SECURE all tools and other loose items to prevent injury to persons working on or below the work platform.

• DO NOT use scaffolding, ladders or similar items to extend your reach while on the work platform.

• DO NOT attempt to climb down the boom assembly if the unit fails while the operator's platform is raised or extended.

• Since the machine may be operated from the ground controls, precautions should be taken to prevent unauthorized personnel from operating the work platform with the ground controls while the platform is in use.

• The "UNPOWERED EMERGENCY MOVEMENT" procedure (described later in this manual) requires releasing the torque hubs, which results in there being no means to stop the unit's travel. TIME CONDOR recommends using this procedure only in cases of emergency, and only for a short distance. Be on guard against unit runaway on sloping surfaces. Movement speed shall not exceed 1 M.P.H. (1.6 K.P.H.).

• DO NOT attempt to open any hydraulic line or component without first relieving all system pressures and shutting off fluid flow from the tank.

• DO NOT allow anyone to tamper with, service or operate the machine from the ground control station while personnel are on the platform, except in an emergency.

• DO NOT alter, modify or disable any safety devices or interlocks.

• DO NOT refuel the unit near sparks or open flames. Gasoline and propane vapors, and Diesel fuel fumes are highly explosive.

• DO NOT use the aerial work platform outdoors in electrical storms or high wind situations.

• DO NOT raise the aerial work platform unless the unit is on a firm, level surface.

MANUAL 92376-001 JUNE 1998

•

•

SAFETY RULES AND PRECAUTIONS (Continned)

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DANGER

• Use caution to prevent ropes, cords, hoses, etc. from becoming entangled in the unit's boom sections when being raised, lowered or repositioned.

• Ensure that the area surrounding the mobile platform is clear of personnel and equipment before: driving the unit; or raising, lowering or extending the boom; or swinging the turret; or, rotating or tilting the platform.

• Maintain a safe distance from overhead and ground obstacles, debris, drop-offs, holes, depressions, electrical wires and other hazards to travel.

• Limit travel speed according to conditions of the ground surface, congestion, slope, location of personnel or any other factors that could cause hazard of collision or injury to personnel.

• DO NOT sit, stand or climb on platform rails.

• DO NOT operate this machine while under the influence of any drugs or alcohol.

• DO NOT operate this machine if you are bothered by heights, seizures, or dizzy spells.

• DO NOT indulge in stunt driving or horseplay while operating this machine.

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WARNING

• Complete the "Operational Checklists" found in this manual (see Table of Contents) at designated intervals.

• Ensurethatthe machine is in "LOW" drive speed while unloading from a truck or trailer.

• Always attach the unit to a winch when loading or unloading from a truck or trailer.

TIME CONDOR does not recommend unassisted loading or unloading of any aerial work platform .

• With the turret swung away from the stowed position, use caution when selecting travel or steering direction. Travel and steer direction will be opposite switch or lever movement. Refer to the large "FORWARD" arrows on the chassis of the unit or the location of the turret lockpin hole for travel orientation.

MANUAl92376-OO1 JUNE 1998

SAFETY RULES AND PRECAUTIONS (Continued)

A. WARNING • Check fuel system for leaks or damaged fuel lines before operating unit. If any damage is found, contact your supervisor immediately. Machine must be removed from service until diagnosis and any necessary repairs have been completed.

• Actuation of the red "EMERGENCY STOP" button will apply brakes immediately, causing unexpected platform movement as the machine comes to a sudden stop. Brace yourself.

• Whenever disengaging the drive torque hubs or before disconnecting from towing vehicle, ensure that the unit cannot roll.

• Immediately report any erratic noises, vibrations or malfunctions of the unit to supervisor. Machine must be removed from service until diagnosis and any necessary repairs have been completed.

• Operating this equipment without all safety and control decals in place can be hazardous.

A. CAUTION • For transporting the machine, the platform must not be tied to the trailer bed.

• Be sure to tum all hydraulic valves back "ON" before starting the machine, or extensive pump damage will occur.

• DO NOT exceed the maximum platform horizontal pull of 100 Ibs. (45.4 kg).

• DO NOT use the boom or platform as a crane to lift oversized or hanging loads.

• DO NOT raise, extend, retract, tilt, rotate, or lower the platform or booms into stationary objects, as this will cause damage to mechanical and hydraulic components.

• DO NOT use the platform or boom functions to push or tow the unit or another vehicle.

• Avoid sudden braking or steering, go slowly and leave more maneuvering room during cold weather operation until the machine is warm.

MANUAL 9237IXJ01 JUNE 1998

•

•

SAFETY RELATED DECALS

ELECTROCUTION HAZARD KEEP CLEAR DEATH OR SERIOUS INJURY CAN RESULT FROM CONTACT WITH THIS EQUIPMENT OR VEHICLE IF IT SHOULD BE ELECTRICALLY CHARGED 21882-

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71618 - Decal, Lower Boom Caution MANUAL 92376-001 JUNE 1998

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SAFETY RELATED DECALS

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37958-500 - Decal, Rated Work Load

MANUAL 92376-001 JUNE 1998

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SAFETY AND CONTROL DECAL LOCATIONS

A WARNING OPERATING TillS EQUIPMENT WITHOUT ALL SAFETY AND CONTROL DECALS IN PLACE CAN BE HAZARDOUS. If any of these items are damaged or missing, replace them immediately. Decals are shown for standards machine. Optional equipment may change the decal locations.

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MANUAL 92376-001 JUNE 1998

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SAFETY AND CONTROL DECAL DESCRIPTIONS

DESCRIPTION

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PART NUMBER

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71634 ............................ Final Assembly Drawing, M-T40-0 1 ........................................ Ref. 71635 ............................ FinaIAssemblyDrawing,M-T461-01 ...................................... Ref.

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71632-Dwg ................... Decal Installation, Dwg. T40-01 .................................................... 1 71640-Dwg ................... Decal Installation, Dwg. T46J-Ol .................................................. l 67938-080 ..................... Decal, 80 PSI Tire Pressure .......................................................... 4 54984-004 ..................... Decal, Lift and Tie Down .............................................................. 4 56023 ............................ Decal, Arrow ................................................................................. 2 56024 ............................ Decal, Forward .............................................................................. 2 21882-001 ..................... Decal, Electrocution Danger ......................................................... 2 21849 ............................ Decal, Unleaded Gas Only ............................................................ 1 54984-007 ..................... Decal, Hydraulic Fluid ................................................................... 1 71618 ............................ Decal, Boom Lower Caution ......................................................... 2 54984-006 ..................... Decal, 110 Volt Ext To Platform ................................................... 1 21079 ............................ Decal, Lube Fitting ........................................................................ I 71795 ............................ Decal, T60 Transport Diagram ...................................................... 1 71614 ............................ Decal, Boom Upper Caution ......................................................... 1 37958-500 ..................... Decal, 500 LB Rated Work Load ................................................. 2 56034-500 ..................... DecaJ, Rated Work Load 3.5 x 13.7 Gray ..................................... 2 71615 ............................ Decal, Panic Stop .......................................................................... 1 38550 ............................ Decal, Platform Fall Arrest ........................................................... 2 71369 ............................ Decal, Platform Control Box ......................................................... 1 71370 ............................ Decal, Turret Control Box ............................................................. 1 71589 ............................ Decal, Error Code Lower Controls ............................................... 1 71617 ............................ Decal, Ground Board Lights .......................................................... 1 56033 ............................ Decal, Twin Stripe ............................................................ 12.23LF. 71763 ............................ Decal, T40 9 x 23.5 Gray .............................................................. 2 55940-060 ..................... Decal, 9.00 x 60.00 CONDOR ..................................................... 1 5594l-017 ..................... Decal, "Bird" .................................................................................. 1 71768 ............................ Decal, Boom Raised Fully ............................................................. 1 71767 ............................ Decal, Boom Extension ................................................................. 1 71785 ............................ Decal, Rotation Stop ...................................................................... 2

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MANUAl92376-OO1 JUNE 1998

This Page is Intentionally Left Blank

MANUAl92376-001 JUNE 1998

MACHINE OPERATIONS. PRIMARY MACHINE COMPONENTS

PLATFORM CON1ROLS

MAIN BOOM ASSEMBLY EXTENSION CYLINDER

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MANUAL 92376-001 JUNE 1998

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MANUAl9237lHlO1 JUNE 1998

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OPERATOR CONTROLS DESCRIPTION (GROUND CONTROLS)

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MANUAl.92376-001 JUNE 1998

OPERATOR CONTROLS DESCRIPTION (GROUND CONTROLS)

Item

Control

Location

Description

1.

Circuit Breaker

On Ground Console Panel

Pops out when the 12 Volt electrical circuit is overloaded. Push in to reset.

2.

Choke/ Glow Plug Button

On Ground Console Panel

Choke button for gas or dual fuel engines. Press and hold while starting a cold engine.

Glow plug button for some Diesels. Press and hold (if so equipped) to preheat combustion chamber before starting a cold engine.

3.

Main Power Key Switch

On Ground Console Panel

Three position main power "ON/OFF" switch.

Straight up position is "OFF".

Turn key left (counterclockwise) one position to turn power"ON" for ground control operation. Turn key right (clockwise) one position to turn power "ON" for platform control operation.

With key switch "OFF", the key may be removed to prevent unauthorized operation.

4.

Engine Start Button

On Ground Console Panel

Press push button to engage engine starter. Release button immediately upon engine start.

NOTE: Main power key switch must be in "GROUND" position.

5.

Axle Not Locked

On Ground Console Panel

When lit, the light indicates that the axles are not locked. This is a danger light that boom has extended or raised and the axle lock cylinders have not locked the axle.

6.

Hour Meter

On Ground Console Panel

Indicates that elapsed time that the engine has been operated in hours and tenths.

7.

Volt Meter

On Ground Console Panel

Indicates electrical system voltage.

MANUAl92376-001 JUNE 1998

OPERATOR CONTROLS DESCRIPTION (GROUND CONTROLS, CONTINUED)

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OPERATOR CONTROLS DESCRIPTION (GROUND CONTROLS, CONTINUED)

Item

Control

Location

Description

8.

Engine Oil Pressure Gauge

On Ground Console Panel

Indicates engine oil pressure.

9.

Gas/Off/ Propane Switch (optional)

On Ground Console Panel

Flip toggle left to use gasoline, right to use propane.

In "CONDOR" position, the engine does not get fuel supply.

10.

Engine Throttle Switch

On Ground Console Panel

Flip toggle to down for low (idle) engine speed, up for mid range (operating) engine speed for generator use.

II.

Boom Fully Raised

On Ground Console Panel

Indicates when boom is fully raised and angle sensor is correctly calibrated.

12.

Emergency Stop Button

On Ground Console Panel

Used to stop all functions in an emergency. Push for emergency stop. Pull or rotate clockwise to reset, depending on style used.

When the button is reset, the engine distress light and axle not extended light will flash three times and the chassis tilt alarm will sound three times. If any of these indications do not occur at reset, do not operate machine.

13.

Turret Swing Toggle

On Ground Console Panel

Push toggle to right to swing turret to right (counterclockwise). Push toggle to left to swing left (clockwise). Turret can rotate 360 0 continuously in either direction.

MANUAL 92376-001

JUNE 1998

OPERATOR CONTROLS DESCRIPTION (GROUND CONTROLS)

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MANUAL 92376-001 JUNE 1998

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OPERATOR CONTROLS DESCRIPTION (GROUND CONTROLS, CONTINUED)

Item

Control

Location

Description

14

Main Boom Lift Toggle

On Ground Console Panel

Push toggle down to raise main boom.

Push toggle down to lower main boom.

15.

Jib Boom Toggle

On Ground Console Panel

Push lever forward to raise jib boom. Pull lever back to lower jib boom. Boom speed will be proportional to handle movement.

16.

Boom Extend!

Retract Toggle

On Ground Console Panel

Toggle controls the boom extend/retract function. Push up to extend boom. Push forward to retract boom.

17.

Main Operating Function Emergency Pump

On Ground Console Panel

Push down for all emergency functions. When engine is running and everything is working properly, push up to operate normal working functions.

MANUAl 92376-001 JUNE 1998

OPERATOR CONTROLS DESCRIPTION (PLATFORM CONTROLS)

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MANUAL92376-001 JUNE 1998

OPERATOR CONTROLS DESCRIPTION (PLATFORM CONTROLS)

Item

Control

Location

Description

l.

Emergency Stop Button

On Platform Console Panel

Used to stop all functions in an emergency. Push for emergency stop. Pull or rotate clockwise to reset, depending on style used.

When the button is reset, the engine distress light and axle not extended light will flash three times and the chassis tilt alarm will sound three times. If any of these indications do not occur at reset, do not operate machine.

2.

OffiOn/Start Toggle

On Platform Console Panel

Three position toggle switch. Up is "OFF". Move to center position to tum ignition "ON", down to engage starter. If the engine does not start within 10 seconds, switch must be turned off and then on again to start.

IMPORTANT: Engine will not start with foot switch depressed.

3.

GlowPlugl Chokelldlel Operating Speed Toggle (Engine Throttle)

On Platform Console Panel

Flip toggle to center position for low (idle) engine speed, up for mid range (operating) engine speed for generator use.

Choke toggle for gas or dual fuel engines. Press and hold while starting a cold engine.

Glow plug toggle for some Diesels. Press and hold (if so equipped) to preheat combustion chamber before starting a cold engine.

4.

Emergency Pump Push Button

On Platform Console Panel

Press and hold to activate battery powered hydraulic pump, allowing operation of boom or platform functions should the engine powered hydraulic pump be disabled.

5.

Engine Distress Light

On Platform Console Panel

Red light indicates low engine oil pressure, high engine coolant temperature or broken fan beIt(if so equipped). Engine will shut down automatically if condition does not correct itself in approximately 10 seconds.

MANUAl92376~1

JUNE 1998

OPERATOR CONTROLS DESCRIPTION (PLATFORM CONTROLS, CONTINUED)

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MANUAL 92376-001 JUNE 1998

13

OPERATOR CONTROLS DESCRIPTION (PLATFORM CONTROLS, CONTINUED) Control

Location

Description

6.

Boom Extend!

Retract Lever

On Platform Console Panel

Lever controls the boom extend! Retract function.

Pull back to extend boom. Push forward to retract boom. Boom speed will be proportional to handle movement.

7.

Main Boom Lift and Swing Lever

On Platfrom Console Panel

Dual function lever.

Item

Push lever forward to raise main boom. Pull lever back to lower main boom. Boom speed will be proportional to handle movement.

Push lever to right to swing turret to right (counterclockwise). Push lever to left to swing left (clockwise). Turret can rotate 360 0 continuously in either direction. Swing speed will be proportional to handle movement.

8.

Platform Rotate Toggle

On Platform Console Panel

Press and hold switch to left to rotate platform to left (counterclockwise). Press and hold switch to right to rotate platform right (clockwise). One speed only.

9.

Platform Leveling On Platform Toggle Console Panel

Press and hold switch forward to tilt platform forward. Press and hold switch back to tilt platform backward. One speed only.

10.

Jib Boom Lever (Jib Units Only)

On Platform Console Panel

Push lever forward to raise jib boom. Pull lever back to lower jib boom. Boom speed will be proportional to handle movement.

11.

Drive Lever

On Platform Console Panel

Lever Controls forward and reverse travel of machine at a speed proportional to handle movement. ( Engine automatically shifts to high range speed when driving.)

A WARNING WITH PLATFORM SWUNG OVER STEERING WHEELS, USE CAUTION WHEN SELECTING THE TRAVEL DIRECTION. TRAVEL DIRECTION WILL BE OPPOSITE DRIVE LEVER MOVEMENT. MANUAL 92376-001 JUNE 1998

OPERATOR CONTROLS DESCRIPTION (PLATFORM CONTROLS, CONTINUED)

7

12

5

2

14

16

9

4

1

MANUAL 92376-001 JUNE 1998

OPERATOR CONTROLS DESCRIPTION (PLATFORM CONTROLS, CONTINUED) Item

Control

Location

Description

12.

Steer Switch

On End of Drive Lever

Move switch left and hold to turn steer wheels to left, and right to turn steer wheels to right. Push and hold in opposite direction to straighten wheels.

A WARNING WITH PLATFORM SWUNG OVER THE STEERING WHEELS, USE CAUTION WHEN SELECTING THE STEERING DIRECTION. STEERING DIRECTION WILL BE OPPOSITE STEER SWITCH MOVEMENT.

13.

Function Speed Toggle

On Platform Console Panel

Press toggle up for "HIGH" function speed, down for "LOW" function speed for all proportional functions (boom,jib, swing, drive). High speed travel is available only while boom is below horizontal and extended less than 3 feet (0.9 Meters).

14.

Horn Button (optional)

On Platform Console Panel

Press button to sound warning horn (if so equipped).

15.

Light Toggle (optional)

On Platform Console Panel

Flip toggle to turn head lights on and off ( if so equipped).

16.

Sensor Override On Platform Button (optional) Console Panel

Press button to override the position sensor(if so equipped).

17.

Axles Not Locked (Optional)

On Platform Console Panel

When lit, the light indicates that the axles are not locked. This is a danger light that boom has extended or raised and the axle lock cylinders have not locked the axle.

18.

Steer Select Switch(optional)

On Platform Console Panel

Press switch up for "FRONT" wheel steer, down for "REAR" wheel steer (with 4 wheel steer option)

19.

Foot Switch

On Platform Floor

Must be depressed to activate main hydraulic pump, allowing operation ofany hydraulic function( drive, steer, boom or platform movement) from the platform. Depress foot switch before selecting function.(Engine automatically shifts to mid range for all functions.)

MANUAl92376-OO1 JUNE 1998

•

START-UP PROCEDURES (CONTINUED) SHIFT CHECKS Before the CONDOR T-Series is put into use each shift, the following checks should be completed to make sure that the machine is safe and in good condition.

Visually inspect all machine components, i.e. missing parts, torn or loose hoses, hydraulic fluid leaks, torn or disconnected wires, flat or damaged tires, etc. Both compartment doors can be opened to inspect components inside.

Check engine oil and fuelleve1s.

Check engine coolant level (with liquid cooled engines).

Check volt meter on ground controls for battery condition and wire connections.

Check hydraulic fluid level with booms fully retracted end lowered.

Check that all shutoff valves on the hydraulic tank are "Open". When open, valve handles will be parallel with the length of the valve.

A

CAUTION

The shutoff valves on the hydraulic tank must be left open at all times, except during repairs or transport. If one or more of these valves are closed when the unit is running, extensive pump damage will occur.

Check wheel lug nuts tightness. Check tire pressure (see Machine Specifications).

Check hoses and cables for worn areas.

Check hose carrier to make sure that it is not bent or sagging.

Check platform rails and safety gate latch for damage.

Check pivot pins for security.

Check that all warning and instructional labels are legible and secure.

Switch the key to platform control and then pull the emergency switch up at the platform.

Verify that you hear three beeps and all platform lights flash three times. If not, a safety light or buzzer has failed should be repaired before operating the machine.

MANUAl 92376-001 JUNE 1998

.,

MACHINE START-UP

A DANGER ALL OPERATORS MUST THOROUGHLY READ AND UNDERSTAND THE "SAFETY RULES AND PRECAUTIONS" SECTION OF TillS MANUAL PRIOR TO OPERATING THE MACHINE.

A COMPLETE VISUAL INSPECTION OF THE MACHINE MUST BE PERFORMED .••...

PRIOR TO OPERATIONAL CHECKS.

•

Disengage lock pin before swinging the turret.

•

Ensure that "EMERGENCY STOP" buttons on ground control panel and platform control console panel are disengaged. Pull out or twist to reset, depending on style.

•

Turn the main power key switch to the "GROUND" position to energize the electrical system.

•

While starting a cold engine or dual fuel engine, press choke button.

For some optional Diesel engines, press glow plug button, and hold it there for 30 to 45 seconds prior to engaging starter motor.

•

Press and hold engine start button to start engine.

MANUAL92376-OO1 JUNE 1998

--

GROUND OPERATION AND CHECKS

A

WARNING

BE SURE BOOM TRAVEL AREA IS CLEAR OF OBSTRUCTIONS. DO NOT OPERATE THE MACHINE IF THE FOLLOWING CHECKS REVEAL A DEFECT.

•

Select "GROUND CONTROLS" with the "GROUND/PLATFORM" key switch.

•

While pressing the "OPERATE CONTROLS" button, press and hold the main "BOOM" toggle to the "UP" position to raise the main boom to the horizontal position or slightly above.

Release the "BOOM" toggle.

•

Press and hold the "JIB BOOM" toggle on the ground control box to the "UP" position to raise the jib boom to the end of its travel (10° above main boom position). Release the "JIB BOOM" toggle.

Listen for any unusual noises.

Check for any vibration while the boom travels up.

Check for uneven or jerky operation.

Check for hydraulic leaks.

Check pivot pin security. Make sure that all retaining bolts and rings are in place on the pin locking point.

•

Press and hold the "JIB BOOM" toggle on the ground control box to the "DOWN" position to lower the jib boom to the end of its travel (90° below the main boom position).

Release the "JIB BOOM" toggle.

•

Press and hold the boom "EXTEND/RETRACT" toggle on the ground control box to the "EXTEND" position. Extend the boom to the end of its travel.

Listen for any unusual noises.

Check for any vibration while the boom extends.

Check for uneven or jerky operation.

Check for hydraulic leaks.

•

Release the "OPERATE CONTROLS" button and "EXTEND/RETRACT" toggle.

Inspect the boom sections visually for any damage along their entire lengths.

•

Push down on each of the three fastened corners of the tilt alarm on the ground controls.

The alarm should sound as each comer is pressed beyond 5 degrees.

MANUAL 92376-001 JUNE 1998

CD

GROUND OPERATION AND CHECKS (Continued) •

While pressing the "OPERATE CONTROLS" button, press and hold "BOOM" toggle to the "UP" position. Raise the boom to the end of its travel. Then, release the "BOOM" toggle.

Listen for any unusual noises.

Check for any vibration while the boom travels up.

Check for uneven or jerky operation.

Check for hydraulic leaks.

Check pivot pin security. Make sure that all securing bolts are in place on the pin locking point.

Visually confirm that the platform has remained level during boom travel.

Report to supervisor and repair any problem.

Press and hold the "BOOM" toggle to lower the boom slightly.

•

Press the "EMERGENCY STOP" button. All machine functions must stop, including the engine.

Pull the button out or twist to reset. Release the "OPERATE CONTROLS" button.

With the engine off, •

Press the "EMERGENCY" button.

Press and hold the "BOOM" toggle to lower the boom slightly.

Listen for any unusual noises.

Check for any vibration while the boom travels down.

Check for uneven or jerky operation.

Check for hydraulic leaks.

Once boom movement had been established using the emergency pump, release the "EMERGENCY" button and "BOOM" toggle. Restart engine.

Return the booms to their stowed positions by using the appropriate toggles for "RETRACT" and "DOWN" correspondingly, and the "OPERATE CONTROLS" button.

Listen for any unusual noises.

Check for any vibration while the booms lower and retract.

Check for uneven or jerky operation.

Check for hydraulic leaks.

Report to supervisor and repair any problem.

•

Operate the "SWING" toggle in each direction while holding the "OPERATE CONTROLS" button.

Listen for any unusual noises.

Check for any vibration while the unit rotates.

Check for uneven or jerky operation.

Check for hydraulic leaks.

-Report to supervisor and repair any problem.

•

Release the "SWING" toggle.

MANUAL92376-OO1 JUNE 1998

GROUND OPERATION AND CHECKS (Continued) •

Press the "EMERGENCY STOP" button. All functions (including engine) must stop immediately. Pull the button out or twist to reset. Restart engine.

•

Return the machine to the stowed position by pressing appropriate toggle switches correspondingly, as well as the "OPERATE CONTROLS" button.

"

Shut the engine off.

PLATFORM OPERATION AND CHECKS •

Complete Ground Operation Checks before performing Platform Operation Checks.

•

Select "PLATFORM CONTROLS" with the "GROUNDIPLATFORM" Key switch.

•

Enter the platform. Close gate securely.

•

Ensure that the "EMERGENCY STOP" button is released.

•

Move "OFF/ON/START" toggle to center position to turn ignition "ON", down to engage starter, then release it to the "ON" position.

•

Flip the "ENGINE THROTTLE" toggle to "OPERATING SPEED".

A

WARNING

BE SURE BOOM TRAVEL AREA IS CLEAROF OBSTRUCTIONS. DO NOT OPERATE MACHINE IF THESE CHECKS REVEL ANY DEFECT OR ABNORMALITY. •

Press the "HORN" button briefly to check that the horn works. The horn also acts as a signal for the tilt alarm as well as its normal warning function.

•

Depress the foot switch mounted on the floor of the platform. (Activate foot switch to operate any of the machine functions.)

•

Slowly move the "JIB BOOM" lever forward to the "JIB UP" position. The jib boom will start to rise. Function speed will be proportional to handle movement. Raise the jib boom to the fully raised position (approximately 10° above the main boom). Slowly return the lever to the center position.

MANUAl 92376-001 JUNE 1998

PLATFORM OPERATION AND CHECKS (Continued)

•

Slowly move the "BOOM/SWING" lever forward to the "BOOM UP" position. The main boom will start to rise. Function speed will be proportional to handle movement. Raise the boom to the horizontal position. Slowly return the lever to the center position.

•

Slowly move the "EXTEND/RETRACT" lever back to the "EXTEND" position. Extend boom out a short distance. Extend speed will be proportional to handle movement.

Listen for any unusual noises.

Check for any vibration while the boom telescopes out.

Check for uneven or jerky operation.

Check for hydraulic leaks.

Report to supervisor and repair any problem.

•

Slowly return the lever to the center position.

•

Slowly move "BOOM/SWING" lever forward to "BOOM UP" position. The main boom will start to rise. Function speed will be proportional to handle movement.

Listen for any unusual noises.

Check for any vibration while the main boom travels up.

Check for uneven or jerky operation.

Check for hydraulic leaks.

Report to supervisor and repair any problem.

Slowly return the lever to the center position.

•

Return the booms to the travel position by slowly operating the levers in the "RETRACT" and "BOOM DOWN" directions correspondingly.

Listen for any unusual noises.

Check for any vibration while booms lower and retract.

Check for uneven or jerky operation.

Check for hydraulic leaks.

Report to supervisor and repair any problem.

•

Slowly return the levers to their center positions.

•

Slowly move the "BOOM/SWING" lever right to swing right (counterclockwise) and left to swing left (clockwise). Swing speed will be proportional to handle movement.

Listen for any unusual noises.

Check for any vibration while the unit rotates.

Check for uneven orjerky operation.

Check for hydraulic leaks.

Report to supervisor and repair any problem.

MANUAl92376-OO1 JUNE1998

.,

PLATFORM OPERATION AND CHECKS (Continued) Slowly return the lever to the center position.

•

Operate the platform rotate function by moving the "PLATFORM ROTATE" toggle.

Move the toggle in both directions.

Listen for any unusual noises.

Check for any vibration while the platform rotates.

Check for uneven or jerky operation.

Check for hydraulic leaks.

Report to supervisor and repair any problem.

•

Return the platform to the center position with the "PLATFORM ROTATE" toggle.

•

Operate the platform level function by moving "PLATFORM LEVEL" toggle. Move the toggle in both directions.

Listen for any unusual noises.

Check for any vibration while platform tilts forward or back.

Check for uneven or jerky operation.

Check for hydraulic leaks.

Report to supervisor and repair any problem.

•

Return the platform to a level position with the "PLATFORM LEVEL" toggle.

•

Switch the machine "FUNCTION SPEED" toggle to "LOW".

IMPORTANT: JIB BOOM SHOULD BE RAISED FOR SUFFICIENT GROUND CLEARANCE.

A.

WARNING

WITH THE PLATFORM SWUNG OVER THE STEERING WHEELS, USE CAUTION WHEN SELECTING THE TRAVEL DIRECTION. TRAVEL AND STEERING DIRECTION WILL BE OPPOSITE CONTROL OPERATION. Slowly move the "DRIVE" lever forward. The machine should smoothly accelerate in the forward direction.

Movement alarm sounds whenever the machine is in motion.

Listen for any unusual noises.

Check for any vibration while the unit travels.

Check for uneven or jerky operation.

Check for hydraulic leaks.

Report to supervisor and repair any problem.

MANUAL92376-OO1 JUNE 1998

PLATFORM OPERATION AND CHECKS (Continued) Operate the "STEER" rocker switch and check for proper steering controL Note position of the platfonn to the steering wheels. (If so equipped, operate the optional rear steering by flipping the "STEER SELECT" switch.)

•

Return the wheels to the straight ahead position.

•

Slowly move the "DRIVE" lever backward. The machine will smoothly accelerate in the reverse direction.

Movement alann sounds whenever the machine is in motion.

•

Press "EMERGENCY STOP" button. All functions (including engine) must stop immediately.

A

WARNING

BRACE YOURSELF FOR UNEXPECTED PLATFORM MOVEMENT BECAUSE THE MACHINE COMES TO A SUDDEN STOP. ACTUATION OF THE "EMERGENCY STOP" BUTTON WILL APPLY BRAKES IMMEDIATELY! •

Reset "EMERGENCY STOP" button by turning or pulling, and restart engine.

PLATFORM OPERATION AND CHECKS (CONTINUED) •

Raise the main boom to above horizontal, and repeat the drive tests. Machine should travel a maximum of 0.5 M.P.H (0.8 K.P.H.). This condition is referred to as "creep speed", and is the maximum rate of travel with the main boom raised or extended.

NOTE: At "creep speed", a tire makes one complete revolution in approximately twenty (20) seconds. If one revolution takes much less than this time, the machine must be adjusted to bring the "creep speed" back down to 0.5 M.P.H. (0.8 K.P.H.).

•

Return the machine to the straight ahead position, with main boom below horizontal and fully retracted. Position jib boom for adequate ground clearance for travel.

Switch the "MACHINE FUNCTION SPEED" toggle to "HIGH", and repeat the drive tests.

$

Move all levers and toggles back to their neutral positions. Release the foot switch.

NOTE: All machine motion should stop upon release of the foot switch.

•

Flip "OFF/ON/START" toggle to the "OFF" position to shut off the engine.

•

Wliile pressing the "EMERGENCYPUMP" pushbutton, slightly raise thejib boom.

Then returnjib boom to stowed position.

MANUAL92376-001 JUNE 1998

COLD WEATHER OPERATION

•

In below zero weather, the hydraulic fluid should be allowed to warm before full operation of the unit.

•

Check for water contamination of the fluid.

•

Check for and remove ice on the platform, swing gear teeth and steering linkage(s) prior to operation.

•

Check that all valve levers operate smoothly, and return freely to the neutral position.

A

CAUTION

Avoid sudden braking or steering, go slow and leave more maneuvering room during cold weather operation.

BOOM OPERATION The boom operation includes SOFT-TOUCH CONTROL which automatically slows the boom motion down in high reach positions for safer operation and also controls the amount of side reach by automatically retracting when booming down into extreme side reach positions. See the following Working Range Diagrams for operation zones.

A

CAUTION

Booming down at the extreme positions will result in the boom retracting to closely follow the side reach curve.

PLATFORM OPERATION Depress the deadman foot switch and the engine will rev up to the required RPM. Then move the required function and the following will move.

GROUND OPERATION Lift the OPERATE FUNCTIONS switch and simultaneously move the required function switch and after a short delay, the engine will rev up and the function will move.

MANUAl92376-OO1 JUNE 1998

CD

DRIVING AND STEERING

I

I

A WARNING

ENSURE THAT THE ROUTE OF TRAVEL IS CLEAR OF PERSONNEL AND DEBRIS. Depress the foot switch. Slowly push the "DRIVE" lever forward to provide forward travel, or pull the lever backward for reverse travel.

NOTE: The speed of the unit will be proportional to handle movement.

To steer, press "STEER" rocker switch on the end of the drive lever to the left or right as required.

Although the unit can be driven with the platform positioned at either end of the unit, the operator may find driving easier when the platform is over the non-steering axle.

The stowed position can be identified by the large "FORWARD" arrows on the undercarriage, or by the line up of the lock pin holes. When driving with the platform over the opposite axle, remember that all directions given to the steer and drive controls will be reversed.

When descending a ramp (incline), it is necessary to control the travel speed. To slow the unit, move the drive lever slowly towards the center "neutral" position.

BRAKING For parking, the brakes are automatically applied when the drive lever is in the center "neutral" position.

I

A. WARNING

RELEASE OF THE DRIVE LEVER OR ACTUATION OF THE RED "EMERGENCY STOP" WILL APPLY BRAKES IMMEDIATELY! BR<\CE YOURSELF FOR UNEXPECTED PLATFOR..\1 MOVEMENT AS THE MACHINE COMES TO A SUDDEN STOP.

MANUAl92376-001 JUNE 1998

GASOLINE ENGINE OPERATION •

To start engine, press "START" button and the "CHOKE" button (at ground station), OR press and hold the "ENGINE THROTTLE" toggle to "CHOKE" and the "OFF/ON/START" toggle to "START" (at platfonn).

•

As soon as the engine starts, release both switches.

DUAL FUEL ENGINE OPERATION GASOLINE OPERATION •

Operate the machine as nonna!.

GASOLINE TO PROPANE SWITCHING This option is done from the Ground Controls. The unit may be switched with engine running or not running.

•

Open valve on propane tank.

•

Switch selector switch to off position so all unburned fuel will be consumed.

•

Switch to "L.P" on selector switch. Start engine as in normal manner.

NOTE: Doing this procedure may shut off ignition circuit if engine has not started after six seconds, turn key switch off then back to "Ground" or "Platform" and restart.

PROPANE TO GASOLINE SWITCHING This procedure is just opposite of switching gasoline to propane.

NOTE: While doing either procedure while engine is running their mayor may not be a hesitation depending on weather conditions.

DIESEL ENGINE OPERATION FOR DIESEL ENGINES EQUIPPED WITH GLOW PLUGS: •

Press the "GLOW PLUG" button (at platfonn or ground controls), and hold for 30 to 45 seconds (when the engine is cold) prior to engaging the starter motor.

MANUAl92376-{)01 JUNE 1998

CD) SHUT-DOWN PROCEDURES

•

When finished with the machine, place the booms in the stowed position.

•

Park the unit on a level surface.

•

With all toggles/levers to "NEUTRAL" position, allow the engine to slow to idle speed.

•

Tum "OFF" the "GROUND/PLATFORM" key switch. Remove key to prevent unauthorized operation.

MOVING JOB SITE TO JOB SITE UNLOADING PROCEDURES

A

WARNING

TO AVOID A SERIOUS PERSONAL INJURY OR DEATH, ENSURE THAT THE MACHINE IS IN "LOW" DRIVE SPEED WHILE UNLOADING FROM A TRUCK OR TRAILER. •

Inspect the outside of the unit for damage (including the underside). Inspect all hoses, boom sections and cables for chafing or road damage. Confirm that all wheel lug nuts and swing bearing bolts are tight (refer to specifications).

•

Remove the pin that locks the turret to the chassis near the swing bearing.

Stow the lock pin in the location provided nearby.

•

Remove all machine tie downs. Remove wheel chocks, if used. Switch the "GROUND/PLATFORM" key switch to "PLATFORM".

Enter the platform, and restart the engine using the platform controls. Select the "OPERATING" engine speed, and test all platform functions.

•

Raise the boom and the jib so that the platform will clear any obstacles as the machine is driven down the loading ramp.

•

Carefully drive the unit off the truck or trailer.

•

Before placing the unit into service, all operators must read and understand the contents of this Operator's Manual.

Upon initial unloading of the machine the "Predelivery Inspection Report" must be completed and returned in order to activate the Time Condor Limited Warranty.

MANUAl. 92376-001 JUNE 1998

TRUCK OR TRAILER TRANSPORT UNASSISTED LOADING OR UNLOADING OF ANY MOBILE PLATFORM IS NOT RECOMMENDED.

1. Enter the platform, secure the safety gate, and start the engine using the platform controls. Select the engine "OPERATING SPEED".

2. Raise the main and jib booms to allow greater ground clearance so that the platform will clear any obstacles as the machine goes up the loading ramp.

3. Carefully drive the unit onto the truck or trailer.

4. Lock the turret to the chassis by installing the lock pin provided.

5. Ensure that the main boom is fully retracted. Next, the jib boom tip should rest on the truck or trailer bed. Then, use the platform level lever to rest the platform base on the bed of the truck or trailer, but do not apply pressure onto bed.

6. Tie down locations are located on all four corners of the chassis and at the base of the jib boom. Use four (4) 112 inch, "Grade 7" chains from each of the tie down lugs, and run the chains as shown in the diagram below.

Ratchet type load binders are recommended. Ifusing lever type load binders, wire or strap them shut, or wrap chains around them to prevent opening.

TRANSPORTING THE UNIT TOWING PROCEDURES WITHOUT OPTIONAL TOWING PACKAGE: •

If optional towing package is not installed, refer to "UNPOWERED EMERGENCY MOVEMENT" in this section.

WITH OPTIONAL TOWING PACKAGE: • •

Securely attach the T40/T46J to a tow vehicle with the tow bar provided.

Disengage torque hubs:

I A WARNING I

MANUAL 92376-{)Ol JUNE 1998

•

WHENEVER DISENGAGINE THE DRIVE TORQUE HUBS OR BEFORE DISCONNECTING FROM TOWING VEHICLE, ENSURE THAT THE UNIT CANNOT ROLL.

Type 1: remove the plate in the center of the torque hub, tum the plate so that the boss faces in, then reinstall the plate.

Type 2: remove the large hex cap in the center of the torque hub, push in and tum screw slot in the center of the torque hub to line up with the "TOW" mark on the hub, then reinstall the cap.

•

Pull steer wander control valve, located near the ground controls, to allow steering wheels to track behind tow vehicle.

The tow vehicle must have sufficient braking capability in order to safely stop itself as well as the T40/T46J. Tow speed shall not exceed 3 MPH (4.8 KPH).

MANUAl92376-001 JUNE 1998

0

EMERGENCY SYSTEM AND PROCEDURES

.. DANGER IF THE UNIT FAILS TO OPERATE WHEN THE PLATFORM IS RAISED OR EXTENDED, DO NOT ATTEMPT TO CLIMB DOWN THE BOOM ASSEMBLY. SERIOUS INJURY MAY RESULT. EMERGENCY PUMP The T40/T46J has an emergency pump which can be operated from the operator's platform or ground controls to safety return the platform to the ground position when the unit has lost engine/pump power. Operation from the ground controls override platform controls.

• •

Press and hold the "PUMP" toggle to "EMERGENCY" on the ground control box, OR Press and hold the "EMERGENCY PUMP" button on the platform control box.

Select the proper function (boom retract, boom lower, or swing) as required to safely lower the platform to ground level.

To prevent the battery from completely discharging and the emergency pump from overheating, release the emergency pump button to allow a 30 second rest period after every 30 seconds of operation. Once the unit has been safely positioned, correct the cause of the failure before returning the unit to service.

UNPOWERED EMERGENCY MOVEMENT •

Every attempt should be made to restore engine/pump power to the unit before using this procedure.

.. DANGER THIS PROCEDURE REQUIRES RELEASING THE VEHICLE BRAKES, WHICH RESULTS IN NO MEANS TO STOP THE UNIT'S TRAVEL. TIME CONDOR RECOMMENDS USING THIS PROCEDURE ONLY IN CASE OF EMERGENCY, AND ONLY A SHORT DISTANCE. BE AWARE OF UNIT RUNAWAY ON SLOPING SURFACES. MOVEMENT SPEED SHALL NOT EXCEED 1 M.P.H. (1.6 K.P.H.).

MANUAL 92376-001 JUNE 1998

•

UNPOWERED EMERGENCY MOVEMENT (CONTINUED) 1.

Secure the unit chains or ropes.

The T40/T46J is equipped with tie down lugs (front and rear of chassis) that can be used for towing the unit The chains or ropes must be of sufficient capacity to move the unit

A WARNING ALWAYS CHOCK THE WHEELS BEFORE YOU RELEASE THE BRAKES TO PREVENT UNEXPECTED UNIT MOVEMENT ON SLOPES. 2.

Chock wheels.

3.

Close brake circuit needle valve located at the center rear of the chassis.

4.

Disengage torque hubs:

A WARNING WHENEVER DISENGAGING THE DRIVE TORQUE HUBS OR BEFORE DISCONNECTION FROM TOWING VEHICLE, ENSURE THAT THE UNIT CANNOT ROLL. Type 1: remove the plate in the center of the torque hub, turn the plate so that the boss faces in, then reinstall the plate.

Type 2: remove the large hex cap in the center of the torque hub, push in and turn screw slot in the center of the torque hub to line up with the "TOW" mark on the hub, then reinstall the cap.

5. Disconnect steer cylinder.

After unchocking the wheels, the unit will be ready to be moved.

After engine/pump power has been restored to the machine, engage the torque hubs, reset the brake circuit needie valve, and connect steer cylinder. The machine is now ready for normal operation.

MANUAL92376-OO1 JUNE 1998

EMERGENCY LOWERING It is not possible for us to foresee every emergency situation that could arise during operation of this machine. Information on the following pages describes three typical emergency situations, and lists appropriate actions that can be taken.

When faced with an emergency, above all please remember: •

Stay calm.

•

Think through the situation before operating the machine.

•

Get help if necessary.

SITUATION ONE: Platform elevated, operator not incapacitated, but unit will not respond to platform controls.

POSSIBLE CONDITION: •

One or more functions not operating correctly.

•

Unit movement from unselected lever.

•

Unit function will not stop unless power is switched off.

CORRECTIVE ACTION 1. Remove foot from foot switch.

2. Push the red "Emergency Stop" Button.

3. Evaluate the nature of the failure. Return to the ground, using the emergency pump and lowering procedure (see "Emergency Pump", earlier in this section).

A. DANGER DO NOT TRY TO CLIMB DOWN THE BOOM. HAVE AN EXPERIENCED OPERATOR USE THE EMERGENCY PUMP TO SAFELY LOWER THE PLATFORM.

MANUAl92376-OO1 JUNE 1998

4. If unable to return to the ground using the platform controls and the emergency pump, contact an experienced operator to lower the machine with the emergency pump using the ground control box (see "Emergency Pump", earlier in this section).

5. Report the incident to your supervisor immediately.

SITUATION TWO: Unit elevated, with operator incapacitated at platform controls.

.. DANGER DO NOT TOUCH UNIT !l!

DETERMINE THE CAUSE OF THE PROBLEM BEFORE YOU TOUCH THE MACHINE.

CORRECTIVE ACTION

1.

Have someone summon first aid or rescue squad.

2.

Attempt to talk to operator before taking any rescue measures.

3.

Check to see if the operator is in a pinned position, or would be endangered if platform is moved, before attempting emergency lowering procedure.

4.

After establishing that the machine is not in contact with live power lines, lower the platform using the emergency lowering procedure (see "Emergency Pump", earlier in this section).

5.

Render first aid to the operator.

6.

Report the incident to your supervisor immediately.

IMPORTANT: Any incident involving personal injury must be immediately reported to the local Time Condor Corporation.

MANUAL92376.{1()1 JUNE 1998

SITUATION THREE: Platform in contact with live power lines and operator incapacitated.

A DANGER DO NOT TOUCH UNIT I!!

ELECTROCUTION HAZARD !!!

CORRECTIVE ACTION

1. Contact authorized personnel to disconnect power supply touching unit.

2. Have someone summon first aid or rescue squad.

3. If operator is unconscious, check to see ifhe is in a pinned position, or would be endangered if platform is moved.

4. AFTER POWER IS CUT, use the emergency lowering procedure to bring platform with operator to a safe location to render first aid (see "Emergency Pump", earlier in this section.)

5. Report the incident to your supervisor immediately.

IMPORTANT: Any incident involving personal injury must be immediately reported to the local Time Condor Corporation.

MANUAL 92376-001 JUNE 1998

MACHINE SPECIFICATIONS

T40

T46J

46' Working Hght.

14.02m 15.85m 52 1 40' PlatformHght.

12.19m 14.02m 46' 7'9" Stow. Height 236m 2.36m 7'9" 17'11 n Stow. Length 5.46m 6.73m 22'1" 7'11" Overall Width 2.41m 2.41m 7'11" Platform Cap. 500lbs 226.8 kg 5001bs 226.8 kg Platform Size 60"x36" 1.5xO.9m 60'i X 361' 1.5xO,9m 47' Horiz. Reach I4.33m 14.33m 47' 1 3'6 12fI Tail Swing 3'6112 n 1.08m l.08m 17 " 8'7/ In. Tum Rad. 2.46m 2.46m 8 / 8" 8 18' 111" Out.TumRad. 5.52m 18' PI" 5.52m 4 4 42% Gradeability 42% 42% 42% Travel Speed 5.25 mph 8.45kmh 5.25 mph 8.45kmh 10112" 26.67cm 101/ " 26.67cm Ground Clear.

2 12 x 16.5 12 x 16.5 12 x 16.5 12 x 16.5 Tire Size NIA NIA 1.83m Jib Length 61 NIA NIA 135 0 Jib Rotation 135° 0 360 C 360° C 360°C 3600 C Turret Rotat.

0 1600 160° Plat. Rot. (hyd.) 160 1600 Gas Gas Gas Power Source Gas Gross Weight 13,OOOlbs 5896 kg 15,7501bs 7144kg 8' 2.44m 2.44m WheelBase 8' 40 gal 151.411 40 gal 151.411 Fuel Tank Cap. 170.341 45 gal 170.341 Hyd. Tank Cap. 45 gal Specifications are subject to change without prior notice!

MANUAL92376-D01 JUNE 1998

SERVICE MANUAL MODELS T40 & T46J BOOM-SUPPORTED ELEVATING WORK PLATFORM Beginning With Serial Number P-ll X-002615

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MANUAl 92376-002 JUNE 1998

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TABLE OF CONTENTS

•

INTRODUCTION ........................................................................................................................................ i SERVICE INFORMATION ........................................................................................................................ ii WARRANTY ............................................................................................................................................. iii Introduction ................................................................................................................................................... 4 Machine Specifications ................................................................................................................................. 6 Machine Component Locator ....................................................................................................................... 7 Lubrication Chart .......................................................................................................................................... 8 Lubrication Diagram ..................................................................................................................................... 9

Section 1: Transportation and Emergency Procedures Transporting the Unit ..................................................................................................................................

Truck or Trailer Transport ..........................................................................................................................

Unloading Procedures .................................................................................................................................

Emergency System and Procedures ...........................................................................................................

Emergency Electrical Pump ........................................................................................................................

Unpowered Emergency Movement ............................................................................................................

Emergency Lowering ..................................................................................................................................

13 13 14 15 15 15 17

Sectiou 2: Hydraulic System Hydraulic Fluid Handling Precautions ..................................................................................................................... 22 Fluid Recommendations ................................................................................................................. 22 Fluid Contamination Checks ........................................................................................................... 23 System Flushing Procedure ............................................................................................................ 23 Hydraulic System Components ................................................................................................................... 24 Main Hydraulic Pump .................................................................................................................... 24 Main Pump Replacement ............................................................................................................... 24 Emergency Pump ........................................................................................................................... 25 Emergency Pump Adjustment ................................................................................................. 25 Maintenance ............................................................................................................................ 25 Hydraulic Circuit Line Check .................................................................................................. 25 Drive Motor ................................................................................................................................... 26 Hydraulic Fluid Reservoir .............................................................................................................. 26 Hydraulic Reservoir Maintenance ........................................................................................... 26 Hydraulic Fluid Filter ...................................................................................................................... 26 Return Filter ............................................................................................................................ 26 High Pressure Filter ................................................................................................................ 26 Main Hydraulic Control Valve ....................................................................................................... 27 Boom Lift System .......................................................................................................................... 28 Boom Lift Valve Segment ....................................................................................................... 28 Flow Control Valve ................................................................................................................. 28 Flow Control Valve Adjustment .............................................................................................. 28 LiftCylinder ............................................................................................................................ 28 Boom Telescope (Extend) System ..................................................................................................... 28 Boom Extend Valve Segment ........................................................................................................ 28 Pressure Relief Valve ..................................................................... ,.............................................. 28 Telescope (Extend) Cylinder ......................................................................................................... 29 Jib BoolnSystem ................................................................................................................................. 29 Jib Boom Valve Segment ............................................................................................................... 29 JibCylinder .................................................................................................................................... 29 Platform Rotate System ...................................................................................................................... 29 Rotary Actuator ............................................................................................................................. 29 Rotary Actuator Maintenance ....................................................................................................... 29 MANUAL 92376-002 JUNE 1998

•

TABLE OF CONTENTS (Continued) Section 2: Hydraulic System (Continued) Platfonn Levelling System .................................................................................................................. 29 Master Levelling Cylinder .............................................................................................................. 30 Slave LevellingCylinder ................................................................................................................. 30 Relief Valves ................................................................................................................................. 30 Steer System ....................................................................................................................................... 30 Selector Valve Segment ................................................................................................................. 30 Steer Pressure Relief Valve .......................................................................................................... 30 Steer Cylinder ................................................................................................................................ 30 Steer System Maintenance ............................................................................................................ 31 Hydraulic Swivel ............................................................................................................................ 31 Section 3: Drive System Drive System Components ......................................................................................................................... 35 Drive Motor ................................................................................................................................... 35 Drive Valve Manifold - Two Wheel Drive .................................................................................... 35 Hi Speed Drive Enable Valve ................................................................................................. 36 Flow Divider! Combiner Valve ................................................................................................ 36 Brake Valve Circuit ................................................................................................................. 36 Drive Valve Manifold - Four Wheel Drive .................................................................................... 36 Hi Speed Drive Enable Valve ................................................................................................. 37 Flow Divider! Combiner Valve ................................................................................................ 37 Brake Valve Circuit ................................................................................................................. 37 Selector Spool Valve Circuit ................................................................................................... 37 Toggle Switch on the Pendant Control .......................................................................................... 37 Platform Control Handle (Joystick) ............................................................................................... 37 Section 4: Electrical System General Operations ............................................................................................................................... 40 Control System Adjustment. .................................................................................................................. 42 Error Codes ........................................................................................................................................... 44 Electrical System ................................................................................................................................... 45 Battery ................................................................................................................................................. 45 Battery Maintenance (In Use) ....................................................................................................... 45 Battery Preventive Maintenance ................................................................................................... 45 Battery Replacement ..................................................................................................................... 46 Movement Alann ................................................................................................................................. 46 TiltAlarnl .............................................................................................................................................. 47 Circuit Breaker ...................................................................................................................................... 47 LimitSwitch .......................................................................................................................................... 47 Elnergency Pump .................................................................................................................................. 47 Emergency Stop Button ........................................................................................................................ 47 Ground Control Box Switch Removal ................................................................................................... 48 Platform Control Box Switch Removal ................................................................................................. 48 Platform Control Board ......................................................................................................................... 48 Electronics Control Module ................................................................................................................... 48

MANUAL 92376-002 JUNE 1998

TABLE OF CONTENTS (Continued) Section 5: Mechanical Components

•

Mechanical Components ............................................................................................................................. 51 Tires ................................................................................................................................................. 51 Changing Tires ............................................................................................................................... 51 Wheels and Lug Nuts ............................................................................................................................ 51 Drive Hub Assembly ............................................................................................................................. 52 Steer Cylinder Pins ................................................................................................................................ 53 Steer Cylinder ............................................... '" ...................................................................................... 53 Steer Cylinder Seal Replacement .................................................................................................. 53 Drive Motor Replacement ............................................................................................................. 54 Turret ............................................................................................................................................. 54 Platform ......................................................................................................................................... 54 Hoses and Cables .................................................................................................................................. 54 Miscellaneous Equipment ...................................................................................................................... 54 Boom ................................................................................................................................................. 55 Boom Pivot Pin and Bushing Replacement ................................................................................... 55 Wear Pads ..................................................................................................................................... 55 Base Boom Top Wear Pad Replacement ............................................................................... 56 Moving Anchor Wear Pad Replacement.. ..................................................................................... 56 Tip Boom Top Wear Pad Replacement .................................................................................. 56 BOOlTI Lift Cylinder ................................................................................................................................ 57 Lift Cylinder Pivot Pin Replacement ............................................................................................ 57 Lift Cylinder Seal Replacement (On Machine) ............................................................................. 57 Bench Replacement Of Lift Cylinder Seals ................................................................................... 58 Counterbalance Valve Inspection .................................................................................................. 60 Jib Boon1 Removal ................................................................................................................................ 60 Jib BOOI11 Installation ............................................................................................................................. 60 Boom Telescope Cylinder ..................................................................................................................... 61 Telescope Cylinder Removal ......................................................................................................... 61 Telescope Cylinder Seal Replacement .......................................................................................... 61 Telescope Cylinder Installation ........................................................................................................... 62 Counterbalance Valve Inspection .................................................................................................. 62 Platform Level Cylinders ...................................................................................................................... 63 Platform Level Cylinder Pin Replacement... .................................................................................. 63 Level Cylinder Seal Replacement .................................................................................................. 63 Platform Leveling Procedure ......................................................................................................... 63 Section 6: Maintenance

Maintenance .......................................................................................................................................... 66 General Maintenance Tips .................................................................................................................... 66 First Three Months of Operation ........................................................................................................... 66 Routine Servicing ...................................... _........................................................................................... 67 Shift Operational Checklist .................................................................................................................... 71 Weekly Operational Checklist ............................................................................................................... 74 Monthly Operational Checklist .............................................................................................................. 76 Semi-Annual Operational Checklist ...................................................................................................... 79

Bolt Torque Chart

MANUAL92376-OO2 JUNE 1998

INTRODUCTION This Service Manual is designed to provide you with the instructions needed to properly maintain the Time Condor Corporation. T40 Aerial Platform with full hydraulic controls. When used in conjunction with the Operators and Parts manuals (provided separately) this Service Manual will Assist you in making necessary adjustments or repairs.

Time Condor Aerial Platforms are designed and built to provide many years of safe, dependable service. To obtain full benefits from your T40, always follow the proper operating and maintenance procedures. Only trained, authorized personnel should be allowed to operate or service this machine.

Service personnel should read and study the Operators, Service and Parts Manuals in order to gain a thorough understanding ofthe unit prior to making any repairs. Exercise all necessary safety precautions when performing maintenance not covered in this manual.

To help you recognize important safety information, we have identified warnings and instructions that directly impact on safety with the following signals:

&

DANGER

"DANGER" INDICATES AN IMMINENTLY HAZARDOUS SITUATION WIDCH, IF NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY. THIS SIGNAL WORD IS TO BE APPLIED TO THE MOST EXTREME SITUATIONS.

"WARNING" INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY.

I

A

CAUTION

lI i

"CAUTION" indicates a potentially hazardous situation which, if not avoided, may result in minor moderate injury. It is also used to alert against unsafe practices which could lead to property-damage-only accidents.

MANUAL 92376-D02 JUNE 1998

Service personnel and machine operators must understand and comply with all warnings and instructional decals on the body of the machine, and at the ground controls and platform control console.

& DANGER MODIFICATIONS OF THIS MACHINE FROM THE ORIGINAL DESIGN AND SPECIFICATION WITHOUT WRITTEN PERMISSION FROM CONDOR ARE STRICTLY FORBIDDEN. A MODIFICATION MAY COMPROMISE THE SAFETY OF THE MACHINE, SUBJECTING USERS TO SERIOUS INJURY OR DEATH. ANY SUCH MODIFICATION WILL VOID ANY REMAINING WARRANTY. Condor reserves the right to change, improve, modify or expand features of its equipment at any time. Specifications, models or equipment are subject to change without notice, and without incurring any obligations to change, improve, modify or expand features of previously delivered equipment.

Any procedures not found within this manual must be evaluated by the individual to assure himself that they are "proper and safe", because all possible procedures cannot be covered.

All Condor manuals are periodically updated to reflect changes that occur in the equipment.

Please contact the factory with any questions you may have regarding your machine, or the availability of more recent manuals.

MANUAL 92376'{)()2 JUNE 1998

•

MACHINE SPECIFICATIONS Working Height ..................................................................................................................................... 46 Ft. Platform Height ..................................................................................................................................... 40 Ft. Horizontal Reach (Boom Angle 0°) ..................................................................................................... 36 Ft. Platform Capacity (Unrestricted) ..................................................................................................... 500 Lbs. Platform Size ............................................................................................................................ 36 In. x 60 In.

Stowed Length ............................................................................................................................ 17 Ft. 11 In. Stowed Height ................................................................................................................................ 7 Ft. 9 In. Machine Width .............................................................................................................................. 7 Ft. 11 In. Wheelbase ............................................................................................................................................. 8 Ft. Ground Clearance ................................................................................................................................ 10.5 In Gross Weight (Approximately) .................................................................................................... 13,000Lbs. Maximum Travel Speed: Boom Stowed ........................................................................................................................... 5.25 MPH BOOln Extended or Elevated ....................................................................................................... 0.5 MPH Tuming Radius Inside ..................................................................................................................................... 8 Ft. 1 In. Outside ................................................................................................................................... 18 Ft. 1 In. Gradeability (On Hard Surface) .............................................................................................................. 42% Platform Rotation .................................................................................................................................... 160° Turret Rotation .............................................................................................................. 360° Non-continuous Tire Size ........................................................................................................................... 15xI6.5-10Ply Tire Pressure (not applicable to foam filled tires) ................................................................................ 80 PSI Hydraulic Pressure (Maximum) ....................................................................................................... 3000 PSI Hydraulic Tank Capacity .................................................................................................................... 45 Gal. Fuel Capacity: Gas or Diesel ................................................................................................................................. 40 Gal. Propane ......................................................................................................................................... 30 Lbs. Electrical System .................................................................................................... One 12 Volt DC Battery

MANUAl 92376-002 JUNE 1998

•

PRIMARY MACHINE COMPONENTS

PLATFORM CONTROLS

'"~~ MAIN BOOM ASSEMBLY EXlENSION CYLINDER

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LIFT CYLINDER

MASTER LEVELING

CYLINDER

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GROUND CONTROLS

CHASSIS LEFT HAND SIDE MANUAL 92376'{)()2 JUNE 1998

LUBRICATION CHART SPECIFIC A nON AND QUANTITY

FREQUENCY OF LUBRICATION

Hydraulic Reservoir

Shell Tell us T -32 to "Full" mark with all cylinders retracted.

Check level & condition each shift.

Analye 6 months or 500 hours. *+ Change yearly or 1000 hours. *+

2.

Hydraulic Filters

Filter elements.

Change 6 months or 500 hours. *+

3.

Swing Bearing (standard open style)

Lithium N.L.G.I. #2 EP. Purge old grease.

Weekly or every 25 hours.*+

4.

Exposed Swing Bearing Gear Teeth

Dry moly lube spray.

Every six (6) months or 500 hours.*+

5.

Swing Drive Gear Box

Fill to plug. SAE 140 EP or N.L.G.I. #00 EP oil.

Check monthly or every 100 hours. *+ Change every two (2) years or 2,000 hours. *

6.

N/A for the T40

N/A for the T40

N/A for the T40.

7.

Wheel Bearings

Lithium N.L.G.I. #2 EP. Clean and repair.

Change every six (6) months or 500 hours.*+

8.

Drive Wheel Power Hubs

SAE 90, halffull.

Change after first 50 hours. Check monthly or every 100 hours. *+ Change yearly or 1,000 hours. *+

NO.

ITEM

l.

* Whichever occurs first. + Different requirements for severe duty applications. See check list.

MANUAL92376-OO2 JUNE 1998

LUBRICATION DIAGRAM

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MANUAl 92376-002 JUNE 1998

SECTION 1: TRANSPORTATION AND EMERGENCY PROCEDURES

MANUAL92376-OO2 JUNE 1998

TABLE OF CONTENTS, SECTION 1 Transporting the Unit ..................................................................................................................................

Truck or Trailer Transport ..........................................................................................................................

Unloading Procedures .................................................................................................................................

Emergency System and Procedures ................................................................................................... :.......

Emergency Electrical Pump ........................................................................................................................

Unpowered Emergency Movement ............................................................................................................

Emergency Lowering ..................................................................................................................................

MANUAl 92376-002 JUNE 1998

13 13 14 15 15 15 17

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MANUAL 92376-002 JUNE 1998

TRANSPORTING THE UNIT TRUCK OR TRAILER TRANSPORT

A

WARNING

ALWAYS ATTACH THE UNIT TO A WINCH WHEN LOADING OR UNLOADING FROM A TRUCK OR TRAILER. CONNECT WINCH CABLE TO THE TIE DOWN LUGS ON THE CHASSIS. UNASSISTED LOADING OR UNLOADING OF ANY MOBILE PLATFORM IS NOT RECOMMENDED.

1.

Enter the platform, secure the safety gate, and start the engine using the platform controls.

Select the engine "OPERATING SPEED".

2.

Raise the main and jib booms to allow greater ground clearance so that the platform will clear any obstacles as the machine goes up the loading ramp.

3.

Using a winch, carefully drive the unit onto the truck or trailer.

4.

Lock the turret to the chassis by installing the lock pin provided.

A

CAUTION

To avoid damaging the unit, the platform MUST NOT be tied to the trailer bed in any way and should only REST on the bed.

5.

The negative battery cables should be disconnected for long distance transport.

It is recommended that the fuel and hydraulic tank valves be closed as well.

6.

Tie down locations are located on all four corners of the chassis and on the platform skirt weldment. Use four (4) 1/2 inch, "Grade 7" chains from each of the tie down lugs, and run the chains as shown in the diagram. (also located on decals on both sides of chassis).

Ratchet type load binders are recommended. If using lever type load binders, wire or strap them shut, or wrap chains around them to prevent opening.

MANUAL 92376-002 JUNE 1998

UNLOADING PROCEDURES

A WARNING TO AVOID A SERIOUS PERSONAL INJURY OR DEATH, ENSURE THAT THE MACHINE IS IN "LOW" DRIVE SPEED WHILE UNLOADING FROM A TRUCK OR TRAILER. •

Inspect the outside of the unit for damage (including the underside). Inspect all hoses, boom sections and cables for chafing road damage. Confirm that all wheel lug nuts and swing bearing bolts are tight (refer to specifications).

•

Remove the pin that locks the turret to the chassis near the swing bearing.

Stow the lock pin in the location provided nearby.

Unlock and open both side compartment doors. Inspect all fuel, electrical and hydraulic connections for damage and security.

•

Connect battery cables to batteries if required. Check electrolyte level.

•

Check engine oil level, and add as required per engine manufacturer's recommendations.

Check fluid level at the sight gauge on the hydraulic tank, and add fluid as required (see Lubrication Chart). Check that shutoff valves on the hydraulic tank are open.

Close side compartment doors.

•

Attach the unit to a winch for the unloading procedure.

i I

!

AWARNING

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

ALWAYS ATTACH THE UNIT TO A WINCH WHEN LOADING OR UNLOADING FROM A TRUCK OR TRAILER. CONNECT WINCH CABLE TO THE TIE DOWN LUGS ON THE CHASSIS. UNASSISTED LOADING OR UNLOADING OF ANY MOBILE PLATFORM IS NOT RECOMMENDED. READ AND UNDERSTAND ALL SAFETY, CONTROL AND OPERATING INFORMATION FOUND ON THE MACHINE AND IN THIS MANUAL BEFORE OPERATING THE UNIT. •

Remove all machine tie downs (see Transporting Unit). Remove wheel chocks, ifused.

Switch the "GROUND /PLATFORM" key switch to "PLATFORM".

MANUAl92376-002 JUNE 1998

•

Enter the platfonn, and restart the engine using the platfonn controls. Select the " OPERATING" engine speed, and test all platfonn functions.

Raise the boom and the jib so that the platform will clear any obstacles as the machine is driven down the loading ramp.

Carefully drive the unit offthe truck or trailer with the assistance of a winch.

NOTE: The brakes are automatically released for driving, and will automatically apply when the unit stops.

•

Before placing the unit into service, all operators must read and understand the contents of the Operator's Manual.

EMERGENCY SYSTEM AND PROCEDURES

.& DANGER IF THE UNIT FAILS TO OPERATE WHEN THE PLATFORM IS RAISED OR EXTENDED, DO NOT ATTEMPT TO CLIMB DOWN THE BOOM ASSEMBLY. SERIOUS INJURY MAY RESULT. EMERGENCY PUMP The T40 has an emergency pump which can be operated from the operator's platform or ground controls to safety return the platform to the ground position when the unit has lost engine/pump power. Operation from the ground controls override platform controls.

• •

Press and hold the "PUMP" toggle to "EMERGENCY" on the ground control box, OR Press and hold the "EMERGENCY PUMP" button on the platform control console.

Select the proper function (boom retract, boom lower, or swing) as required to safely lower the platform to ground level.

To prevent the battery from completely discharging and the emergency pump from overheating, release the emergency pump button to allow a 30 second rest period after every 30 seconds of operation. Once the unit has been safely positioned, correct the cause of the failure before returning the unit to service.

UNPOWERED EMERGENCY MOVEMENT •

Every attempt should be made to restore engine/pump power to the unit before using this procedure.

MANUAl 92376-002 JUNE 1998

THIS PROCEDURE REQUIRES RELEASING THE VEHICLE BRAKES, WHICH RESULTS IN NO MEANS TO STOP THE UNIT'S TRAVEL. TIME CONDOR RECOMMENDS USING THIS PROCEDURE ONLY IN CASE OF EMERGENCY, AND ONLY A SHORT DISTANCE. BE AWARE OF UNIT RUNAWAY ON SLOPING SURFACES. MOVEMENT SPEED SHALL NOT EXCEED 1 M.P.H. (1.6 K.P.H.) .

.. DANGER, UNPOWEREDEMERGENCYMOVEMENT(CONTINUED) 1.

Secure the unit chains or ropes.

The T 40 is equipped with tie down lugs (front and rear ofchassis) that can be used for towing the unit. The chains or ropes must be ofsufficient capacity to move the unit.

I.i WARNING I

AL WAYS CHOCK THE WHEELS BEFORE YOU RELEASE THE BRAKES TO PREVENT UNEXPECTED UNIT MOVEMENT ON SLOPES. 2.

Chock wheels.

3.

Close brake circuit needle valve located atthe centerrearofthe chassis.

4.

Disengage torque hubs:

A

WARNING

WHENEVER DISENGAGING THE DRIVE TORQUE HUBS OR BEFORE DISCONNECTION FROM TOWING VEHICLE,ENSURE THAT THE UNIT CANNOT ROLL. Type 1: remove the plate in the center ofthe torque hub, turn the plate so that the boss faces in, then reinstall the plate.

MANUAL 92376-002 JUNE 1998

Type 2: remove the large hex cap in the center ofthe torque hub, push in and

tum screw slot in the center of the torque hub to line up with the "TOW" mark on the hub, then reinstall the cap.

5. Disconnect steer cylinder.

After unchocking the wheels, the unit will be ready to be moved.

After engine/pump power has been restored to the machine, engage the torque hubs, reset the brake circuit needle valve, and connect steer cylinder. The machine is now ready for normal operation.

EMERGENCY LOWERING It is not possible for us to foresee every emergency situation that could arise during

operation ofthis machine. Information on the following pages describes three typical emergency situations, and lists appropriate actions that can be taken.

When faced with an emergency, above all please remember: •

Stay calm.

•

Think through the situation before operating the machine.

•

Gethelpifnecessary.

SITUATION ONE: Platform elevated, operator not incapacitated, but unit will not respond to platform controls.

POSSIBLE CONDITION:

•

One or more functions not operating correctly.

•

Unit movement from unselected lever.

•

Unit function will not stop unless power is switched off.

CORRECTIVE ACTION 1. Remove foot from foot switch.

MANUAL 92376-002 JUNE 1998

2. Push the red "Emergency Stop" Button.

3. Evaluate the nature ofthe failure. Return to the ground, using the emergency pump and lowering procedure (see "Emergency Pump", earlier in this section).

•

DANGER

DO NOT TRY TO CLIMB DOWN THE BOOM.

HAVE AN EXPEIDENCED OPERATOR USE THE EMERGENCY PUMP TO SAFELY LOWER THE PLATFORM. 4. Ifunable to return to the ground using the platform controls and the emergency pump, contact an experienced operator to lower the machine with the emergency pump using the ground controls (see "Emergency Pump", earlier in this section).

5. Report the incident to your supervisor immediately.

SITUATION TWO: Unit elevated, with operator incapacitated at platform controls.

•

DANGER DO NOT TOUCH UNIT I!!

DETERMINE THE CAUSE OFTHE PROBLEM BEFORE YOU TOUCH THE MACHINE. CORRECTIVE ACTION 1.

Have someone summon first aid orrescue squad.

2.

Attempt to talk to operator before taking any rescue measures.

3.

Check to see if the operator is in a pinned position, or would be endangered ifplatform is moved, before attempting emergency lowering procedure.

4.

After establishing that the machine is not in contact with live power lines, lower the platform using the emergency lowering procedure (see "Emergency Pump", earlier in this section).

5.

Render first aid to the operator.

6.

Report the incident to your supervisor immediately.

IMPORTANT: Any incident involving personal injury must be immediately reported to the local Time Condor Corporation.

MANUAL 92376·{I02 JUNE 1998

SITUATION THREE: Platform in contact with live power lines and operator incapacitated.

&

DANGER· DO NOT TOUCH UNIT !l!

ELECTROCUTION HAZARD I!!

CORRECTIVE ACTION

1. Contact authorized personnel to disconnect power supply touching unit.

2. Have someone summon first aid orrescue squad.

3. If operator is unconscious, check to see ifhe is in a pinned position, or would be endangered ifplatform is moved.

4. AFTER POWER IS CUT, use the emergency lowering procedure to bring platform with operator to a safe location to render first aid (see "Emergency Pump", earlier in this section.)

5. Report the incident to your supervisor immediately.

IMPORTANT: Any incident involving personal inj ury must be immediately reported to the local Time Condor Corporation.

MANUAL92376-002 JUNE1998

SECTION 2: HYDRAULIC SYSTEM

MANUAL 92376-002 JUNE 1998

TABLE OF CONTENTS, SECTION 2:

•

Hydraulic Fluid ............................................................................................................................................ 22 Handling Precautions ............................................................................................................................ 22 FluidRecommendations ........................................................................................................................ 22 Fluid Contamination Checks .................................................................................................................. 23 SystelTI Flushing Procedure ................................................................................................................... 23 Hydraulic System Components ................................... ,............................................................................... 24 Main Hydraulic Pump ........................................................................................................................... 24 Main Pump Replacement ............................................................................................................... 24 Emergency Pump .................................................................................................................................. 25 Emergency Pump Adjustment ....................................................................................................... 25 Maintenance .................................................................................................................................. 25 Hydraulic Circuit Line Check .................................................................................................. 25 Drive Motor ........................................................................................................................................... 26 Hydraulic Fluid Reservoir ...................................................................................................................... 26 Hydraulic Reservoir Maintenance ................................................................................................. 26 Hydraulic Fluid Filter ............................................................................................................................. 26 Return Filter ................................................................................................................................... 26 High Pressure Filter ....................................................................................................................... 26 Main Hydraulic Control Valve .............................................................................................................. 27 Boom Lift System ................................................................................................................................. 28 Boom Lift Valve Segment ............................................................................................................. 28 Flow Control Valve ........................................................................................................................ 28 Flow Control Valve Adjustment ..................................................................................................... 28 Lift Cylinder ................................................................................................................................... 28 Boom Telescope (Extend) System ........................................................................................................ 28 Boom Extend Valve Segment ........................................................................................................ 28 Pressure Relief Valve .................................................................................................................... 28 Telescope (Extend) Cylinder ......................................................................................................... 29 Jib Boom System ................................................................................................................................... 29 Jib Boom Valve Segment ............................................................................................................... 29 Jib Cylinder .................................................................................................................................... 29 Platform Rotate System ........................................................................................................................ 29 Rotary Actuator ............................................................................................................................ 29 Rotary Actuator Maintenance ................................................................................................. 29 Platform Levelling System .................................................................................................................... 29 Master Levelling Cylinder .............................................................................................................. 30 Slave Levelling Cylinder ................................................................................................................ 30 Relief Valves ................................................................................................................................. 30 Steer System ......................................................................................................................................... 30 Selector Valve Segment ................................................................................................................ 30 Steer Pressure Relief Valve .......................................................................................................... 30 Steer Cylinder ................................................................................................................................ 30 Steer System Maintenance ............................................................................................................ 31 Hydraulic Swivel ............................................................................................................................ 31

MANUAl 92376-002

JUNE 1998

HYDRAULICFLillD HANDLING PRECAUTIONS

A WARNING PERSONS IN REGULAR CONTACT WITH MINERAL - BASED HYDRAULIC FLUID NEED TO BE AWARE OF THE IMPORTANCE OF THOROUGH HYGIENE,AND THE PROPER METHODS FOR HANDLING MINERAL OILS IN ORDER TO AVOID POTENTIAL HAZARDS TO HEALTH. Ifmineral- based hydraulic fluid is SPLASHED INTO THE EYES, it must be WASHEDOUTTHOROUGHL Yusingabundantquantitiesofwater.

If irritation persists, medical advice should be sought.

Mineral oils act as solvents on the natural oils in the skin. FREQUENT AND PROLONGED SKIN CONTACT CAN CAUSE DERMATITIS OR SEVERE IRRITA TION. Mineral- based hydraulic fluids normally present no health hazard when used properly. Protective clothing and proper washing facilities should be provided or be accessible.

AWARNING HYDRAULIC FLUID UNDER PRESSURE CAN PENETRATE AND BURN THE SKIN, DAMAGE EYES, AND MAY CAUSE SERIOUS INJURY, BLINDNESS, AND EVEN DEATH. FLUID LEAKS UNDER PRESSURE MAY NOT ALWAYS BE VISIBLE. IF MINERAL - BASED HYDRAULIC FLUID HAS PENETRATED THE SKIN, IT MUST BE MEDICALLY TREATED, BY A DOCTOR FAMILIAR WITH THIS TYPE OF INJURY, WITHIN AFEW HOURS. FLUID RECOMMENDATIONS We strongly recommend the use of SHELL TELLUS T-32 HYDRAULIC FLUID. An EQUIV ALENT substitute can be used if absolutely necessary. Mineral - based hydraulic fluids produced by different companies will USUALLY mix with each other satisfactorily, but this IS NOT RECOMMENDED. When in doubt, consult your supplier.

MANUAl 92376-002 JUNE 1998

FLUID CONTAMINATION CHECKS Use the following as a guide to determine when analysis of the hydraulic fluid is necessary.

•

Any time the hydraulic pump is replaced.

•

If fluid discoloration is noticed in the hydraulic reservoir sight tube.

If, after the first 50 hours of operation, the hydraulic filter elements are plugged.

•

Any time the hydraulic filter elements show signs of metal content.

•

Once every six months, under normal operating conditions.

•

Every 3 months, in extremely dusty or dirty operating conditions.

The hydraulic fluid analysis must be done by a qualified laboratory. To ensure that you receive accurate recommendations about the fluid being analyzed, always provide the following information with the test sample.

Type of hydraulic fluid. (See Lubrication Chart) •

Model and serial number of unit from which sample was taken.

Purpose of analysis: i.e. pump failure, discoloration, etc.

•

Type of analysis: i.e. complete to show additive breakdown, acid buildup, viscosity, type and percent of contaminants. Comparison to new fluid and recommendations.

Comply with contamination analysis and recommendations to achieve a clean, contamination free hydraulic system.

Following the above guide will prevent premature failure of pumps, cylinder seals and drive motors, and unnecessary down time.

If system flushing and replacement of fluid is recommended, refer to the flushing procedure.

SYSTEM FLUSHING PROCEDURE With BOTH MAIN BOOM AND JIB BOOM DOWN AND FULLY RETRACTED (in stowed position), drain hydraulic fluid from hydraulic tank into a clean, empty container.

This can be done with an oil filter cart so the fluid may be reused if analysis is good.

When the hydraulic tank is empty, remove suction hoses and return line hose. Remove all hoses between pump and high pressure filter. Flush the hoses. Remove hydraulic fluid filter, and flush the filter body and attaching hoses. Discard old filter element and replace.

With hoses removed from the hydraulic tank, flush out the tank. When this is complete, all the hoses removed in the previous steps should be properly reinstalled EXCEPT the system return line to tank. This hose should be lengthened to drain into the reservoir fluid container.

Fill hydraulic tank with filtered, fresh hydraulic fluid (refer to Lubrication Chart).

MANUAL 92376-002 JUNE 1998

Make sure the suction lines are open to allow fluid to flow to the hydraulic pump. Loosen hose fittings at pump to allow pump to flood with hydraulic fluid, then tighten pump fittings.

Turn the main power key switch to the "GROUND" position. Press engine start button to start engine. After a brief warm-up period, select the "HIGH" engine RPM setting.

Briefly cycle all boom functions to flush the hydraulic components ofthe hydraulic fluid.

Use care when doing this as hydraulic fluid is now being returned to container provided.

This will remove old fluid from the hydraulic system as the boom is cycled to its maximum limits.

A. CAUTION Monitor the hydraulic reservoir fluid level when cycling the unit functions, adding fluid as necessary to replace that being discharged to container at system return line. This fluid may be returned to the reservoir through a filter cart, if good.

Three cycles of all hydraulic cylinder functions should remove old hydraulic fluid.

When the above procedures have been completed, reconnect system return hose to tank.

Fill hydraulic tank to full mark on sight gauge. Operate all functions to their full extreme positions to ensure proper operation. Check for leaks and correct as necessary. Unit is now ready to be placed back in operation.

HYDRAULIC SYSTEM COMPONENTS Following is a description of the major components of the hydraulic system.

Main Hydraulic Pump The SAUER-SUNDSTRAND SERlES40-M46 hydrostatic pump is a 46cc variable pump.

The pump's displacement can be controlled by three different methods; manually, electrically, or hydraulically_ The pump comes with Electric Displacement Control (EDC), the pump displacement and output flow, in either direction, is approximately proportional to an electrical input signal.

Main Pump Replacement 1.

With all ball valves closed, ensure hydraulic tank is filled with oil.

2.

The replacement pump should be installed with the same orientation as the existing pump.

IMPORTANT: When installing the replacement pump, the pUlnp shaft couplil1gteeth must properly mate with the engine nylon element. Adjust the coupling on the pump shaft for maximum engagement.

MANUAL 92376-002 JUNE 1998

3.

Open all ball valves from hydraulic tank.

4.

Fill the pump case with hydraulic fluid by loosening the vent/fill plug in the pump case, opening the inlet line and allowing gravity to prefill the inlet line pump case.

5.

Disable engine ignition and crank engine for a maximum of 30 seconds to ensure that pump is primed. (For gasoline engine, pull coil wire: for Diesel engine, disconnect fuel solenoid).

6.

Tighten vent/fill plug in the pump case.

7.

Check all inlet connections to be sure they are air-tight. An air leak in the inlet line can cause the pump case to drain down and cause the pump to loosen prime during succeeding start-ups.

8.

The pressure compensator is factory set and can be adjusted (if necessary) for start-up.

Clockwise rotation increases the compensator setting and counterclockwise rotation decreases this setting. Pump compensator should be set with the system deadheaded.

9.

Differential pressure adjustment and horsepower control adjustment are factory set.

Readjustment is NOT recommended. Consult Time Condor Corporation, if necessary.

EMERGENCY PUMP The emergency pump is driven by a 12 volt DC electric motor. This pump delivers hydraulic fluid, under pressure, to the manifold assembly. The electric motor is rated for noncontinuous duty and will fail prematurely if activated continuously for extended time periods.

NOTE: This pump should only be used in emergency situations.

EMERGENCY PUMP ADJUSTMENT The emergency pump pressure setting screw is located on the side of the adapter plate. To adjust the relief pressure on the pump, remove the acorn nut, loosen the jam nut and turn the adjusting screw in to increase pressure. To decrease pressure, turn the adjusting screw out.

MAINTENANCE Hydraulic Circuit Line Check Insert hydraulic lines and connections for signs oflooseness or obstruction.

Tighten loose fittings and correct any crimped hoses: From pump through pressure filter to valve stack.

•

Lines between valve stack and reservoir.

•

All hoses to the cylinders.

•

Tie-down of hoses.

MANUAL 92376-002 JUNE 1998

NOTE: Entrapped air in the hydraulic lines is common upon start-up and may result in temporary irregular motion. However, if after a reasonable operating period this condition persists, hydraulic lines should be bled to remove entrapped air and carefully inspected for leaks, starting with the pump suction line.

DRIVE MOTORS For two wheel drive systems, there are two drive motors on the rear wheels, and for four wheel drive systems there are four drive motors (front and rear wheels). The drive motor connects to the torque hub which has an integral brake. The SAUER-SUNDSTRAND SERIES 40-M35 fixed displacement motor is used as the T40's drive motor.

HYDRAULIC FLUID RESERVOIR The hydraulic fluid reservoir consists of the tank, a sight gauge, a filler cap with filter, a strainer, a vent, a sump with drain plug, one valve for suction line, five valves for return lines and a valve for the emergency pump suction line.

HYDRAULIC RESERVOIR MAINTENANCE Check tank for signs of leakage. Inspect tank securing bolts for tightness. Clean cap filter by flushing with clean water and dry thoroughly.

HYDRAULIC FILTER There are two hydraulic filters: a return filter and a high pressure filter. They are both located near the hydraulic tank.

MANUAL92376'()()2 JUNE 1998

•

MAIN HYDRAULIC CONTROL VALVE

The main control valve is located on the same side as the ground controls on the hydraulic tray assembly. The location of the different hydraulic functions' solenoids, reliefvalves (if applicable),. and flow controllers are located on the isometric drawing below. The individual hydraulic functions that the main hydraulic control valve regulates are described in more detail in the following pages. and the isometric drawing below shows the location of the individual solenoids, reliefvalves (ifapplicable), and flow controllers.

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MANUAL92376-002 JUNE199B

BOOM LIFT SYSTEM The boom lift system consists of a hydraulic valve segment on the ground valve bank, a flow control valve, a lift cylinder with a counterbalance valve, a lift toggle switch on the ground control box and a control lever on the platform control box.

BOOM LIFT VALVE SEGMENT When the boom control lever on the platform control box or the boom control toggle switch on the ground control box is activated, an electrical signal is transmitted to the valve cartridge in the boom lift valve segment. This allows hydraulic fluid at the correct pressure to be sent to the proper end of the lift cylinder to raises or lower the boom.

FLOW CONTROL VALVE The flow control valve, located at the boom up outlet on the boom lift valve segment, controls boom down speed. The flow control valve allows full hydraulic fluid flow for the boom up function. For the boom down function, the flow control valve meters the hydraulic fluid flow, thus allowing a smooth descent.

Flow Control Valve Adjustment If boom bounces while descending, adjust the valve clockwise until boom descends smoothly.

LIFT CYLINDER The boom lift function is controlled by a double acting cylinder. The cylinder contains a counterbalance valve, which will prevent unintended movement of the cylinder should a hose or fitting develop a leak. When the boom is lowered, fluid flows to the rod end cylinder port and to the counterbalance valve, and allowing fluid in the base end of the cylinder to flow back to the hydraulic reservoir. When the boom section is raised, fluid flows to the base end cylinder port and to the counterbalance valve, opening this valve and allowing fluid in the rod end of the cylinder to flow back to the hydraulic reservoir.

BOOM TELESCOPE SYSTEM The boom telescope system consists of a hydraulic valve segment on the ground valve bank, a pressure relief valve, a double telescope cylinder with two counterbalance valves, an extend toggle switch on the ground control box and a control lever on the platform control box.

BOOM TELESCOPE VALVE SEGMENT When the boom telescope control lever on the platform console or the boom telescope control toggle switch on the ground control box is activated, an electrical signal is transmitted to the valve cartridge in the boom telescope valve segment. This allows hydraulic fluid at the correct pressure to be sent to the proper end of the telescope cylinder to extend or retract the boom.

PRESSURE RELIEF VALVE The pressure relief valve limits the pressure on the base end of the cylinder to 1500 PSI (103 Bar, lO5.5 Kg/cm2) to preventthe cylinder rod from buckling. The pressure relief valve is factory set and needs no adjustment.

MANUAL 92376-002 JUNE 1998

TELESCOPE CYLINDER The telescope cylinders control the extending and retracting ofthe boom.

JIB BOOM SYSTEM The jib boom system consists of a hydraulic valve segment on the ground valve bank, a cylinder with a counterbalance valve, and a control lever on the platform control box and a toggle switch on the ground control box.

JIB BOOM VALVE SEGMENT When the jib boom control lever on the platform console or ground control station is activated, an electrical signal is transmitted to the valve cartridge in the j ib boom valve segment. This allows hydraulic fluid at the selected flow to be sent to the proper end of the cylinder to raise or lower jib boom.

JIB ARTICULATION CYLINDER The jib boom function is controlled by a double acting cylinder. The cylinder contains a counterbalance valve, which will prevent unintended movement of the cylinder should a hose or fitting develop a leak. When the boom is lowered, fluid flows to the rod end cylinder port and the counterbalance valve, opening this valve and allowing fluid in the base end ofthe cylinder to flow back to the hydraulic reservoir. When the jib boom section is raised, fluid flows to the base end cylinder port and to the counterbalance valve, opening this valve and allowing fluid in the rod end of the cylinder to flow back to the hydraulic reservoir.

PLATFORM ROTATE SYSTEM The platfonn rotate system consists of a platform rotate toggle switch and valve, a double pilot operated check valve, a rotary actuator and a platform rotator manifold. The platform rotate system can onlybe operated from platform console.

ROTARY ACTUATOR The rotary actuator is a helical gear type. Hydraulic fluid enters the actuator from either side depending on the control valve direction, and moves the rack which causes the pinion shaft to rotate.

ROTARY ACTUATOR MAINTENANCE Change the hydraulic fluid once every year (see Lubrication Chart).

PLATFORM LEVELLING SYSTEM The platform levelling system automatically keeps the platfonn level, using a master/slave cylinder arrangement. As the boom is raised or lowered, fluid is forced from one cylinder to the other in a closed loop, which keeps the platform parallel to the ground in any boom position. Due to slight intemalleakage,fluid circuit through the platfonn level control valve.

The platfonn levelling system in only controlled from the platfonn console.

Refer to "Boom Component Locators" in the introduction of this manual for platform leveling system component locations.

MANUAL92376-OO2 JUNE 1998

MASTER LEVELLING CYLINDER The master levelling cylinder is a double acting cylinder located between the upper frame of the superstructure and the boom. Whenever the boom is raised or lowered, the master cylinder is forced to extend or retract. The fluid displacement from the master cylinder is in turn sent up the boom to the slave cylinder. This forces the slave cylinder to move the same distance as the master levelling cylinder; thereby keeping the platform level.

SLAVE LEVELLING CYLINDER The slave levelling cylinder is a double acting cylinder located between the jib boom and the platform. This cylinder controls the position of the platform relative to the tip boom.

The slave levelling cylinder contains two counterbalance valves. The counterbalance valves prevent platform movement in the event of hose failure.

RELIEF VALVES The relief valves are factory set at 3000 PSI (207 Bar/21! Kg/cm2) and prevent high pressure spikes in the levelling circuit that could result in component damage. High pressure spikes can occur when the platform is manually controlled for levelling, which cause the slave level cylinder to bottom out before the master level cylinder stops moving as the boom is lowered.

STEER SYSTEM The two wheel steering system consists of a selector valve assembly, a steer valve segment, hydraulic swivel, a steer cylinder, a steer toggle switch on the remote control pendant and a steer rocker switch on the drive lever at the platfonn console. Refer to "Component Locators" in the introduction of this manual.

The four wheel steering system also includes a diverter valve located all the undercarriage, that is activated by a toggle switch at the platform controls. This valve is used to select front or rear steer.

STEER VALVE SEGMENT When the steer control lever on the platform console or the steer control toggle switch on the remote control pendant is activated, an electrical signal is transmitted to the valve cartridge in the steer valve segment. This allows hydraulic fluid to be sent to the steer cylinder.

STEER PRESSURE RELIEF VALVE The steer pressure relief valves limits the pressure on the base end of the cylinder to 1900 PSI (131 Bar, 131.5 Kg/cm2) to prevent the cylinder rod from buckling. The pressure relief is factory set and needs no adjustment.

STEER CYLINDER The cylinder is double acting and is directly connected to the steering linkage assembly. This cylinder powers all steering movements.

MANUAL 92376-002 JUNE 1998

STEER SYSTEM MAINTENANCE Check all pins on steering linkage and steer cylinder for excessive play, and ensure that all retaining rings are in place and secure.

Lubricate linkage as required (see Lubrication Chart).

HYDRAULIC SWIVEL The hydraulic swivel allows passage of hydraulic fluid from the steer valve segment in the turret to the steer cylinder in the undercarriage and back. The swivel allows for 360 0 of continuous turret rotation in either direction.

MANUAL92376-002

JUNE 1998

This page intentionally left blank

MANUAL92376-002

JUNE 1998

SECTION 3: DRIVE SYSTEM

MANUAL92376-002 JUNE 1998

TABLE OF CONTENTS, SECTION 3 Drive System Components ......................................................................................................................... 35 Drive Motor ........................................................................................................................................ 35 Drive Valve Manifold - Two Wheel Drive ......................................................................................... 35 Hi Speed Drive Enable Valve ................................................................................................. 36 Flow Divider! COlnbiner Valve ................................................................................................ 36 Brake Valve Circuit ................................................................................................................ 36 Drive Valve Manifold - Four Wheel Drive ......................................................................................... 36 Hi Speed Drive Enable Valve ................................................................................................. 37 Flow Divider! Combiner Valve ................................................................................................ 37 Brake Valve Circuit ................................................................................................................ 37 Selector Spool Valve Circuit ................................................................................................... 37 Platform Control Handle (Joystick) ....................................................................................................... 37

MANUAl92376-OO2 JUNE 1998

DRIVE SYSTEM COMPONENTS

The standard T40 is propelled by two hydraulic drive motors. The optional 4 wheel drive T40 is propelled by four hydraulic drive motors .The drive circuit consists ofthe hydraulic drive motors, the drive valve segment, the drive manifold, a toggle switch on the ground control and a platform drive control lever (joystick).

DRIVE MOTOR

For two wheel drive systems, there are two drive motors on the rear wheels, and for four wheel drive systems there are four drive motors (front and rear wheels). The drive motor connects to the torque hub, which ifit has an internal brake, or to a separate brake ifneeded.

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DRIVE VALVE MANIFOLD - TWO WHEEL DRIVE NOTE: Refer to "Machine Specifications" to determine maximum system pressure for your T40.

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SPEED DRIVE ENABLE VALVE

The hi speed drive enable valves are 2 positions, 2 way solenoid valves that bypass the flow divider valve and are used to control the fluid flow for travel speed. The valves require no adjustment and seal kits are available (see Illustrated Parts Catalog).

FLOW DIVIDER/COMBINER VALVE In the forward direction, this valve divides flow, and in the reverse direction it combines the flow. The single flow divider directs the flow so that 50% goes to the left and 50% goes to the right. The valve requires no adjustment and a seal kit is available (see Illustrated Parts Catalog).

There is a non-serviceable, fixed orifice that allows hydraulic fluid to transfer from one drive motor to the other. When making turns, the outside tire turns faster and requires more hydraulic fluid flow. Since the flow divider gives each motor equal flow, this orifice will allow the transfer of hydraulic fluid from the inside wheel to the outside wheel and prevent tire scrubbing on hard surfaces.

BRAKE VALVE CIRCUIT The brake valve circuit consists of a shuttle valve, a pressure reducing valve and a flow control valve. The shuttle valve diverts maximum pressure from either the forward or reverse supply ports and sends it to the pressure reducing valve which reduces it to 500 PSI maximum. The flow control valve delays the application of the spring applied hydraulically released brake when releasing the drive handle. This delay allows for a smooth stop by restricting the return flow of oil. The valves require no adjustment and seal kits are available (see Illustrated Parts Catalog).

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DRIVE VALVE MANIFOLD - FOUR WHEEL DRIVE NOTE: Refer to "Machine Specifications" to determine maximum system pressure for your T40.

•

HI SPEED DRIVE ENABLE VALVE The hi speed drive enable valves are 2 positions, 2 way solenoid valves that bypass the flow divider valve and are used to control the fluid flow for travel speed. The valves require no adjustment and seal kits are available (see Illustrated Parts Catalog).

FLOW DIVIDER/COMBINER VALVE In the forward direction, these valves divide flow, and in the reverse direction they combines the flow. The single flow divider directs the flow so that 50% goes to the left and 50% goes to the right The remaining two flow dividers direst the flow for each side so that 50% goes to the front and 50% goes to the rear. These two valves guarantee flow to all wheels (4 wheel positraction) and are only active while the function speed switch at the platform console is in low. The valves require no adjustment and seal kits are available (see Illustrated Parts Catalog).

There is a non-serviceable, fixed orifice that allows hydraulic fluid to transfer from one drive motor to the other. When making tums, the outside tire tums faster and requires more hydraulic fluid flow. Since the flow divider gives each motor equal flow, this orifice will allow the transfer of hydraulic fluid from. the inside wheel to the outside wheel and prevent tire scrubbing on hard surfaces.

BRAKE VALVE CIRCUIT The brake valve circuit consists of a shuttle valve, a pressure reducing valve and a flow control valve. The shuttle valve diverts maximum pressure from either the forward or reverse supply ports and sends it to the pressure reducing valve which reduces it to 500 PSI maximum. The flow control valve delays the application of the spring applied hydraulically released brake when releasing the drive handle. This delay allows for a smooth stop by restricting the retum flow of oil. The valves require no adjustment and seal kits are available (see Illustrated Parts Catalog).

SELECTOR SPOOL VALVE CIRCUIT The hi speed selector valve is a 2 position, 4 way solenoid valve that pilots the two selector spools open when energized in high speed. This results in a series - parallel flow operation. When the hi speed selector valve is not energized, the system diverts 25% of the flow to each wheel motor. The selector spool flow valves divert flow from the flow dividers and reduce heat generation.

PLA TFORM CONTRL HANDLE (JOYSTICK) To opereate the drive function from the platform, use the platform control handle. See Section 4: Electrical System" for control handle adjustment or replacement.

MANUAl 92376-002 JUNE 1998

SECTION 4: ELECTRICAL SYSTEM

MANUAL 92376-002 JUNE 1998

TABLE OF CONTENTS, SECTION 4

General Operations ............................................................................................................................... 40 Control System Adjustment ................................................................................................................... 42 Error Codes ........................................................................................................................................... 44 Electrical System .................................................................................................................................. 45 Battery ................................................................................................................................................. 45 Battery Maintenance (In Use) ....................................................................................................... 45 Battery Preventive Maintenance ................................................................................................... 45 Battery Replacement ..................................................................................................................... 46 Movement Alarm .................................................................................................................................. 46 Tilt Alarm .............................................................................................................................................. 47 Circuit Breaker ........................................................................................................................................... 47 Limit Switch ................................................................................................................................................ 47 Emergency Pump ........................................................................................................................................ 47 Emergency Stop Button .............................................................................................................................. 47 Ground Control Cabinet Switch Removal ................................................................................................... 48 Platform Console Switch Removal ............................................................................................................. 48 Platform Control Board ............................................................................................................................... 48 Electronics Control Module ......................................................................................................................... 48

MANUAl92376-OO2 JUNE 1998

GENERAL OPERATION The control system in the T-Series machines consists ofthe following parts. (See Diagram On Page 43) Platform Joysticks and Switches Platform Control Board Ground Control Switches Ground Control Board Hydraulic Valve Hydraulic Actuators All platform switches and proportional joystick wires are connected directly to the platform control board.

Communication of these inputs is transmitted to the ground contro board via two wires in the 8 conductor shielded boom cable using RS232 protocol. This data is transmitted at a very high speed where no delay in operation is noticed. The ground control board receives the signal and outputs the correct signal to drive the hydraulic valve. Hydraulic actuation then takes place. The ground board is a solid state switching board that takes the place of many failure prone mechanical relays.

The ground control board consists of24 on/off outputs and 12 proportional outputs. All switches and lights are controlled by the on/off outputs. All joysticks are controlled by the proportional outputs.

MANUAL 92376-002

JUNE 1998

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No adjustments are made on the platform control board. Function speeds are adjusted using the following three potentiometers: MAX Potentiometer This adjusts the current (or speed) of the function when the joystick is at full on. Initial current settings for each function are listed in Table 1. The function speed (time to move through the complete motion of function in seconds) is also listed. The procedure should be to initially set the current, then go back and do any final tweaking to get the correct speed. Valve tolerances vary from one to another so function speed should always be the final setting. Adjusting the MIN potentiometer will effect the MAX setting.

You will have to go back and forth to get the final setting for both.

MIN Potentiometer This adjusts the current (or speed) ofthe function when joystick is moved just slightly. This is sometimes referred to as the threshold. In order to achieve the smoothest full joystick range of proportional control, it is desired to have the machine initially start to move when the joystick is just moved slightly, and at full speed when the joystick is full on. With the ammeter connecter (see diagram 1), move the joystick until the first reading is displayed. The required current for the specific function is listed in Table 1.

If the current needs to be increased, turn the pot in (clockwise). If it needs to be reduced turn it out (counterclockwise). If the machine lurches when the joystick is initially moved, the setting is to high and should be reduced. The final adjustment should be based on how the functions feel. If you have to move the joystick a long way before the function starts moving, the setting is too low. Adjusting the MAX potentiometer will also effect the MIN setting, so you have to go back and forth. Remember, if you increase the MAX, it will increase the MIN slightly and vice versa. The MIN adjustment also directly effects the speed when the platfornl function speed switch is set to low. This is sometimes a more important adjustment based on feel.

RAMP Potentiometer The ramp adjustment determines how quickly the function will start and stop when the joystick is moved suddenly. Caution should be used because when ramping off, you do not have the control to quickly stop the function unless you remove your foot from the deadman switch. Initial settings are listed in Table 1.

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The error codes identify where to look for bad connections or failed components.

MANUAL923760IIZ JUNE 1998

ELECTRICAL SYSTEM The following section is a description of mainten;mce for the major components of the electrical system.

BATTERY One 12 volt batteries supply the electrical power required to operate the machine.

BATTERY MAINTENANCE (IN USE) Check battery and surrounding area for signs of damage or corrosion.

Check battery terminals for: Corrosion. Regular clean connections and apply a non-metallic grease or protective spray to retard corrosion.

Loose Connections. Be sure all cable connections are tight, and that good contact is made to terminals.

•

Broken or Frayed Cables. Be sure all cable connections are good, and that no loose or broken wires are exposed. Replace as needed.

Check battery electrolyte level. Replenish the electrolyte, if necessary. Remove vent caps before filling, and USE ONLY DISTILLED WATER. Fill all cells to the proper level. Do not overfill. Fill to level indicator ( or 112 inch over the top of the separators if there is no level indicator). Fill after charging to prevent overflow of acid due to expansion. Do not use a hose to add water to batteries.

Allowing the electrolyte level to drop below the top of the separators will lead to shortened battery life. Excessive water usage can indicate that a battery has been overcharged, has been subjected to excessively high temperatures, or is nearing the end of its service life.

Keep battery clean. Wash the top of the battery, making sure all vents are in place. Do not allow cleaning water or other foreign matter to enter the cells. Use a solution of bicarbonate of soda and water to wash the battery if there is an accumulation of acid.

BATTERY PREVENTIVE MAINTENANCE Once a month, after the battery has been charged, spot check the specific gravity of two or more cells.

A fully charged battery should indicate 1.28 specific gravity. If low readings are noted, check the following: Check terminals for corrosion, loose connections and broken or frayed cables.

•

Check all cells with a hydrometer for variation in specific gravity. A variation of 0.03 points or more between cells is cause for concern.

Recheck specific gravity of all cells after recharging.

MANUAL 92376-002 JUNE 1998

G

BATTERY REPLACEMENT To remove the battery, follow these procedures:

AWARNING

I

BEFORE REMOVING BATTERY FROM THE UNIT, TURN OFF THE IGNITION SWITCH. THERE SHOULD BE NO POWER TO THE MACIDNE.

I

AWARNING

!

Always disconnect the negative battery cables first.

Remove bolts holding battery to turret.

Lift the battery from the tUlTet. Put the battery to the side and dispose of properly.

AWARNING Always connect the positive battery cable first.

To install the battery, lift and position it on turret. Secure battery in position with wing nuts and battery hold downs. Connect battery cables.

MOVEMENT ALARM The optional movement alarm is activated as soon as the platform console drive controller or drive toggle switch on the ground control is moved off the center ''Neutral'' position.

iAWARNING L THE MOVEMENT ALARM IS PROVIDED FOR YOUR PROTECTION, ANDPRo-TECTIONOF PERSONS WORKING IN IMMEDIATE AREA. DISABLING THIS IMPORTANT SAFETY DEVICE MAY RESULT IN DEATH OR SERIOUS INJURY. MANUAL 92376-002 JUNE 1998

TILT ALARM The tilt alarm gives an audible warning when the machine is 4-112° or more out of level. It is located in the platform control box. To replace the tilt alarm, open the platform control box, disconnect the wires and remove it from the platform control box.

TILT ALARM TEST The alarm can be tested by manually tipping the alarm sensor. This "Push-to Test" feature enables tilt alarm to be tested without losing its adjustment. Select "Platform" at the ground key (selector) switch.

With the boom raised above horizontal, individually push down on each of the three fastened comers of the tilt alarm. On the tilt alarm, there are three LED's. The green LED indicates the unit has power. The red LED indicates the sensor is tilted beyond 4-112°. The yellow LED indicates the sensor is tilted beyond 4112° and the 3 second delay has expired (tilt alarm should sound at the platform). On these units, there is an in-line 2 amp fuse. Check the fuse first, if the alarm sounds continuously when the sensor is level.

Then, check the flange nuts.

TILT ALARM ADJUSTMENT The tilt alarm can be adjusted. Before attempting to adjust the alarm, park the machine on a flat, level surface.Level the base of the alarm by adjusting each of the three flange nuts until the level bubble is centered.

CIRCUIT BREAKER There is one 20 amp circuit breaker mounted on the face of the ground control box.

If the breaker is tripped, reset it by pushing in the button. If the breaker trips again, the cause of the high current draw must be corrected prior to further operation.

LIMIT SWITCH There are limit switches for the boom telescope and boom lift. The boom telescope limit switch is located on the lower left side of the base boom. The boom lift limit switch is located on the center post of the turret. Unless the boom lift and telescope limit switches are closed as shown on the machine electrical schematic at the end of this manual, the machine will only be able to travel at creep speed from platform.

EMERGENCY PUMP There is an emergency pump mounted near the ground control box. It is activated when the Emergency Pump push button on the platform control box or on the ground control box is pressed. When either push button is pressed and held, the emergency pump is energized, allowing all hydraulic functions to operate should the main motor powered hydraulic pump is disabled. When either of the emergency pump pushbuttons is energized, main pump, high speed, and low speed throttle solenoids are turned off automatically.

EMERGENCY STOP BUTTON There is an emergency stop button on the ground control box and on the platform control box.

When the emergency stop buttons are pressed, all functions stop immediately and the wheel brakes are automatically applied. To replace the emergency stop button, open the ground control box or platform control box to gain access for button removal. Remove the appropriate button mounting screws and WIres.

MANUAL 92376-002 JUNE 1998

CD

GROUNDCONTROLBOXS~TCHREMOVAL

To replace a ground control switch or button, disengage the ground control cover retaining screws to gain access for switch or button removal. Remove the appropriate button mounting screws and wires.

PLATFORM CONTROL BOX SWITCH REMOVAL To replace a platform switch,joystick or light, remove the six platform box screws and swing the box lid up on its hinges, to gain access for removal. Remove the appropriate switch, joystick, or light mounting screws and wires.

PLATFORM CONTROL BOARD The platform control board contains the microprocessor or related electronics for the control of platform lights and sending data to the electronics control module.

To replace the platform control board remove the six platform console screws and swing the console up on its hinges to gain access for removal. Unlatch the individual connectors by pressing on top of the connector locks and remove connectors. Remove four bolts holding the board in place.

ELECTRONIC CONTROL MODULE The electronics control module, located in the ground control box, contains the microprocessor and related electronics for the control of all of the machine functions. It is a non-serviceable unit. If the module is suspected of being faulty, remove the four bolts that secure it in place inside the ground control box. Also, unplug the two connectors. Return the module to TIME CONDOR Corporation.

When installing the electronics control module, secure it in place with the four bolts, and plug in the two cable connectors. The connectors are keyed so they cannot be interchanged.

Refer to the troubleshooting section for electronics console module fault code identifications and diagnostic procedures.

MANUAL 92376-002 JUNE 1998

SECTION 5: MECHANICAL COMPONENTS

MANUAL 92376-002 JUNE 1998

., Table of Contents, Section 5 Mechanical Components ............................................................................................................................. 51 Tires ................................................................................................................................................. 51 Changing Tires ............................................................................................................................... 51 Wheels and Lug Nuts ............................................................................................................................ 51 Drive Hub Assembly ............................................................................................................................. 52 Steer Cylinder Pins ................................................................................................................................ 53 Steer Cylinder ........................................................................................................................................ 53 Steer Cylinder Seal Replacement .................................................................................................. 53 Drive Motor Replacement ..................................................................................................................... 54 Turret ................................................................................................................................................. 54 Platform ................................................................................................................................................. 54 Hoses and Cables .................................................................................................................................. 54 Miscellaneous Equipment ...................................................................................................................... 54 Boom ................................................................................................................................................. 55 Boom Pivot Pin and Bushing Replacement ................................................................................... 55 Wear Pads ..................................................................................................................................... 55 Base Boom Top Wear Pad Replacement ............................................................................... 55 Moving Anchor Wear Pad Replacement ................................................................................ 56 Tip Boom Top Front Wear Pad Replacement.. ....................................................................... 56 Boom Lift Cylinder ................................................................................................................................ 56 Lift Cylinder Pivot Pin Replacement ............................................................................................. 57 Lift Cylinder Seal Replacement (On Machine) ............................................................................. 57 Bench Replacement Of Lift Cylinder Seals ................................................................................... 57 Counterbalance Valve Inspection .................................................................................................. 58 Jib B00l11 Relnoval ................................................................................................................................ 60 Jib BOOln Installation ............................................................................................................................. 60 Boom Telescope .................................................................................................................................... 61 Telescope Cylinder Removal ......................................................................................................... 61 Telescope Cylinder Seal Replacement .......................................................................................... 61 Telescope Cylinder Installation ...................................................................................................... 62 Counterbalance Valve Inspection .................................................................................................. 62 Platform Levelling Cylinders ................................................................................................................. 63 Platform levelling Cylinder Pin Replacement.. ............................................................................... 63 Levelling Cylinder Seal Replacement ............................................................................................ 63 Platform Levelling Procedure ........................................................................................................ 63

MANUAL 92376-002 JUNE 1998

MECHANICAL COMPONENTS Following is a description of the major mechanical components.

TIRES

Tires used are pneumatic or the optional foam filled. Inspect tires for cuts, sidewall damage or abnormal wear. Any tire faults MUST BE CORRECTED before further machine operation.

CHANGING TIRES

AWARNING CALCIUM FILLED AND/OR FOAM FILLED TIRES ARE EXTREMELY HEAVY. CARE MUST BE TAKEN TO AVOID PERSONAL INJURY. When a tire change is necessary, follow these steps:

A

CAUTION

ALWAYS BLOCK THE WHEELS before you raise the machine.

Loosen and remove lug nuts, and pull off the wheel assembly and tire.

Replace the tire and reinstall.

Fasten lug nuts and tighten to proper torque (see Machine Specifications).

•

Lower the machine and remove the blocks.

WHEELS AND LUG NUTS Check the security of the wheel lug nuts (see Machine Specification for proper torque) and examine the wheel rims for damage.

MANUAl 92376-002 JUNE 1998

DRIVE HUB ASSEMBLY

Drive hub assembly consists ofa hydraulic motor, and a torque hub.

•

To remove drive hub assesmbly: 1. Block the steer wheels and raise the machine at the drive end.

AWARNING CALCIUM FILLED AND/OR FOAM FILLED TIRES ARE EXTREMELY HEAVY. CARE MUST BE TAKEN TO AVOID PERSONAL INJURY. 2.

Remove tire and wheel assembly: a. Loosen and remove the lug nuts. b.

Pull off the tire and wheel assembly.

A

CAUTION

Plug all open hydraulic fittings to prevent contamination by dirt or other foreign objects.

3. Disconnect hoses to the drive hub assembly.

•

4.

Loosen and remove eight capscrews and flat washers on the drive hub assembly.

5.

Slide off hydraulic motor and torque hub as one unit.

Install drive hub assembly: 1. Align the drive hub assembly (hydraulic motor and torque hub) with the axle tube assembly.

2.

Install and torque the eight capscrews with flat washers.

3. Connect hydraulic hoses to the drive hub assembly.

MANUAL 92376-002 JUNE 1998

A

WARNING

CALCIUM FILLED AND/OR FOAM FILLED TIRES ARE EXTREMELY HEAVY. ARE l\ruST BE TAKEN TO AVOID PERSONAL INJURY. 4. Install tire and wheel assembly: a. Position tire and wheel assembly. b. Install and torque lug nuts.

5. Lower the machine and remove the steer wheel blocks.

STEER CYLINDER PINS Check all pins for wear. Ifpin rotates, check for a missing retaining ring. If wear is detected, the pin must be replaced.

CYLINDER PIN REPLACEMENT 1.

Remove retaining rings (rod end) or hair pin clips (base end).

2.

Remove the pin.

3.

Grease and install new pin retaining rings or hair pin clips.

STEER CYLINDER The steer cylinder is of the double acting type. Check the cylinder for hydraulic fluid leaks.

STEER CYLINDER SEAL REPLACEMENT 1.

Disconnect the hydraulic hoses.

2.

Remove the steer cylinder pin.

3.

Remove the cylinder.

4.

Clean the end of the cylinder.

5.

Loosen the end cap and withdraw it over the piston rod.

MANUAl 92376-002 JUNE 1998

A

CAUTION

Take care not to damage the rod surface and guard against dirt entering the system.

6. Remove the rod and piston assembly.

7. Replace the seals and "0" rings.

8. Install teh rod and piston assembly.

9. Install and tighten the end cap.

10. Install cylinder.

11. Connect the hydraulic hoses.

DRIVE MOTOR REPLACEMENT Disconnect hoses and remove bolts that secure drive motor to drive assembly. Then slide motor out.

To install drive motor, secure it to the drive assembly with bolts. Connect hoses to drive motor.

TURRET The turret consists of two compartments; one is the engine compartment and the other is the hydraulic compartment.

Steam clean the turret once a year, and inspect all welds and brackets. Check for cylinder pins that turn in their mounting, which will indicate sheared pin lock bolts.

PLATFORM Steam clean the platform and inspect all welds and brackets. Check all the hydraulic and electrical components.

HOSES AND CABLES Inspect all hoses and electrical cables for security and damage. Check for leaks at fittings. ANY DAMAGED HOSES OR CABLES SHOULD BE REPLACED. Cables and hoses should be examined for rubbing and chafing, especially in the swing bearing area and the hose track area.

MISCELLANEOUS EQUIPMENT Check all miscellaneous equipment mounted on the machine for secure attachment. Check for evidence of oil or hydraulic fluid leakage.

MANUAL 923 76-002 JUNE 1998

BOOM Clean the boom once a year and inspect along the boom structure, especially all welds and brackets.

BOOM PIVOT PIN AND BUSHING REPLACEMENT IMPORTANT: It is NECESSARY TO MAINTAIN THE CORRECT ALIGNMENT between the boom and turret weldment druing this operation. Any relative movement will make fitting of the pin more difficult.

A

WARNING

THE BOOM WILL FALL IF NOT SUPPORTED WHEN THE PIVOT PIN IS REMOVED.

1.

SUPPORT THE BOOM securely (on a boom stand or similar rigid platform).

2.

Remove the retaining rings, capscrew and locknut, and drive out the boom pivot pin, taking care not to damage the inner bore, bushings, sleeve bearings or thrust bearings.

3.

Check bushings, sleeve bearings and thrust bearings and replace if necessary.

4.

Install new pivot pin.

5.

Install capscrew, locknut and retaining rings.

6.

Apply grease to pin through the grease fitting.

WEAR PADS Wear to boom sections is prevented by the installation of wear pads at several points along the boom length. The wear pads should be checked for wear approximately every six months.

Fully retract the boom, and check the gap between the wear pad and the boom section.

Wear pads are located at the top front of the tip boom, and at the top, bottom and side rear of the base boom. There is also a moving anchor wear pad mounted on a weldment located on the side of the base boom.

I

I I

A

CAUTION

If a pad wears to approximately 3/8" (9.5) thick, it should be replaced or shimmed.

Generally, only the bottom pad at the upper end and the top pad at the lower end of the boom will show wear.

MANUAL 92376-002 JUNE 1998

•

Base Boom Wear Pad Replacement 1. Fully retract and lower the boom.

2. Remove the capscrews, lockwashers and jam nuts holding the top and side wear pads.

3. Slide out the top and side wear pads.

4. Use a crane to hold the tip boom section off the bottom wear pad.

5. Remove the capscrews, lockwashers and jam nuts holding the boom wear pad.

6. Remove the bottom wear pad.

7. Install new bottom wear pad with capscrews, lockwashers and nuts.

8. Rest the tip boom section on the new bottom wear pad.

9. Install new base boom top and side wear pads.

10. Install capscrews, lockwashers and jam nuts.

Moving Anchor Wear Pad Replacement 1. Fully retract and lower the boom.

2. Remove the capscrews, flat washers and locknuts holding moving anchor wear pad.

3. Remove wear pad.

4. Install new wear pad.

5. Install capscrews, flat washers and locknuts.

Tip Boom Top Front Wear Pad Replacement

1. Fully extend the boom and support the boom in the horizontal position.

2. Remove bolts, washers and nuts; wear pad will easily fall out.

3. Install new wear pad with bolts, lockwashers and nuts.

MANUAL 92376-002 JUNE 1998

BOOM LIFT CYLINDER The boom lift cylinder is of the double acting type. During operation, the cylinder should not leak, but a slight dampness at the rod seal is acceptable. The pins should be checked for wear. Check the pin capscrew for tightness. The cylinder and holding valve should be inspected for fluid leakage, damage and security.

LIFT CYLINDER PIVOT PIN REPLACEMENT

A

CAUT'ION

Support the boom any time maintenance is required on the boom or boom cylinders.

1. Support the boom securely (on a boom stand or similar rigid platform).

2. Operate the boom lift control to release hydraulic pressure and remove any load on the lift cylinder.

3. Remove the retaining rings.

4. Remove the capscrews and nuts.

I

I

A

CAUTION

The cylinder will fall if not supported when the pivot pin is removed.

5. SUPPORT THE LIFT CYLINDER and remove the pin.

6. Install new pin, capscrews, nuts and retaining rings.

7.

Apply grease to pin through grease fitting.

LIFT CYLINDER SEAL REPLACEMENT (ON MACHINE)

A

CAUTION

Support the boom any time maintenance is reqnired on the boom or boom cylinders.

MANUAL 92376-002 JUNE 1998

•

1.

Support the boom securely in the horizontal position (on a boom stand or similar rigid platfonn).

2.

Operate the boom lift control to release hydraulic pressure and remove any load in the lift cylinder circuit.

3.

Clean the cylinder, and loosen the cylinder end cap by several turns.

A

CAUTION

The cylinder barrel will fall if not supported when the pivot pin is removed.

4.

Remove the rod end pivot pin, and support the cylinder barrel.

5.

Loosen the end cap completely, and withdraw it carefully over the piston rod.

A

CAUTION

Take care no to damage the rod surface and guard against dirt entering the system.

6.

Remove the rod and piston assembly.

7.

Replace the "0" -rings, seals and backup rings.

8.

Reassemble the lift cylinder, again AVOIDING DIRT AND ROD DAMAGE.

9.

Tighten the end cap.

10. Install rod end pin.

BENCH REPLACEMENT OF LIFT CYLINDER SEALS The lift cylinder can also be removed from the machine for seal replacement.

1.

Operate boom lift to horizontal position.

lA

CAUTIONl

Support the boom any time maintenance is required on the boom or boom cylinders.

MANUAL92376.Q02 JUNE 1998

2.

SUPPORT THE BOOM (on a boom stand or similar rigid platform) at the horizontal position.

3.

Disconnect the hydraulic hoses from the cylinder.

.6., CAUTION The cylinder will fall if not supported when rod end pin is removed.

4.

Support the cylinder with a crane.

5.

Remove the rod end cylinder pin.

6.

With the cylinder supported, remove the base end cylinder pin.

7.

Move the cylinder to a bench for examination.

8.

Extend the cylinder, and examine the protruding rod for score marks and damage.

9.

Clean the holding valve and examine for signs of leakage.

10. Clean the end of the cylinder.

11. Loosen the end cap, and withdraw it carefully over the piston rod.

A. CAUTION I Take care not to damage the rod surface and guard against dirt entering the system.

12. Remove the rod and piston assembly.

NOTE: It is recommended that the backup rings be placed when seals are changed.

13. Replace the seals and backup rings and reassemble the cylinder, AVOIDING DIRT AND ROD. DAMAGE. 14. Tighten the end cap.

15. Install the base end of the cylinder on the machine.

16. Connect all the hydraulic hoses.

17. Extend the lift cylinder and install the rod end to the boom.

18. Remove cylinder support.

MANUAL 923764Xl2 JUNE 199B

19. Remove boom support.

20. BLEED THE SYSTEM after reinstalling the cylinder.

COUNTERBALANCE VALVE INSPECTION 1.

Place rated load in platfonn, raise the boom to the horizontal position, extend the boom to full side reach and stop the engine.

2.

If the cylinder subsequently begins to move, the counterbalance valve is faulty and the cartridge should be replaced. ~

~ r,

. ,

A. DANGER i: . ,,

•

J

'

BOOM MUST BE SUPPORTED WHEN CHANGING THE COUNTERBALANCE VALVE. CYLINDER WILL RETRACT WHEN CARTRIDGE IS REMOVED. NOTE: The counterbalance valve is preset at the factory and is not field adjustable.

JIB BOOM REMOVAL

A

CAUTION

Plug all open hydraulic fittings to prevent contamination by dirt or other foreign objects.

1.

Raise jib boom and support the platform.

2.

Disconnect all electrical cables and hydraulic hoses at the platform and from the jib boom.

Note the connection of cables and hoses for ease of proper assembly.

3.

Remove articulation cylinder pin.

4.

Remove parallel ann pin to freejib boom weldment.

5.

Remove upper jib boom pin to free jib boom weldment.

JIB BOOM INSTALLATION To installjib boom and platform.

1.

Attachjib boom weldment to tip boom withjib boom pin.

2.

Attach parallel ann weldment to tip boom with parallel ann pin.

3.

Attachjib boom articulation cylinder to jib boom weldment with articulation cylinder pin.

4.

Connect all electrical cables and hydraulic hoses at the platform and to the jib boom.

MANUAL 92376'()(}2 JUNE 1998

BOOM TELESCOPE CYLINDER

The function of the telescope cylinder is to extend and retract the boom segment to allow positioning of the work platform. The double acting cylinder must be removed from the machine before a thorough inspection can be accomplished.

TELESCOPE CYLINDER REMOVAL 1.

Elevate the boom to the horizontal position.

A.

CAUTION

Support the boom any time maintenance is required on the boom or boom cylinders.

2.

Extend the boom until the telescope cylinder rod end mounting pins on the tip boom are exposed.

3.

SUPPORT THE EXTENDED TIP BOOM (on a boom stand or similar rigid platform).

4.

Remove retaining clips and the two pins at the rod end of the telescope cylinder to the tip boom.

5~

Close the hydraulic valves and disconnect the hydraulic hoses from the telescope cylinder.

Plug hose ends.

6.

Remove the remaining rings, flat washers and pins from the boom base end ofthe cylinder.

7.

Using a crane, withdraw the cylinder from the back end ofthe boom.

TELESCOPE CYLINDER SEAL REPLACEMENT 1.

Remove the end cap from the cylinder.

A.

CAUTION

Take care not to damage the rod surface and guard against dirt entering the system.

MANUAL 92376-D02 JUNE 1998

2.

Pull the cap and rod straight out ofthe cylinder barrel.

3.

Remove the nut from the end of the rod.

4.

Slip off the piston.

5.

Examine the rod and seals for signs of damage or wear.

6.

Remove the old seals and backup rings. Refer to Illustrated Parts Catalog.

7.

Install new seals and backup rings. Refer to Illustrated Parts Catalog.

TELESCOPE CYLINDER INSTALLATION

Ii CAUTION

Support the boom any time maintenance is required on the boom or boom cylinders.

1.

SUPPORT THE EXTENDED TIP BOOM (on a boom stand or similar rigid platform) IN THE HORIZONTAL POSITION.

2.

Connect the hydraulic hoses to the telescope cylinder and open hydraulic lines.

3.

Cycle the telescope cylinder several times to BLEED THE SYSTEM.

4.

Measure the distance from base boom pin holes to tip boom pin holes, and extend the telescope .... cylinder that direction.

5.

Using a crane, slide the telescope cylinder into the boom and align the rod end mounting holes with the holes in the tip boom.

6.

Install the two pins and retaining rings holding the rod end of the telescope cylinder to the tip boom.

7.

Install the pin, flatwashers and retaining rings in the base end of the cylinder.

COUNTERBALANCE VALVE INSPECTION 1.

Place rated load in the platform, hoist the boom to full elevation and extend the telescope cylinder, then stop the engine.

2.

lfthe telescope cylinder subsequently begins to move, the counterbalance valve is faulty and the cartridge should be replaced.

NOTE: The counterbalance valve is preset at the factory and is not adjustable.

MANUAL 92376"()()2 JUNE1998

PLATFORM LEVELLING CYLINDERS The platform levelling system automatically keeps the platform level, using a master! slave cylinder arrangement. Whenever the boom is raised or lowered, the master cylinder is forced to move.

The fluid displacement from the master cylinder is in turn sent up the boom to the slave cylinder.

This forces the slave cylinder to move the same distance as the master cylinder, which keeps the platform parallel to the ground in any boom position.

The platform levelling cylinders (master and slave) are of the double acting type. The pivot pins should be checked for wear. Check the pivot pin locking bolts for tightness. The cylinders should be inspected for fluid leakage, damage and security. The seals should be replaced whenever the cylinder is serviced.

LEVELLING CYLINDER PIN REPLACEMENT SUPPORT THE PLATFORM to remove the load on both master and slave cylinders. Remove the retaining ring, the pin locking bolts and nuts, and remove the pin.

Install new pin, locking bolts and nuts (lubricate bolts before installation) and retaining ring.

Apply grease to pin.

LEVELLING CYLINDER SEAL REPLACEMENT Lower the main boom. SUPPORT THE PLATFORM to remove the load on both master and slave cylinders. Remove the lock collar and pin. Slave cylinder seals can be replaced on the machine.

Master cylinder must be removed for seal replacement.

Clean the end of the cylinder. Unscrew the end cap and pull the cap and rod straight out to the cylinder barrel. TAKE CARE NOT TO DAMAGE THE ROD SURF ACE, AND GUARD AGAINST DIRT ENTERING THE SYSTEM. Remove the split pin and nut from the end of the rod. Slip off the collar. Examine the rod and seals for signs of damage or wear.

Remove the old seals and install a new seal kit.

PLATFORM LEVELLING PROCEDURE After a platform levelling cylinder has been repaired or replaced, or if the platform does not remain level with the raising and lowering of the boom, the platform levelling circuit may need to be bled.

With the platform near ground, operate the platform level control to move the platform fully backward and forward. Perfonn procedure five (5) times in order to expel any air from the system.

A.

CAUTION

CARE MUST BE TAKEN WHEN OPERATING LEVEL CONTROL. AIR IN CYLINDERS CAN CAUSE UNCONTROLLED PLATFORM MOTION.

MANUAl 92376-002 JUNE 1998

SECTION 6: MAINTENANCE

MANUAL 92376-D02 JUNE 1998

Table of Contents, Section 6 Maintenance Schedule ................................................................................................................................ 66 General Maintenance Tips .......................................................................................................................... 66 First Three Months Of Operation ............................................................................................................... 66 Routing Servicing ........................................................................................................................................ 67 Shift Operational Checklist ......................................................................................................................... 71 Weekly Operational Checklist ..................................................................................................................... 74 Monthly Operational Checklist .................................................................................................................... 76 Semi-Annual Operational Checklist ............................................................................................................ 79

MANUAL 92376-002 JUNE 1998

MAINTENANCE The T40 is designed to require a minimum amount of maintenance. However, it is essential that the specified services be performed at the indicated intervals, and that the instructions contained in this manual are followed to ensure safety and reliability. , .,'

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DEATH OR SERIOUS INJURY MAY RESULT IF MACHINE IS OPERATED IN AN UNSAFE CONDITION. DO NOT OPERATE ANY MACHINE IF IN UNSAFE OPERATING CONDITION. GENERAL MAINTENANCE TIPS •

AL WAYS clean the surrounding area before opening hydraulic components.

Never open a hydraulic system when there are contaminants in the air.

Never leave components or hoses open. They must be protected from contamination (including rain) at all times.

•

Use only recommended lubricants (see Lubrication Chart in this manual). Improper lubricants or incompatible lubricants may be as harmful as no lubrication.

Watch for makeshift "fixes", which can jeopardize safety as well as lead to more costly repairs.

Any work platform found not to be in safe operating condition should be removed from service until repaired. All repairs should be made by authorized personnel in conformance with the manufacturer's operating, maintenance, and repair manuals.

FIRST THREE MONTHS OF OPERATION As with any new machine, minor fluid leaks may occur until the various hydraulic components and pipe fittings are fully seated.

It is particularly important that, for the first three months of operation, all hydraulic components, hoses and pipe fittings be checked regularly for leaks and tightness, and corrective action taken as required.

The hydraulic pump, electric motor, cylinders and pressure valves are self-lubricating.

MANUAL 92376-002 JUNE1998

ROUTINE SERVICING NOTE: The following recommendations are based on advice of our component suppliers, and the requirements of various safety regulations. They should be followed with discretion based on factors such as amount and type of machine usage, environmental conditions, and local safety regulations.

IMPORTANT: Make certain that the unit is inspected per the operational checklists at the end of this section.

SHIFT SERVICE

Hydraulic System Before checking the hydraulic fluid level, ensure that the machine booms are stowed in the traveling position, and the machine is standing on level ground. Fluid level must be to full mark on sight gauge, located on the side of tank. Refer to Lubrication Chart for correct grade of hydraulic fluid.

Ensure that the filler cap is secure to prevent entry of water or other impurities into the tank.

Tire Condition Check that the tires are not damaged.

Platform Rails and Safety Gate Check security of platform and safety gate.

Steering Check the steer cylinder for fluid leakage. Inspect steering linkage for signs of wear.

Batteries Check the electrolyte level in battery cells. Replenish with distilled water, if necessary.

Pivot Pins Examine all pivot pins on booms and cylinders to ensure that they are positively secured in position.

Test All Machine Systems Test the operation of the drive assembly, including drive motor and steering. Test the operation of all machine boom functions.

MANUAL 92376-002 JUNE 1998

Checklist Perform all items on the Shift Checklist found later in this section.

WEEKLY SERVICE Swing Bearing and Drive Pinion Gear Lubricate standard open swing bearing and drive pinion gear, and check optional oil bath swing bearing case.

Checklist Perfoffil all items on the Weekly Checklist found later in this section.

MONTHLY SERVICE Hydraulic System Pressurize the hydraulic circuit and inspect the system for any signs of leakage, particularly at flexible hoses, connections and hydraulic components. Check hydraulic fluid color. If the hydraulic fluid does not appear clear amber, but has a cloudy appearance, it is usually an indication that water is present. A dark drown color, accompanied by a strong "burnt" smell, indicates that the fluid has overheated. If either condition occurs, a complete hydraulic fluid and filter change will be necessary.

The cause of hydraulic fluid deterioration should be investigated and rectified. Have fluid analyzed by a qualified laboratory.

Chassis Bolts Check all bolts for signs of looseness. Refer to individual items in the Monthly Checklist.

Cylinders Check all cylinders for hydraulic fluid leakage.

Pivot Pins and Grease Fittings Lubricate all pivot pins and grease fittings.

MANUAL 92376-002 JUNE 1998

Platform Mounting Check that platform weldments and platform frame members are in good condition.

Checklist Perform all items on the Monthly Checklist found later in this section.

SEMI-ANNUAL SERVICE Boom Cylinders Fully retract, then extend the boom lift cylinder. At each extreme position, check that there is no movement between cylinder rod and bearing housing, or between cylinder cap and tube.

Fully retract, then extend the boom telescope cylinder. At each extreme position, check that there is no movement of the cylinder pin.

Hydraulic Filter Change the high pressure and return filter elements.

In severe use applications, more frequent filter changes will be necessary.

Checklist Perform all items on the Semi-Annual Checklist found later in this section.

ANNUAL SERVICE NOTE: Machine Annual Inspection Report Forms are available from TIME CONDOR. Flexible Hoses Inspect all hoses over their complete length. Replace any hoses showing looseness or corrosion at the end fittings. Replace hoses with cracking, blistering or excessive wear of outer protective covering.

Hydraulic Fluid Ifthe hydraulic system has been properly maintained, the fluid should only need to be changed once each year. This, of course, will depend on machine application, amount of use, temperature, atmospheric conditions and other factors.

MANUAL 92376.002 JUNE 1998

Hydraulic Fluid Tank Carefully check the condition of the fluid inside the tank to ensure that it flows easily and is of clear, amber color. In cases of gross contamination, it will be necessary to completely drain and refill the entire hydraulic system.

Place a suitable waste oil container under the drain tap, or attach a suitable hose from the drain tap to the container. Open the drain tap, and completely drain the fluid from the tank.

Clean or replace the suction hose, and close the drain tap. Refill the tank to the correct level.

Structural Examination A thorough examination of the machine should be carried out for signs of corrosion, misalignment, material fractures, and other damage. Particular attention should be given to the condition of welded joints.

FOUR YEAR INTERVAL SERVICE Pivot Pins and Bearings Remove the pivot pins for examination. Check the pivot pin bearings with the pivot pins removed. Replace with the correct type of pins and bearings, as necessary.

MANUAl 92376-002 JUNE 1998

SIllFT OPERATIONAL CHECKLIST All checks must be completed before operation ofthe unit.

These checklists can be copied as needed to aid in performing these inspections.

DA1E:

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

MODELNUMBER: _ _ _ _ __

INSPECTED BY:

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

SERIAL NUMBER:

GENERAL INFORMATION 1.

2.

3.

Keep inspection records up-to-date.

Record and report all discrepancies to your supervisor.

A dirty machine crumot be properly inspected.

KEEP YOUR CONDOR MACHINE CLEAN!!!

A

WARNING

THIS CHECKLIST MUST BE USED AT DAILYINTERVALS OR AFTER EVERY 6 TO 8 HOURS OF USE, WHICHEVER IS SOONER. FAILURE TO DO SO COULD ENDANGER THE LIFE OF THE OPERATOR. ALWAYS REMEMBER, A LITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH MORE THAN IT COSTS.

INITIAL

DESCRIPTION 1. Check unit for any prior-shift or transportation drunage, i.e. missing parts, torn or loose hoses, hydraulic fluid leaks, tom or disconnected wires, flat or drunaged tires etc. The compartment doors on both sides can be opened to inspect components inside.

2. Check for machine damage, broken welds, improper or makeshift reprurs.

3. Check hydraulic system for leaks, exrunine hoses for signs of excessive wear, chafing or twisting.

4. Check engine oil and fuellevels.

5. Check engine coolant level (liquid cooled engine only).

MANUAL92376-002 JUNE 1998

SIllFT OPERATIONAL CHECKLIST (Continued) INITIAL

DESCRIPTION 6. Check battery electrolyte level. Check battery terminals for tight connections and cleanliness.

7. Check hydraulic fluid leveL The level should be at the line marked on the sight gauge with the unit in stowed position. Inspect condition ofhydraulic fluid in the reservoir. Fluid should be a clear amber color.

8. Check that all shutoff valves on hydraulic tank are open (parallel to flow).

9. Check tires proper inflation pressure (see Machine Specifications).

10. Check if wheel lug nuts are tight.

11. Check hose carrier to verifY that it is not bent or sagging.

12. Inspect safety equipment as required by OSHA, government and local rules.

13. Inspect the work platfoffil and boom structure for signs of damage and broken welds. Check platform gate latch for damage.

14. Check pivot pins for security.

15. Check that no attempt had been made to override the drive interlock system by a previous operator.

16. Check that all warning and instructional decals are legible and secure.

17. Start engine. Check hydraulic pressure (see Machine Specifications).

18. Check that the tilt alarm is working properly.

19. When all pre-inspection checks have been completed, test the ground controls for proper operation.

MANUAL 92376-D02 JUNE 1998

SHIFT OPERATIONAL CHECKLIST (Continued)

INITIAL

DESCRIPTION 20. Check emergency pumps for operation and pressure (see Machine Specifications ).

21. With the main boom raised, check for the smooth operation of drive, creep speed.

22. Follow instructions for servicing engine daily. Refer to the Engine Maintenance Manual supplied with your machine.

ADDITIONAL MAINTENANCE REQUIREMENTS FOR HARSH ENVIRONMENTS

NOTE: Do not lubricate wear pads or boom cables in dusty or sandblast environments.

There are boots and guards available to extend the unit's life in these applications.

Consult TIME CONDOR Service Department.

INITIAL

DESCRIPTION Inspect cylinder bots, valve spool boots, etc., for cuts or other damage after every eight (8) hours of service. Repair if necessary.

Check hydraulic system for leakage after every eight (8) hours of operation.

Follow instructions for servicing engine when used severely. Refer to the Engine Maintenance Manual supplied with your machine.

MANUAL 92376-002 JUNE 1998

WEEKLY OPERATIONAL CHECKLIST INSPECTED BY:

DATE: --------------------MODEL NUMBER: -

_ _ _ _ __

SERIAL NUMBER:

Tbese checklists can be copied as needed to aid in performing these inspections.

GENERAL INFORMATION 1.

2.

3.

Keep inspection records up- to-date.

Record and report all discrepancies to your supervisor.

A dirty machine cannot be properly inspected.

Keep your Condor machine clean!!

I

A. WARNING]

THIS CHECKLIST MUST BE USED AT WEEKLY INTERVALS OR EVERY 25 HOURS, WHICHEVER OCCURS FIRST. FAILURE TO DO SO COULD ENDANGER THE LIFE OF THE OPERATOR. ALWAYS REMEMBER, A LITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH MORE THAN IT COSTS. INITIAL

DESCRIPTION 1. Perform all checks listed on Shift Operational Checklist.

2. Check wheel lug nut torque (120 LB-FT).

3. Check hydraulic connections for leaks, corrosion and wear.

4. Lubricate swing bearing and drive pinion gear.

5. Apply lubricant swing to exposed swing bearing and drive pinion gear (see Lubrication Chart).

Check lubricant in optional oil bath swing bearing case, if so equipped, for proper level, and check for dirt or mental contamination (see Lubrication Chart).

MANUAl92376-OO2 JUNE 1998

WEEKLY OPERATIONAL CHECKLIST (CONTINUED) ADDITIONAL MAINTENANCE REQUIREMENTS FOR HARSH ENVIRONMENTS NOTE: Do not lubricate wear pads or boom cables in dusty or sandblast environments. There are boots and guards available to extend unit's life in these applications. Consult Time Condor Parts Depaliment.

INITIAL

DESCRIPTION •

Lubricate all grease fittings (see Lubrication Chart).

Check oil level in swing drive motor assembly (see Lubrication ChaIi).

•

Check oil level in power hubs (see Lubrication Chart).

Follow instructions for servicing engine when used severely. Refer to the Engine Maintenance Manual supplied with your machine.

MANUAL 92376-002 JUNE 1998

MONTHLY OPERATIONAL CHECKLIST DATE:--------------------

INSPECTED BY:

MODEL NUMBER: - -_ _ _ _ __

SERIAL NUMBER:

These checklists can be copied as needed to aid in performing these inspections.

GENERAL INFORMATION 1.

2.

3.

Keep inspection records up- to-date.

Record and report all discrepancies to your supervisor.

A dirty machine cannot be properly inspected.

Keep your Condor machine clean!!

I

,4 WARNING

i

THIS CHECKLIST MUST BE USED AT MONTHLY INTERVALS OR EVERY 100 HOURS, WHICHEVER OCCURS FIRST. FAILURE TO DO SO COULD ENDANGER THE LIFE OF THE OPERATOR. ALWAYS REMEMBER, A LITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH MORE THAN IT COSTS.

INITIAL

DESCRIPTION 1. Perform all checks listed on Shift and Weekly Operational Checklists.

2. Lubricate all grease fittings (see Lubrication Chart).

3. Lubricate all hydraulic valve spool linkages.

4. Check hose and electrical wire routed from the main boom, through the jib boom and to the platform for any damage.

5. Check protective rubber cover around hoses at moving anchor, tip boom, boom hose passages, and at swing bearing.

6. Check boom hose carrier for sag and damage. If damaged, have them repaired.

7. Check torque of swing bearing bolts (170LB-FT).

MANUAL 92376-002 JUNE 1998

MONTHLY OPERATIONAL CHECKLIST (CONTINUED) INITIAL

DESCRIPTION 8. Check torque of rear axle mounting bolts (200 LB-FT).

9. Check adjustment and security of swing drive motor assembly.

There should be a slight amount of backlash between the turret and chassis when properly adjusted. Check torque of mounting bolts (55LB-FT).

10. Check oil level in swing drive gear box (see Lubrication Chart).

11. Check oil level in power hubs (see Lubrication Chart).

12. Check that tires are not leaning in or out.

13. Check that wheel spindles turn freely, with no end play.

14. Check drive wheel power hub mounting bolt torque (llOLB-FT).

15. Check that neither the main boom nor jib boom drift with a full load, when there is no hydraulic pressure (engine off) and the controls are in the "BOOM DOWN" position.

16. Inspect boom cables.

17. Check to make sure boom sections are not dented or bent.

18. Check that all adjustable flow valves are locked. Check settings if any are not locked.

19. Check fuel shutoff rack for proper operation. Loosen lever arm and lubricate with WD-40 or equivalent.

20. Follow instructions for servicing engine monthly. Refer to the Engine Maintenance Manual Supplied with your equivalent.

ADDITIONAL MAINTENANCE REQUIREMENTS FOR HARSH ENVIRONMENTS EVERY 90 DAYS INITIAL

DESCRIPTION •

Replace high pressure filter element.

•

Follow instructions for servicing engine when used severely. Refer to the Engine Maintenance Manual supplied with your machine.

MANUAL 92376-002 JUNE 1998

•

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MAMJAL9237&002 JUNE 1996

SEMI-ANNUAL OPERATIONAL CHECKLIST INSPECTED BY:

DATE:--------------------MODEL NUMBER: -

_ _ _ _ __

SERIAL NUMBER:

These checklists can be copied as needed to aid in performing these inspections.

GENERAL INFORMATION 1.

2.

3.

Keep inspection records up- to-date.

Record and report all discrepancies to your supervisor.

A dirty machine cannot be properly inspected.

Keep your Condor machine clean!!

I

A. WARNINGl

THIS CHECKLIST MUST BE USED AT SIX MONTH INTERVALS OR EVERY 500 HOURS, WmCHEVER IS SOONER. FAILURE TO DO SO COULD ENDANGER THE LIFE OF THE OPERATOR. ALWAYS REMEMBER, A LITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH MORE THAN IT COSTS.

INITIAL

DESCRIPTION 1. Perform all checks listed on Shift and Weekly Operational Checklists.

2. Have hydraulic fluid sample analyzed at a test laboratory.

Comply with test results and recommendations to ensure long, trouble free operation.

NOTE: lfhydraulic fluid has been regularly maintained, it should only require changing once every year, depending on maintenance, temperature, application, duty cycle, and atmospheric conditions.

3. Inspect the entire machine for signs of structural damage and broken welds, and worn or damaged components. Replace as necessary.

4. Clean and lubricate all electrical switches with an electrical contact cleaner and ensure that the switches operate freely inall positions.

5. Check the electrical mounting and hardware connections for security.

MANUAL92376-OO2 JUNE1998

SEMI-ANNUAL OPERATIONAL CHECKLIST (CONTINUED)

INITIAL

DESCRIPTION 6. Replace high pressure and return filter elements.

7. Clean and lubricate the exposed swing bearing gear teeth with dry moly lube spray (not required for oil bath swing bearing option).

8. Repack front wheel bearings.

9. Follow instructions for servicing engine semi-annually. Refer to the Engine Maintenance Manual supplied with your machine.

EVERY YEAR

10. Drain and replace fluid from hydraulic reservoir. Drain and replace fluid from drive wheel power hubs. Ifbadly contaminated, it may be necessary to disassemble and inspect components.

EVERY TWO YEARS 11. Drain and replace fluid from swing drive motor assembly. Ifbadly contaminated, it may be necessary to disassemble and inspect components.

ADDITIONAL MAINTENANCE REQUIREMENTS FOR HARSH ENVIRINMENTS EVERY SIX MONTHS Drain and replace fluid swing drive motor assembly and drive wheel power hubs.

Follow instructions for servicing engine when used severely. Refer to the Engine Maintenance Manual supplied with your machine.

MANUAl 92376-002 JUNE 1998

ILLUSTRATED PARTS MANUAL MODELS T40 & T46J BOOM-SUPPORTED ELEVATING WORK PLATFORM Beginning With Serial Number P-ll X-00261S

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MANUAL 92376-003 JUNE 1998

•

CONDOR® Model T40/46J-Ol ILLUSTRATED PARTS BREAKDOWN TABLE OF CONTENTS INTRODUCTION ........................................................................................................................ i . Service Infonnation ........................................................................................................................ii Table of Contents .......................................................................................................................... 1 FIGURE NO.

DESCRIPTION

PAGE

A ......................................... How To Order Parts .............................................................. 3 B ......................................... Serial Number Location ......................................................... 5 1.1 ....................................... FinalAssembly ...................................................................... 6 2.1 ....................................... Tire Installation ...................................................................... 8 3.1 ....................................... ChassisInstallation ................................................................. 10 3.2 ....................................... Chassis Rotation Assembly ................................................... 12 3.3 ....................................... HydraulicSwivel .................................................................... 16 3.4 ....................................... Electrical Slip Ring ................................................................. 18 3.5 ....................................... Non-Drive Front Axle Assembly ........................................... 20 3.6 ....................................... Tie Rod Assembly ................................................................. 22 3.7 ....................................... Steer Cylinder ........................................................................ 24 3.8 ....................................... Stationary Block Assembly .................................................... 26 3.9 ....................................... Non-Steer Rear Axle Assembly ............................................ 28 3.10 ..................................... 2WD Drive Manifold Assembly ............................................ 30 3.11 ..................................... DriveManifold ....................................................................... 31 3.12 ..................................... 2 STR Valve Assembly ......................................................... 32 3.13 ..................................... Check Valve .......................................................................... 33 4.1 ....................................... Turret Installation ................................................................... 34 4.2 ....................................... Tray Installation ..................................................................... 36 4.3 ....................................... Turret Rotation Assembly ..................................................... .40 4.4 ....................................... Battery Assembly .................................................................. 42 4.5 ....................................... Engine Pump Filter Assembly ................................................ 44 4.6 ....................................... Air Cleaner Installation .......................................................... 45 4.7 ....................................... EngineInstallation .................................................................. 46 4.8 ....................................... EngineAssembly ................................................................... 48 4.9 ....................................... Engine Electric Panel Assembly ............................................ 50 4.10 ..................................... Nissan Engine Panel Schematic ............................................ 52 4.11 ..................................... Muffler Installation ................................................................. 53 4.12 ..................................... LiftCylinderInstallation ......................................................... 55 4.13 ..................................... Boom Lift Telescope Cylinder ............................................... 56 4.14 ..................................... Master Cylinder Installation ................................................... 59 4.15 ..................................... Master Level Cylinder ........................................................... 60 4.16 ..................................... Eprom Installation .................................................................. 62 4.17 ..................................... Lower Control Box Assembly ............................................... 64 5.1 ....................................... Counterweight Assembly ....................................................... 70

MANUAL 92376·003 JUNE 1998

•

FIGURE NO.

DESCRIPTION

PAGE

6.1 ..................................... Boom/SkirtInstallation ........................................................... 72 6.2 .....................................

6.3 .....................................

6.4 .....................................

6.5 .....................................

6.6 .....................................

6.7 .....................................

6.8 .....................................

6.9 .....................................

6.10 ...................................

6.11 ...................................

6.12 ...................................

Main Boom Assembly ........................................................... 74 Base Boom Assembly ........................................................... 76 Hose Carrier Installation ........................................................ 77 Boom Extension Cylilnder Assembly ..................................... 78 Boom Extension Cylinder ...................................................... 79 Mid Boom Assembly ............................................................. 80 Tip Boom Assembly .............................................................. ,81 Slave Cylinder Assembly ....................................................... 82 Slave Level Cylinder .............................................................. 83 Angle Sensor Installation ....................................................... 85 Skirt Installation ..................................................................... 86

7.1 .....................................

7.2 .....................................

7.3 .....................................

7.4 .....................................

7.5 .....................................

PlatformInstallation ...............................................................

Platform Electrical Installation ...............................................

110VoitLine to Platform Assembly ......................................

Platform Control Box Assembly ............................................

Foot Switch Installation .........................................................

88 90 91 92 96

8.1 ..................................... Chassis Cover Assembly ....................................................... 97 9.1 ..................................... Fiberglass Door Assembly ..................................................... 98 9.2 ..................................... Gas Cover Shock Assembly .................................................. 99 10.1 ................................... Manuallnstallation ................................................................. 100 11.1 ................................... Decal Kit ............................................................................... 102 12.1 ................................... LP/Gas Dual Fuel (Liquid) .................................................... 106 Electrical Schematic .........

Hydraulic Schematic .........

Chassis Hose Kit ..............

Turret Hose Kit ................

Boom Hose KiL ...............

Skirt Hose Kit ...................

71675 71674 71015 71619 71853 71621

MANUAL 92376-003 JUNE 1998

FIGURE A: How to Order Parts •

1.

When ordering parts for your CONDOR®, ensure that you are able to give the model and serial numbers of all units for which parts are needed. The serial number(s) will assist the Condor Parts Department in providing the correct parts for your machine(s).

2.

Ifknown, please specify the Condor part number(s) for the partes) 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 Condor Parts Department.

Credit will be authorized through the Service Department after a Warranty Claim has been submitted to Condor. A Warranty Claim is to be filed for any part received as "defective".

5.

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.

Condor classifies its orders in the following ways: Emergency

Top priority. All efforts are made to ship the order the day the order is received; when possible, parts may be pulled off of the assembly line.

Standard

Order to be shipped within a 48-hour period.

Stock

Order to be shipped within 2 weeks.

7.

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 Condor packing list and subsequent invoice butnot 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 92376-003 JUNE 1998

•

FIGURE A: How to Order Parts

IPURCHASER

ACCOUNT # C U S T

0 M E R

I N F

0 R M A T I

0

SALES ORDER # NAME

NAME ADDRESS

CITY

STATE

PHONE

( ) N CUST. PURCHASE ORDER NO.

ZIP

T

0

FAX

(

)

I ORDER DATE

I

I

I

SHIPPING INSTRUCTIONS

PART NUMBER

S H I P

iADDRESS ~ITY

STATE

!PHONE

FAX

(

(

)

REQUEST DATE

FOR ORDER STATUS PLEASE CHECK APPROPRIATE BOX BELOW EMERGENCY STOCK MANUAL 92376·003 JUNE 1998

)

SPECIAL MARKS & NUMBERS

DESCRIPTION

QTY.

ZIP

NOTES

FIGUREB:SerialNumberLocation •

1

61 F

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Data Plate

2

The CONDOR® Model T40/46J Serial Number is stamped in two locations on the machine.

1.

The first place to find the serial number is on the top side ofthe front axle.

2.

The second place to find the serial number is on the left side of the turret weldment adjacent to the ring gear bolts.

The Data Plate is located on the left side of the chassis.

MANUAL 92376-003 JUNE 1998

•

FIGURE 1.1: Final Assembly

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MANUAL 92376-003 JUNE 1998

FIGURE 1.1: Final Assembly • ITEM

PART NUMBER

Ref.

M-T40-01 ...................... CondorModeI40 ...................................................................... Ref. M-T46J-0 1 .................... Condor Model46J .................................................................... Ref. 71634 ............................ Final Assembly Dwg; M-T40-01 ................................................... 1 71635 ............................ FinaIAssemblyDwg;M-T46J-01 ................................................. 1 71129 ............................ Tire Installation .............................................................................. 1 71014 ............................ Chassis Installation ........................................................................ 1 71235-T40 ..................... TurretInstallation; T40-01 ............................................................. 1 71235-T46J ................... Turret Installation; T46J-Ol ........................................................... 1 71391 ............................ CounterweightAssembly .............................................................. 1 710 13-T40 ..................... Boom/SkirtInstallation; T40 .......................................................... 1 71013-T46J ................... BoomlSkirtInstallation, T46J ......................................................... 1 71513 ............................ Platform Installation; 36 x 60 ......................................................... 1 71019-001 ..................... Platform Elect Installation, T40 ..................................................... 1 71019-002 ..................... PlatformElectInstallation, T46J-Ol .............................................. 1 71451 ............................ Chassis Cover Installation ............................................................. 1 71392 ............................ Fiberglass Door Installation; Turret ............................................... 1 71632 ............................ Decal Installation; T40 ................................................................... 1 71640 ............................ DecaIInstallation, T46J-Ol ............................................................ 1 71639 ............................ ManualsInstallation ....................................................................... 1 15843 ............................ Nameplate ..................................................................................... 1 71675 ............................ Schematic,Electrical .............................................. :...................... 1 71674 ............................ Schematic,Hydraulic ..................................................................... 1 67470-002 ..................... HydraulicOil ......................................................................... 45GL. 67472-001 ..................... MotorOil ........................................................................................ .

67471 ............................ Fuel Type ............................................................................... 40GL.

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

DESCRIPTION

- Indicates Items Not Shown

MANUAL 92376-003 JUNE 1998

QTY

•

FIGURE 2.1 :Tire Installation 2 WD

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MANUAL 92376-003

JUNE

1998

FIGURE 2.1:Tire Installation 2WD •

QTY

ITEM

PART NUMBER

Ref. -1 -2

71129 ............................ Tire Installation 2WD ............................................................... Ref. 71129-DWG ................. Tire Installation; 2WD 12x16.5 Air EA ......................................... 1 71066-RH ..................... Tire & Wheel Assembly 12x16.5 RH ........................................... 2 71148 ............................ Wheel; 16.5x9.75 ........................................................................... 1 71168 ............................ Tire; 12x16.5AirTraction ............................................................. 1 71066-LH ...................... Tire & Wheel Assembly 12x16.5 LH ........................................... 2 71148 ............................ Wheel; 16.5x9.75 ........................................................................... 1 71168 ............................ Tire; 12x16.5 Air Traction ............................................................. 1

-3

DESCRIPTION

- Indicates Items Not Shown

MANUAL 92376-003 JUNE 1998

•

FIGURE 3.11:ChassisInstallation

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MANUAL 92376-003 JUNE 1998

FIGURE 3.1: Chassis Installation • DESCRIPTION

QTY

ITEM

PART NUMBER

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

71 0 14 ............................ Chassis Installation ................................................................... Ref. 710 14-Dwg ................... Installation Drawing, Chassis ........................................................ 1 71014-HW .................... Hardware Kit ................................................................................ 1 71031 ............................ Chassis Weldment ......................................................................... 1 71453 ............................ Chassis Rotation Assembly ........................................................... 1 71549 ............................ Valve Assembly, 2 Steer ............................................................... 1 71032 ............................ Axle Assembly, Rear Non-Steer ................................................... 1 71035 ............................ Axle Assembly, FrontNon-Drive .................................................. 1 71483 ............................ StationaryBlockAssembly ........................................................... 2 71490 ............................ ManifoldAssembly,2WD ............................................................. 1 66770-250 ..................... Thrust Bearing ............................................................................... 2 71015-Std ...................... Hose Kit, Std Chassis .................................................................... 1 71686 ............................ Hardline #10 Rear Axle ................................................................ 4 71687 ............................ Hardline #16, ManifoldIRotator ..................................................... 1

Ref 1 2 3 4 5

71014-Hw ..................... Hardware Kit ........................................................................... Ref. 71014-Dwg ................... InstallationDwg,Chassis .............................................................. 1 65099-022 ..................... Clamp, Wire Loom ........................................................................ 3 BOW34272 ................... Nut ................................................................................................. 3 BOW36701 ................... Washer .......................................................................................... 3 Ref ................................ Tie Raps ................................................................................... Ref.

o

Indicates parts in Hardware Kit

- Indicates Items Not Shown

MANUAL 92376-003 JUNE 1998

•

FIGURE t2: Chassis RotationAssembly "

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MANUAL 92376-003 JUNE 1998

FIGURE 3.2: Chassis Rotation Assembly •

DESCRIPTION

QTY

ITEM

PART NUMBER

Ref. -1 2 3 4 5 6 7

71453 ............................ Chassis Rotation Assembly ...................................................... Ref. 71453-DWG ................. Chassis Rotation Assembly DWG ................................................. 1 71453-HW .................... Hardware Kit; Chassis Rotation .................................................... 1 71453-FTG .................... FittingKit, Chassis Rotation .......................................................... 1 71140 ............................ HydraulicSwivel ............................................................................ 1 71141 ............................ ElectricaISlipRing ......................................................................... 1 37737 ............................ Motor, 10 CIPR Swing Rotation .................................................... I 71142 ............................ Swing Bearing ............................................................................... 1

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

71453-HW .................... Hardware Kit Chassis Rotation ................................................ Ref. 71453-DWG ................. Chassis Rotation Assembly DWG ................................................. I BOW39159 ................... Bolt, Hex 5/8-1 I UNC-2B5"LGR8 ........................................... 20 BOW36707-HD ........... Washer, 5/8 Hard Flat ................................................................. 20 BOW33636 ................... Bolt .38-16UNC x 1.25 GR8 ........................................................ .4 BOW31327 ................... Washer 3/8 Lock ........................................................................... 4 BOW36703 ................... Washer .37ID .810D GR8 SAE Flat ............................................ 4 BOW36106 ................... Bolt, Hex HD I12-13UNC x I I12"L. ............................................ I BOW31329 ................... Washer, .50 Gr 5 Split Lock .......................................................... I BOW30 108 ................... Bolt, Hex HD I12-13UNC x 2 ilL. .................................................. I BOW36784 ................... Nut, 1/2 Jam .................................................................................. I

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

71453-FTG .................... Fitting Kit, Chassis Rotation Assembly ..................................... Ref. 71453-DWG ................. Assembly DWG, Chassis Rotation ................................................ 1 02579 ............................ StraightMJ16 M016 .................................................................... 4 00267 ............................ Straight MJ12 MOl2 .................................................................... 2 04563 ............................ Straight MJ06 M006 Long ......................................................... .4 02662 ............................ Elbow 90° MJ06 M006 ................................................................ I 02447 ............................ PlugM006 .................................................................................... 2 00353 ............................ Tee MJ06 MJ06 FJ06 ................................................................... 1 00485 ............................ Straight FJ12 MJ06 ....................................................................... I 02328 ............................ Elbow45° MJ12 FJ12 ................................................................. 1 02312 ............................ Elbow 45° MJ16 FJl6 ................................................................. 2 04070 ............................ Straight MJ06 MOI0 ................................................................... 2 00425 ............................ FittingFJ06 MJ04 ......................................................................... 2 02337 ............................ Elbow 45° MJ06 M006 .............................................................. 1 00488 ............................ Tee MJ06 FJ06 MJ06 ......................................................... 2Ref. 02662 ............................ Elbow90° MJ06 M006 ......................................................... 2Ref.

- Indicates Items Not Shown

MANUAL 92376·003 JUNE 1998

FIGURE3 .2: Chassis RotationAssembly

STEP BOLT HEADS

SIZE

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MANUAL 92376-003 JUNE 1998

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FIGURE 3 .2: Chassis Rotation Assembly

DESCRIPTION

QTY

ITEM

PART NUMBER

Ref. -1 2 3 4 5 6 7

71453 ............................ ChassisRotationAssembly ...................................................... Ref. 71453-DWG ................. Chassis Rotation Assembly DWG ................................................. 1 71453-HW .................... Hardware Kit; Chassis Rotation .................................................... 1 71453-FTG .................... Fitting Kit, Chassis Rotation .......................................................... 1 71140 ............................ HydrauIicSwivel ............................................................................ 1 71141 ............................ ElectricaISIipRing ......................................................................... 1 37737 ............................ Motor, 10 CIPR Swing Rotation .................................................... 1 71142 ............................ Swing Bearing ............................................................................... 1

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

71453-HW .................... Hardware Kit Chassis Rotation ................................................ Ref. 71453-DWG ................. Chassis Rotation Assembly DWG ................................................. 1 BOW39159 ................... Bolt, Hex 5/8-11 UNC-2B 5"L GR8 ........................................... 20 BOW36707-HD ........... Washer, 5/8 Hard Flat ................................................................. 20 BOW33636 ................... Bolt .38-16UNC x 1.25 GR8 ......................................................... 4 BOW31327 ......... ;......... Washer 3/8 Lock ........................................................................... 4 BOW36703 ................... Washer .37ID .810D GR8 SAE Flat ........................................... .4 BOW36106 ................... Bolt, Hex HD 1/2-13UNC xl 1I2"L ............................................. 1 BOW31329 ................... Washer, .50 Gr 5 Split Lock .......................................................... 1 BOW30108 ................... Bolt, HexHD 1I2-13UNC x 2"L ................................................... 1 BOW36784 ................... Nut, 1/2 Jam .................................................................................. 1

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

71453-FTG .................... FittingKit, Chassis RotationAssembly..................................... Ref. 71453-DWG ................. Assembly DWG, Chassis Rotation ................................................ 1 02579 ............................ Straight MJ16 MOI6 .................................................................... 4 00267 ............................ Straight MJ12 M012 .................................................................... 2 04563 ............................ Straight MJ06 M006 Long ......................................................... .4 02662 ............................ Elbow 90° MJ06 M006 ................................................................ 1 02447 ............................ PlugM006 .................................................................................... 2 00353 ............................ Tee MJ06 MJ06 FJ06 ................................................................... 1 00485 ............................ Straight FJ12 MJ06 ....................................................................... 1 02328 ............................ Elbow45° MJ12 FJ12 ................................................................. 1 02312 ............................ Elbow 45° MJ16 FJ16 ................................................................. 2 04070 ............................ Straight MJ06 MO 10 .............. '" .................................................. 2 00425 ......................•..... Fitting FJ06 MJ04 ......................................................................... 2 02337 ............................ Elbow 45° MJ06 M006 .............................................................. 1 00488 ............................ Tee MJ06 FJ06 MJ06 ......................................................... 2Ref. 02662 ............................ Elbow 90° MJ06 M006 ......................................................... 2Ref.

- Indicates Items Not Shown

MANUAL 92376-003 JUNE 1998

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FIGURE 3.3: Hydraulic Swivel •

DESCRIPTION

QTY

ITEM

PART NUMBER

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

71140 ............................ HydraulicSwivel ....................................................................... Ref. 71140-101 ..................... HousingAssembly ......................................................................... 1 71140-102 ..................... Spool .............................................................................................. 1 71140-103 ..................... Keeper Plate ................................................................................. 1 * .................................... Wear Ring ..................................................................................... 1 * .................................... Wear Ring ..................................................................................... 1 71140-100 ..................... Seal Kit (Indicated by *) ................................................................ 6 * .................................... Crown Seal .................................................................................... 2 * .................................... O-Ring Seal ................................................................................... 2 71140-104 ..................... Lock Washer ................................................................................. 4 71140-105 ..................... Hex Head Cap Screw ................................................................... 4 71140-106 ..................... Lock Washer ................................................................................. 2 71140-107 ..................... Hex Head Cap Screw ................................................................... 2 71140-108 ..................... TorqueArm ................................................................................... 1

- Indicates Items Not Shown

MANUAL 92376·003 JUNE 1998

FIGURE3.4:ElectricalSlipRing

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MANUAL 92376-003 JUNE 1998

FIGURE 3.4: Electrical Slip Ring DESCRIPTION

QTY

ITEM

PART NUMBER

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

71141 ............................ Electrical Slip Ring .................................................................... Ref. ...................................... Shaft Seal ...................................................................................... 1 ...................................... NylonBearing ................................................................................ 1 ...................................... Aluminum Base Bracket ............................................................... 1 ...................................... Cover Seal ..................................................................................... 1 ...................................... Nylon Outboard Bearing ................................................................ 1 ...................................... Spun Aluminum Cover ................................................................... 1 ...................................... Nylon Rub Disk ............................................................................. 1 ...................................... Vinyl Sleeves Cover Knife Disconnect Terminals ........................ 2 ...................................... Drain Holes In Cover .................................................................... 2 ...................................... 5/16-18 UNC Brush Studs ............................................................. 2 ...................................... Set Screws .................................................................................... 3 ...................................... 112-13 UNC Retaining Hole .......................................................... 1 ...................................... 3/4"NPTLiquid TightConnector .................................................. 1

- Indicates Items Not Shown

MANUAL 92376-003 JUNE 1998

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FIGURE 3.5: Non-Drive Front Axle Assembly . , DESCRIPTION

QTY

ITEM

PART NUMBER

Ref. -1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

71035 ............................ Non-Drive Front Axle Assembly .............................................. Ref. 71035-DWG ................. Assembly DWG, Front Axle Non-Drive ....................................... 1 71034-HW .................... Hardware Kit, Front Axle ............................................................. 1 71035-FTG .................... Fitting Kit, Front Axle STD ........................................................... 1 71085 ............................ PivotPin, Axle ............................................................................... 1 71095 ............................ Yoke, Steering WeldmentR.H ...................................................... 1 71096 ............................ Yoke, Steering Weldment L.H ...................................................... 1 71097 ............................ KingPin ......................................................................................... 2 71126 ............................ Idler Hub w/l.,ug Nuts ................................................................... 2 65260 ............................ Grease Seal ................................................................................... 2 30289 ............................ Dust Cover ., .................................................................................. 2 71547 ............................ Tie Rod Assembly ......................................................................... 1 71115 ............................ Cylinder, Steer ............................................................................... 2 92097 ............................ Bearing .......................................................................................... 2 65239 ............................ Bearing .......................................................................................... 2 80119 ............................ Bearing, Thrust .............................................................................. 4 92105 ............................ Nut, Spindle ................................................................................... 2 71113 ............................ AxleWeldment,Front ................................................................... 1 81368-40-32 .................. SIeve Bearing, 2 112 x 3 x 2" L ...................................................... 2 34145 ............................ Bushing(R#81368) ........................................................................ 4

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

See Note 1 71035-HW .................... Hardware Kit ........................................................................... Ref. BOW36720 ................... Washer, Flat 1.06 ID x 2.00 OD ................................................... 2 BOW38232 ................... Pin, .12 x 1/75 L Cotter ................................................................. 2 BOW39068 ................... Bolt, Hex HD 3/8-16UNC x 5 GR8 .............................................. 2 BOW34274 ................... Nut, 3/8-16 Lock ............................................................................ 2 BOW35300 ................... SnapRing#5160-150Truarc ........................................................ 2 91029 ............................ Lug Nut, 1I2-20UNF Wheel ........................................................ 18 BOW30 170-450 ............ Bolt, Hex HD 1-8 UNC x 4 112 Gr 8 ............................................ 2 BOW34280 ................... Nut, Hex 1-8 UNC ........................................................................ 2 BOW39117 ................... Bolt, Hex HD 112-13 UNC x 4 112 Gr 8 ....................................... 2 BOW34276 ................... Nut, Hex 112-13 UNC ................................................................... 2 BOW38240 ................... Cotter Pin .156 Dia x 1.75 ............................................................. 4 65240 ............................ Clevis Pin, 1" Dia ........................................................................... 4

1 2 3

See Note 2 71035-FTG .................... FittingKit .................................................................................. Ref. 02662 ............................ Elbow, 90° M006 MJ06 ............................................................... .4 00488 ............................ Tee, MJ06 FJ06 MJ06 ................................................................... 2

- Indicates Items Not Shown

MANUAL 92376-003 JUNE 1998

•

FIGURE 3.6: Tie Rod Assembly

This page intentionally left blank

MANUAL 92376-003 JUNE 1998

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PART NUMBER

Ref.

71547 ............................ Tie Rod Assembly .................................................................... Ref. 71547-DWG ................. DWG, Tie Rod Assembly .............................................................. 1 65238 ............................ Rod End, Male 1" LH .................................................................... 1 51226 ............................ Rod End, Male 1" RH R#67821 .................................................... 1 7lO90 ............................ Tie Rod ;Steering Knuckle ............................................................ 1 68486 ............................ Nut HEX Jam 1.25-12UNF RH .................................................... 1 68487 ............................ Nut, HEX Jam 1.25-12UNF LH ................................................... 1

-1

2 3 4 5 6

DESCRIPTION

- Indicates Items Not Shown

MANUAL 92376-003 JUNE 1998

QTY

•

FIGURE 3.7:Steer Cylinder

(

{ ---=--ooL r--.\:::)

MANUAL 92376-003 JUNE 1998

FIGURE 3.7:Steer Cylinder . , DESCRIPTION

QTY

ITEM

PART NUMBER

Ref. 1 2 3 4 5 6 7 8 -9 10 11 12 13 14 15 16 17 18 19

71115 ............................ Steer, Cylinder .......................................................................... Ref. * .................................... Wiper ............................................................................................. 1 * .................................... U-Cup (Dual Lip) .......................................................................... 1 * .................................... O-Ring ........................................................................................... 1 * .................................... O-Ring ........................................................................................... 1 * .................................... Back-Up ........................................................................................ 1 * .................................... Cap Seal ........................................................................................ 1 * .................................... O-Ring ........................................................................................... 1 * .................................... Wear Ring ..................................................................................... 1 71115-101 ..................... Seal Kit (Indicated by *) ................................................................ 1 71115-102 ..................... Locknut .......................................................................................... 1 71115-103 ..................... Setscrew ........................................................................................ 1 71115-104 ..................... RetainingRing ............................................................................... 1 71115-105 ..................... NylonPlug ..................................................................................... 1 71115-106 ..................... PortPlug ........................................................................................ 2 71115-107 ..................... TubeAssembly .............................................................................. 1 71115-108 ..................... Rod ................................................................................................ 1 71115-109 ..................... RodClevis ..................................................................................... 1 71115-110 ..................... Head .............................................................................................. 1 71115-111 ..................... Piston ............................................................................................. 1

- Indicates Items Not Shown

MANUAL 92376-003 JUNE 1998

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FIGURE 3.8: Stationary Block Assembly •

DESCRIPTION

QTY

ITEM

PART NUMBER

Ref. -1 2 3 4

71483 ............................ Stationary Block Assembly ...................................................... Ref. 71483-DWG ................. DWG Assembly, Stationary Block ................................................ 1 71483-HW .................... Hardware Kit, Stationary Block .................................................... 1 71106 ............................ StationaryWeldmentBlock ........................................................... 1 71105 ............................ Shim Pack ...................................................................................... 2

Ref. 1 2 3 4

71483-HW .................... Stationary Block Installation - Hardware Kit .......................... Ref. BOW39108 ................... Bolt 112-13 c 2"LG GR8 Hex ........................................................ 4 BOW36705-HD ........... Washer, .50 x 1.06 O.D. HD Flat ................................................. 8 BOW34276 ................... Nut, .50-13UNC Hex Lock ........................................................... 4 71483-DWG ................. Installation DWG, Stationary Block ............................................... 1

- Indicates Items Not Shown

MANUAL 92376·003 JUNE 1998

. , FIGURE 3;9:AxleAssembly,RearNon-Steer

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MANUAL 92376-003 ruNE 1998

1 1

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FIGURE 3.9:AxleAssembly,RearNon-Steer DESCRIPTION

QTY

ITEM

PART NUMBER

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

71032 ............................ Axle Assembly, Rear Non-Steer .............................................. Ref. 71032-DWG ................. Assembly DWG, Rear Axle .......................................................... 1 71032-HW .................... Hardware Kit, Rear Axle .............................................................. 1 71032-FTG .................... Fitting Kit; Rear Axle Assembly ................................................... 1 71043 ............................ Planetary Wheel Drive .................................................................. 2 71042 ............................ HydraulicMotor ............................................................................ 2 71100 ............................ Rear Axle Backing Plate ................................................................ 2 71094 ............................ Spacer, Rear Axle ......................................................................... 2 71171 ............................ Spacer, Rear Axle ......................................................................... 4 71075 ............................ Axle Weldment, Rear .................................................................... 1

1 2 3 4 5 6 7 8 9 10 11

See Note 1 71032-HW .................... Hardware Kit ........................................................................... Ref. BOW36149 ................... Bolt, .63-11 UNC x 2" Hex ......................................................... 16 BOW39729 ................... Lockwasher 112" ............................................................................ 4 BOW39172 ................... Bolt, .75-10 UNC x 2.00" Gr 8 Hex .............................................. 2 BOW30 160-850 ............ Bolt, .75-10 UNC x 8.50" Lg Hex .................................................. 2 BOW34278 ................... Nut, 3/4-10 UNC Elastic Stop ....................................................... 2 BOW36708 ................... Washer, .750 Flat .......................................................................... 4 BOW36108 ................... Bolt, 112-13 UNC x 2 Gr 8 ........................................................... .4 BOW31331 ................... Washer, 5/8 Gr 5 Lock ................................................................ 16 BOW31415 ................... 1/2" Flatwasher .............................................................................. 4 91029 ............................ Nut .50-20 UNF Wheel ............................................................... 18

1 2 3 4

See Note 3 71032-FTG .................... FittingKit .................................................................................. Ref. 03197 ............................ Elbow, 90° MOIO MJ06 ................................................................ 2 04051 ............................ Straight,MOI2MJ10 .................................................................... 4 04733 ............................ Elbow, 45° M004 MJ04 ................................................................ 2

.:. Indicates Items Not Shown

MANUAL 92376-003 JUNE 1998

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FIGURE3.10:2WDDriveManifoldAssembly

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MANUAL 92376-003 JUNE 1998

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DESCRIPTION

QTY

ITEM

PART NUMBER

Ref. -1 -2 -3 4 5

71490 ............................ 2WD Drive Manifold Assembly ............................................... Ref. 71490-DWG ................. AssemblyDWG, 2WD Drive Manifold ........................................ 1 71490-FTG .................... FittingKit,2WDDriveManifold ................................................... 1 71490-HW .................... Hardware Kit ................................................................................ 1 71424 ............................ Drive Manifold Bracket Weldment ............................................... 1 71047 ............................ 2WDDriveManifold ..................................................................... 1

Ref. 1 2 3 4 5

71455 ............................ 4WDManifoldAssembly ......................................................... Ref. 71544-Dwg ................... 4WDManifoldInstaUationDrawing .............................................. 1 BOW39106 ................... Bolt, 1/2-13 UNCx 1.50"L ............................................................ 4 BOW34284 ................... Nut, 112-13 UNC Stop Elastic ...... , ................................................ 4 BOW30053 ................... Bolt, 3/8-16 UNC x 7/8" L ........................................................... 2 BOW31327 ................... Washer, 3/8" ID Split Lock ........................................................... 2 Indicates piece parts for the Hardware Kit

Ref. 1 2 3 4

5 6

71455 ............................ 4WDManifoldAssembly ......................................................... Ref. 71455-DWG ................. 4WD Manifold Assembly Installation Dwg ................................... 1 04051 ............................ StraightMJI0MOI2 ..................................................................... 2 00267 ............................ Straight MJ12 MO 12 ..................................................................... 2 02579 ............................ Straight MJ16 MO 16 ..................................................................... 2 00456 ............................ Straight MJ04 M006 ..................................................................... 2 00344 ............................ Tee MJ04 FJ04 MJ04 .................................................................... 1 Indicates piece parts for the Fitting Kit

- Indicates Items Not Shown

MANUAL 92376·003 JUNE 1998

FIGURE 3. 11·. Drive . Manifold

.J

MANUAL 92316.om JUNE 1998

FIGURE 3.11: DriveManifold ITEM

PART NUMBER

DESCRIPTION

QTY

Ref. 71047 ............................ DriveManifold .......................................................................... Ref. PLG12 ...................................... PortPlug ........................................................................................ 1' PLG6 ...................................... Port Plug ........................................................................................ 9 PLG4 ...................................... Port Plug ........................................................................................ 1 ORFl,ORF2 71047-102 ............... OrificePlug ................................................................................... 2 PDl,PD2 ...................................... PD12-44-0-P-II0 .......................................................................... 2 HSI ...................................... HS50-42-0-P ................................................................................. 1 FDI ...................................... FD16-42-0-P-66 ............................................................................ 1 CL8 71047-101 ..................... Coil ................................................................................................ 2 SVl,SV2 ...................................... SV08-30-0-N-OO ............................................................................ 2 71047-100 ..................... Service Kit ..................................................... ;............................... 1 - Indicates Items Not Shown

MANUAL 92376-003 JUNE 1998

e

FIGURE 3.12: 2 STR Valve Assembly DESCRIPTION

QTY

ITEM

PART NUMBER

Ref. -1 -2 -3

71549 ............................ 2 STR Valve Assembly ............................................................ Ref. 71549-DWG ................. 2 STR Valve Assembly Drawing .................................................. 1 71549-FTG .................... Fitting Kit; 2 STR Valve Assembly ............................................... 1 71554 ............................ Dual P.O. Check Valve ................................................................ 1

- Indicates Items Not Shown Drawing not available at this time

MANUAL 92376-003 JUNE 1998

FIGURE 3.13: Check Valve • ITEM

PART NUMBER

Ref. 1 2 3

71554 ............................ Dual P.O. Check Valve ................................. :......................... Ref. ...................................... BlockMlC ..................................................................................... 1 71554-100 ..................... Check Valve .................................................................................. 2 ..• ;.................................. PilotPiston .. ;.................................................................................. 1

DESCRIPTION

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MANUAL 92376-003 JUNE 1998

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MANUAL 92376-003 JUNE 1998

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FIGURE 4.2: Tray Installation •

QTY

ITEM

PART NUMBER

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

71045-001 ...................... Tray Installation ............................................................................ Ref. 71045-0WG .................. Tray Assembly OWG; Telescope Hyd .............................................. 1 71045-HW ..................... HardwareKit ...................................................................................... 1 71045-FTG-1 ................. FittingKit ........................................................................................... 1 71059 ............................. Tray Weldment .................................................................................. 1 71060 ............................. Bracket Weldment; Ground Box ........................................................ 1 71041 ............................. Fuel Tank; 40 Gallons ........................................................................ 1 71040 ............................. Hydraulic Tank; 45 Gallons ............................................................... 1 CLL00650-004 ............... Tube Rd I" 00 .25W .50"L .............................................................. 4 35659 ............................. MotorlPump 12 VOC Electric ........................................................... 1 71039 ............................. Turret Tray/Door Lock Plate ............................................................. 2 71261 ............................. Front Brace Tray Plate ....................................................................... 1 71023 ............................. Rear Brace Tray Plate ........................................................................ 1 33430 ............................. Filter Assembly, Hydraulic ................................................................. 1 69327 ............................. Gauge, Fuel Tank Magnetic ............................................................... 1 71550 ............................. Control Valve w/o Axle Lpck ............................................................ 1 37042 ............................. Filter, R# 66445 Suction .................................................................... 1 67585-005 ...................... Valve, 3/4" NPTBall .......................................................................... 1 67585-006 ...................... Valve, 1" NPT Ball ............................................................................. 1

13

14 15 16 17 18 19 20

DESCRIPTION

04625-001 ...................... Valve,MiniBall .................................................................................. 1

- Indicates Items Not Shown

MANUAL 92376-003 JUNE 1998

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NON-OSCILLATIf'lG VAL\;

FIGURE 4.1: Turret Installation • PART NUMBER

Ref.

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

71235-T40 ..................... Turretlnstallation ...................................................................... Ref 71235-T46J ................... Turret Installation ..................................................................... Ref. 71235-DWG ................. Installation DWG, TurretT40 ........................................................ 1 71619-STD ................... Hoses, Kit, Turret T40/60 .............................................................. 1 71235-HW .................... Hardware Kit; Turret Installation .................................................. 1 71045-001 ..................... Tray Installation, 2WD (T40) ........................................................ 1 71045-003 ..................... Tray Installation, Non-Osc/Jib (T46J) ........................................... 1 71492 ............................ Turret Rotation Assembly ............................................................. 1 71386 ............................ Battery Assembly .......................................................................... 1 71387 ............................ Filter Assembly, EnginePump ....................................................... 1 71495 ............................ Air Cleaner Assembly ................................................................... 1 71 0 18 ............................ Engine Installation, Nissan H2O Gas .............................................. 1 71389 ............................ MasterCylinderInstallation ........................................................... 1 71390 ............................ LiftCylinderInstallation ................................................................ 1 71538 ............................ Stop Pin; Turret Rotation ............................................................... 1 65328-013 ..................... Sash Chain; 13 Links ..................................................................... 1 71622-T40 ..................... Lower Control Box Installation, T40 STD ..................................... 1 71058 ............................ Turret Weldment; Telescope ......................................................... 1 51036 ............................ Switch, Limit Body Only ................................................................ 1 51037 ............................ Offset Head Limit Switch ............................................................. 1 71691 ............................ Arm Mod; Limit Switch ................................................................. 1 67114-002 ..................... Strain Relief 112 NPT .25/.38 ........................................................ 1 67123-001 ..................... Seal, Connector Elect 112" ............................................................. 1 71173 ............................ LockingTube, Turret ..................................................................... 2 71796 ............................ GroundStrap ................................................................................. 1 71856 ............................ Turret, Hardline Kit ....................................................................... 1

-1 -2 -3

71235-HW .................... Hardware Kit; Turret Installation ............................................. Ref. BOW31145 ................... Screw, #10-32 UNF 3/4 RD HD SIt ............................................. 2 BOW31323 ................... Washer, #10 ID Split Lock ............................................................ 2

-1 2 3 4

DESCRIPTION

QTY

ITEM

- Indicates Items Not Shown

MANUAL 92376-003 JUNE 1998

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QTY

ITEM

PART NUMBER

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

71045-001 ...................... Tray Installation ............................................................................ Ref. See Note 1 ................................................................................................................................... .

71045-HW ..................... Hardware Kit ................................................................................. Ref. BOW30029 .................... Bolt, .31-18 UNC x 1.00 Gr 5 Hex .................................................... 8 BOW30030 .................... Bolt, Hex .31-18 UNC x 1.25 .......................................................... 12 BOW30054 .................... Bolt, .38-16 UNC x 1.00" Gr 5 Hex .................................................. 2 BOW30056 .................... Bolt, .38-16 UNC x 1.50" Lg Hex ................................................... 10 BOW30 106 .................... Bolt, .50-13 UNC x 1.50" Or 5 Hex .................................................. 4 BOW31327 .................... Washer, 3/8" ID Split Lock ............................................................... 6 BOW31412 .................... Washer, 5/16"ID Flat ......................................................................... 8 BOW31415 .................... Washer,.50 1.38"OD USS Or 5 Flat ............................................... 8 BOW31432 .................... Washer, .31 "ID x .68"OD Flat ........................................................ 32 BOW31433 .................... Washer, .38.81 "OD SAE Or 5 Flat ................................................ 16 BOW34273 .................... Nut, 5/16-18 UNC Hex Lock ........................................................... 20 BOW34274 .................... Nut, 3/8-16 UNC Hex Lock ............................................................... 6 BOW34276 .................... Nut, .50-13 UNC Hex Lock ............................................................... 4

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

See Note 2 ................................................................................................................................... .

71045-FTO-l ................. FittingKit ...................................................................................... Ref. 00222 ............................. Straight, MJ10 M010 ........................................................................ 2 00281 ............................. Straight, MP20 FP16 ......................................................................... 1 00328 ............................. Tee MJ12 FJ12 MJI2 ........................................................................ 3 00342 ............................. Straight, FJI0 MJ08 .......................................................................... 1 00423 ............................. Straight, FJ12 MJ08 .......................................................................... 1 00456 ............................. Straight, MJ04 M006 ........................................................................ 6 00458 ............................. Straight, MJ08 M008 ........................................................................ 1 00485 ............................. Straight, FJ12 MJ06 .......................................................................... 1 00498 ............................. Elbow, 90° MJ06 MP06 .................................................................... 1 02234 ............................. Elbow, MJ08 M008 .......................................................................... 1 02314 ............................. Elbow, 90° MJ16 FJI6 ...................................................................... 1 02315 ............................. Straight, MP16 FP12 ......................................................................... 1 02320 ............................. Elbow, 90° MJ12 FJI2 ...................................................................... 2 02387 ............................. Tee, MJ16 FJ16 MJI6 ....................................................................... 1 02447 ............................. Plug, M006 ........................................................................................ 1 02448 ............................. Straight, MJ06 M006 ........................................................................ 2 02473 ............................. Straight, MJ06 M008 ........................................................................ 3 02675 ............................. Elbow, 90° MJ12 MP12 .................................................................... 1 02803 ............................. Straight, MJ08 MP12 ........................................................................ 1 02807 ............................. Straight, MJ12 MP12 ........................................................................ 1 02810 ............................. Straight, MJ16 MP16 ........................................................................ 1 04055 ............................. Tee, MJI0 FJ10 MJI0 ....................................................................... 1 04087 ............................. Reducer FJ12 MJ04 .......................................................................... 1 04100 ................. '" ......... Straight, MP06 FJ06 .......................................................................... 1 04122 ............................. Straight, MP16 MP16 ........................................................................ 1 04176 ............................. Straight, MP12 MP12 ........................................................................ 2 04210 ............................. Straight, MJ06 MP06 ........................................................................ 1 04523 ............................. Elbow, 90° MJ08 M008 ................................................................... 1 04525 ............................. Straight, FJ16 MJ12 .......................................................................... 1 04699-06 ........................ Plug, .38 NPT Socket Hex ................................................................ 1

- Indicates Items Not Shown MANUAL 92376-003 JUNE 1998

•

FIGURE 4.3:TurretRotationAssembly

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MANUAL 92376-003 JUNE 1998

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PART NUMBER

DESCRIPTION

Ref. -1 2 3

71492 ............................ Turret Rotation As~bly ........................................................ Ref. 71492-DWG ................. DWG, Turret Rotation Assembly .................................................. 1 71351 ............................ PositionForkHydraulicRotator .................................................... 1 71492-HW .................... Hardware Kit, Turret Rotation ...................................................... 1

Ref. -1 2 3

71492-HW ..................... Hardware Kit Turret Rotation ..................................... ,............ Ref. 71492-DWG ................. TurretRotation Assembly DWG ................................................... 1 BOW46159 ................... Bolt,5/S-11 UNC-2Bx5.00"LGRS .........:................................. 20 BOW36707-}ID ........... Washer, Flat .63ID Hard ............................................................. 20

QTY

- Indicates Items Not Shown

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MANUAL 92376-003 JUNE 1998

~ . . . , FIGURE 4.4: Battery Assembly

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MANUAL 92376-003 JUNE 1998

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FIGURE 4.4: Battery Assembly DESCRIPTION

QTY

ITEM

PART NUMBER

Ref. -1 2 3 4 5

71386 ............................ Battery Assembly ..................................................................... Ref. 71386-DWG ................. DWG, Battery Assembly .............................................................. 1 65176 ............................ Battery - 12 Volt 1000 CCA ......................................................... 1 71282 ............................ Hold-down, 14112"LBattery ........................................................ 1 66270 ............................ J-Bolt .31-18UNC x 10.00"LG ...................................................... 2 BOW31239 ................... Nut, HEX Keps .31-18UNC ......................................................... 2

- Indicates Items Not Shown

MANUAL 92376·003 JUNE 1998

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QTY

ITEM

PART NUMBER

Ref. -1 2

71387 ............................ Engine Pump Filter Assembly .................................................. Ref. 71387-DWG ................. Filter Assembly Dwg; Engine Pump ............................................. 1 81254 ............................ Filter ............................................................................................... 1 71387-HW .................... Hardware Kit ................................................................................ 1 71387-FTG .................... FittingKit ....................................................................................... 1

3 4

71387-HW .................... Hardware Kit ........................................................................... Ref. BOW39054 ................... Bolt, 3/8-16 x 1 Gr 8 Hex Hd ....................................................... .4 BOW31327 ................... Washer, 3/8" ID Split Lock .......................................................... .4

5 6

71387-FTG .................... FittingKit .................................................................................. Ref. 04051 ............................ Straight, MJIO M012 .................................................................... 1 02333 ............................ Elbow,90oMJIOMOI2 ................................................................ 1

- Indicates Items Not Shown

MANUAL 92376-003 JUNE 1998

FIGURE4.6:AirCleanerInstallation • DESCRIPTION

QTY

ITEM

PART NUMBER

Ref. -1 -2 -3

71495 ............................ Air Cleaner Installation ............................................................. Ref. 71495-DWG ................. Air Cleaner Installation Dwg ......................................................... 1 71495-HW .................... Hardware Kit ................................................................................ 1 65278 ............................ Air Cleaner Kit .............................................................................. 1 65278-001 ..................... Air Cleaner .................................................................................... 1 65278-003 ..................... Mounting Bracket .......................................................................... 2

- Indicates Items Not Shown Drawing not available at this time

MANUAL 92376-003 JUNE [998

•

FIGURE4.7:EngineInstallation ::: ~e=====""'====;'ll d~~oii<''''r-----~fU­

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MANUAL 92376-003 JUNE 1998

FIGURE 4.7: Engine Installation • DESCRIPTION

QTY

ITEM

PART NUMBER

Ref. -1 2 3 4 5 6

71018 ............................ EngineInstallation ..................................................................... Ref. 71018-DWG ................. Engine Installation; Nissan H-25 ................................................... 1 71018-HW .................... Hardware Kit ................................................................................ 1 71559 ............................ Engine Assenbly; Nissan H-25 Gas .............................................. 1 71494 ............................ Electric Panel Assembly ................................................................ 1 71574 ............................ MufflerInstallation ........................................................................ 1 71366 ............................ Engine Support Brace .................................................................... 1

-1 -2 -3

71018-HW .................... Hardware Kit ........................................................................... Ref. BOW36705-HD ........... Washer, .50 x 1.06 OD HD Flat ................................................... 2 BOW39105 ................... Bolt, 112-13 x 1 114 Gr 8 HD Hex ................................................. 2

- Indicates Items Not Shown

MANUAL 92376-003 JUNE 1998

•

FIGURE 4.8: Engine Assembly

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MANUAL 92376-003 JUNE 1998

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FIGURE 4.8: Engine Assembly DESCRIPTION

QTY

ITEM

PART NUMBER

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

71559 ............................ EngineAssembly ...................................................................... Ref. 71559-DWG ................. Engine Assembly Dwg .................................................................. 1 71559-HW .................... Hardware Kit ................................................................................ 1 71559-FTG .................... FittingKit ....................................................................................... 1 71049 ............................ Engine; Nissan H-25 Gas .............................................................. 1 21368 ............................ Check Valve .................................................................................. 1 71718 ............................ ExhaustPipe Assembly ................................................................. 1 71051 ............................ Pump;Hydraulic ............................................................................ 1 71052 ............................ PumpHydraulic ............................................................................. 1 71631 ............................ ManifoldAdapter .......................................................................... 1 69203-001 ..................... Mount,EngineStud ....................................................................... 4 BOW9750-5/16 ............. Hose, Fuel 5116" 10 ........................................................... 3.50 LIF

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

71559-HW .................... Hardware Kit ........................................................................... Ref. BOW39000 ................... Bolt, 114-20 x 112 Gr 8 Hex Hd ..................................................... 4 BOW31325 ................... Washer,.25 ID Split Lock ............................................................. 4 BOW39027 ................... Bolt, 5116-18 x 3/4 Gr 8 Hex Hd .................................................. .4 BOW34273 ................... Nut, 5/16-18 UNC Hex Lock ....................................................... .4 BOW39054 ................... Bolt, 3/8-16 x 1 Gr 8 Hex Hd ........................................................ 4 BOW39055 ................... Bolt,3/8-16x 1114"HexHd ......................................................... 2 BOW31327 ................... Washer, 3/8" ID Split Lock ........................................................... 6 BOW31403 ................... Washer, .38 x 1 00 USS Gr 5 Flat.. ............................................. 2 BOW36106 ................... Bolt, .50-13 UNC x 1.50 Gr 8 Hex ................................................ 2 BOW31329 ................... Washer, .50 Gr 5 Split Lock .......................................................... 2 BOW36784 ................... Nut, .50-13 UNC Lock Hex .......................................................... 1 BOW31415 ................... Washer, .50 1.3800 USS Gr 5 FlaL ............................................ l

-1 -2 -3 -4 -5 -6 -7

71559-FTG .................... FittingKit .................................................................................. Ref. 02579 ............................ Straight,MJ16M016 .................................................................... 3 00267 ............................ Straight,MJ12M012 .................................................................... 2 00222 ............................ Straight, MJ10 M010 .................................................................... 2 04051 ............................ Straight,MJ10M012 .................................................................... 1 02333 ............................ Elbow, 90° MJIO M012 ................................................................ 1 04693 ............................ Elbow, 90° MJ10 MOIO LL .......................................................... 1

-1 -2 -3 -4 -5

71718 71721 71722 71709 80399

............................ Exhaust Pipe Assembly ............................................................ Ref. ............................ Tube Weldment ............................................................................. 1 ............................ 2" 00 Flexible Tubing ........................................................... 79LF. ............................ Reducer; 1.7500 x2.00 00 ....................................................... 1 ............................ MuffierClamp,2" .......................................................................... 2

- Indicates Items Not Shown

MANUAL 92376·003 JUNE 1998

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FIGURE4.9:EngineElectricPanelAssembly •

DESCRIPTION

QTY

ITEM

PART NUMBER

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

71494 ............................ Engine Electric Panel Assembly ............................................... Ref. 71494-DWG ................. Electric Panel Assembly Drawing; Nissan Eng ............................ 1 71494-HW .................... Hardware Kit ................................................................................ 1 71676 ............................ Extension; Electric Panel ............................................................... 4 71354 ............................ Electric Engine Panel Plate ........................................................... 1 34552-012 ..................... Terminal Strip ................................................................................ 1 67280 ............................ Relay, Anti-Restart ........................................................................ 1 CLROOIIO-038 ............. Tube, Hyd .3750D .049Wx 1.75"Lg ............................................ 4 71704 ............................ Nissan Engine Panel Schematic .................................................... 1 71571 ............................ Cover, Engine Electric Plate .......................................................... 1 71572 ............................ Standoff; Engine Elec Plate ........................................................... 4 71588 ............................ Decal, Electric Panel Tags ............................................................ 1

1 2 3 4 5 6 7 8 9

71494-HW .................... Hardware Kit ........................................................................... Ref. BOW31126 ................... Screw, #6-32 x 3/4 Lg Round Head .............................................. 2 BOW31144 ................... Screw, 10-32 UNF x .50 Round SIt ............................................... 1 BOW30009 ................... Bolt, .25-20 UNC x 2.250 Gr 5 Hex ............................................. .4 BOW34376 ................... Screw, 114-20 x 112 Round Hd SIt.. .............................................. .4 BOW31401 ................... Washer, .25 ID x .63 OD Flat ....................................................... 4 BOW31142 ................... Bolt, Sltd. Mach. #10-32 x 2 3/8 .................................................... 4 BOW31233 ................... Nut, #10-32 Keps Hex .................................................................. 5 BOW31400 ................... Washer,#10Flat ........................................................................... 8 BOW31244 ................... Nut, Hex #6-32 .............................................................................. 2

- Indicates Items Not Shown

MANUAL 92376-003 JUNE 1998

RED/WHT BLI.I/WHT IG/lt; CABLE FROM LOWER CON TF:OL [lOX

EiLI.I/REU WHT/BU< GRN/WHT ElLII RED /BLK F:[[>

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DESCRIPTION

rJQTY

ITEM

PART NUMBER

Ref. -1 -2 3 4 5 6

71574 ............................ Muffler Installation ................................................................... Ref. 71574-DWG ................. MufflerInstallationDrawing ......................................................... 1 71574-HW .................... Hardware Kit ................................................................................ 1 65279-001 ..................... Muffler .......................................................................................... 1 65279-002 ..................... Mounting Bracket .......................................................................... 2 71695 ............................ Tailpipe .......................................................................................... 1 80399 ............................ MufflerClamp2" ........................................................................... 1

- Indicates Items Not Shown

MANUAL 92376-003 JUNE 1998

•

FIGURE 4.12: LiftCylinderInstallation

n LJ

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MANUAL 92376-003 JUNE 1998

FIGURE 4.12: Lift Cylinder Installation • DESCRIPTION

QTY

ITEM

PART NUMBER

Ref. -1 -2 -3

71390 ............................ LiftCylinderInstallation ........................................................... Ref. 71390-Dwg ................... DWG,LiftCylinderInstallation ..................................................... 1 71390-Hw ..................... Hardware Kit ................................................................................ 1 71144 ............................ BoomLiftCylinder ........................................................................ 1 71212 ............................ Pin, Turret Lift Cylinder ................................................................ 1 713 90-Ftg ...................... Fitting Kit, Lift Cylinder Installation............................................... 1

-4

-5

Ref. -1 2

71390-Hw ..................... Hardware Kit, Lift Cylinder Installation ................................... Ref. 71390-Dwg ................... Dwg,iftCylinderInstallation ......................................................... 1 BOW39066 ................... Hex Hd Bolt 3/8-16 x 4" Gr8 ......................................................... 2 BOW34274 ................... Nut, 3/8-16UNC Hex Lock ........................................................... 2

Ref -1

71390-Ftg ...................... FittingKit, Lift Cylinder Installation.......................................... Ref. 71390-Dwg ................... Dwg,LiftCylinderInstallation ....................................................... 1 01397 ............................ Elbow,MJ06MOI0 ...................................................................... 2

- Indicates Items Not Shown

MANUAL 92376-003 JUNE 1998

•

FIGURE 4.13: Cylinder, Boom Lift Telescope

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MANUAL 92376-003 JUNE 1998

FIGURE 4. 13: Cylinder, Boom Lift Telescope • DESCRIPTION

QTY

ITEM

PART NUMBER

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

71144 ............................ Cylinder, Boom Lift Telescope ................................................. Ref. * .................................... Wiper ............................................................................................. 1 * .................................... O-Cup (Dual Lip) .......................................................................... 1 * .................................... O-Ring ........................................................................................... 1 * .................................... Back Up ........................................................................................ 1 * .................................... Cast Iron Ring ............................................................................... 1 * .................................... O-Ring ........................................................................................... 1 * .................................... AQ Seal ......................................................................................... 1 * .................................... O-Ring ........................................................................................... 1 * .................................... WearRing ..................................................................................... 1 * .................................... Wear Ring ..................................................................................... 2 71144-101 ..................... Seal Kit (Indicated by *) ................................................................ 1 71144-102 ..................... Washer Seal .................................................................................. 1 71144-103 ..................... Locknut .......................................................................................... 1 71144-104 ..................... PortPlug ........................................................................................ 2 71144-105 ..................... Cartridge Valve ............................................................................. 1 71144-106 ..................... Bushing .......................................................................................... 4 71144-107 ..................... Throttle Check Valve .................................................................... 1 71144-108 ..................... Bleeder Plug .................................................................................. 1 71144-109 ..................... Tube Assembly .............................................................................. 1 71144-110 ..................... RodAssembly ............................................................................... 1 71144-111 ..................... Head .............................................................................................. 1 71144-112 ..................... Piston ............................................................................................. 1 71144-113 ..................... Bushing .......................................................................................... 1

- Indicates Items Not Shown

MANUAL 92376-003 JUNE 1998

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........

MANUAL 92376-003 JUNE 1!1911

FIGURE 4.14: Master Cylinder Installation DESCRIPTION

QTY

ITEM

PART NUMBER

Ref. -1 2 3 4 5

71389 ............................ MasterCylinderInstallation ...................................................... Ref. 71389-DWG ................. Master Cylinder Installation Drawing ............................................ 1 71389-HW .................... Hardware Kit ................................................................................ 1 71145 ............................ Master Level Cylinder ................................................................... 1 71211 ............................ Pin, Turret Master Cylinder. .......................................................... 1 71389-FTG .................... Fitting Kit, Lift Cyl Inst .................................................................. 1

Ref. 1 2 3

71389-HW .................... Hardware Kit, Lift Cylinder Installation ................................... Ref. 71389-DWG ................. Dwg, Lift Cylinder Installation ....................................................... 1 BOW39064 ................... Hex Hd Bolt 3/8-16 x 3 112 Gr8 .................................................... 2 BOW34274 ................... Nut, 3/8-16 UNC Hex Lock .......................................................... 2

Ref 1 2

71389-FTG .................... Fitting Kit, Lift Cylinder Installation .......................................... Ref. 71389-DWG ................. Dwg,LiftCylinderInstallation ....................................................... 1 02793 ............................ Straight MJ04, M006 .................................................................... 3

- Indicates Items Not Shown

MANUAL 92376-003 JUNE 1998

G

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FIGURE4.15:Cylinder,MasterLevel

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MANUAL 92376-003 JUNE 1998

FIGURE 4.15: Cylinder, Master Level . , DESCRIPTION

QTY

ITEM

PART NUMBER

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

71145 ............................ Cylinder, Master Level ............................................................. Ref. * .................................... Wiper ............................................................................................. 1 * .................................... O-Cup (Dual Lip) .......................................................................... 1 * .................................... O-Ring ........................................................................................... 1 * .................................... BackUp ........................................................................................ 1 * .................................... O-Ring ........................................................................................... 1 * .................................... O-Ring ........................................................................................... 1 * .................................... AQ Seal ......................................................................................... 1 * .................................... Wear Ring ..................................................................................... 1 * .................................... Wear Ring ..................................................................................... 2 71145-101 ..................... 55A Seal Kit (Indicated by *) ........................................................ 1 71145-102 ..................... Locknut .......................................................................................... 1 71145-103 ..................... Port Plug (Steel) ............................................................................ 3 71145-104 ..................... Bushing .......................................................................................... 4 71145-105 ..................... ReliefValve ................................................................................... 2 71145-106 ..................... Tube Assembly .............................................................................. 1 71145-107 ..................... RodAssembly ............................................................................... 1 71145-108 ..................... Head .............................................................................................. 1 71145-109 ..................... Piston ............................................................................................. 1

- Indicates Items Not Shown

MANUAL 92376-003 JUNE 1998

(8

FIGURE 4. 16:EpromInstallation

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MANUAL 92376-003

JUNE 1998

FIGURE 4. 16:EpromInstallation . ,

QTY

ITEM

PART NUMBER

DESCRIPTION

Ref. -1 2 3

71622-T40 .....................

71622-DWG .................

71046-001 .....................

71603 ............................

Lower Control Box Installation, T40 ........................................ Ref. Eprom Installation DWG; Lower Control Box .............................. 1 Box Assembly, Lower Control Box ............................................... 1 Eprom; T40 .................................................................................... 1

- Indicates Items Not Shown

MANUAL 92376-003 JUNE 1998

•

FIGURE 4.17: Lower Control Box Assembly

1 ,.--------+-------,.1

_----'(~ ~l,,-__

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42

42

ope;

ADD 1 Te· JIB AND NGI~ JIB IF FUEL OPTION SV{ITCH IS USED

80 TO

81 TO Cl-16

TO Cl-2:2 1A SEE "IOTE 2 3 TO Cl-2

NOTES: 1. ITEI"., 40 IS USED ONLY ','.iITH OPTION A652. OSCILLATING AXLE.

\;z.l~~~S;) C 1 - 8 THIS IS THE FUEL SElE':TI')I-l Si\HCH REFER E) DWG #71797 FOP. S·JLEUOID HOOKUP

42 TO Cl-19

&Ltc "'-HD FR·:JM

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BUTT SPLICE E796.3-0Ql BO\V23085

1~1PES

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......

18

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TO P2-11 ::LGPESEIISC'R P2-14

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FIGURE 4.17: Lower Control Box Assembly

PART NUMBER

Ref. 1

71046-001 ..................... Lower Control Box Assembly ................................................. Ref. 71643-001 ..................... Box, T40 Lower Control Mach ..................................................... 1 71643-002 ..................... Box, T46J Lower Control Mach .................................................... 1 71534 ............................ Computer Board, Lower Control Box ........................................... 1 67280 ............................ Bosch Relay ., ................................................................................ 2 80027 ............................ Hour Meter .................................................................................... 1 65393 ............................ Oil Pressure Gauge ........................................................................ 1 67830 ............................ Meter, Volt .................................................................................... 1 50075 ............................ Switch (Jib) R#67760 .................................................................... 5 50075 ............................ Switch (N"on-Jib) R#67760 ............................................................ 4 52671 ............................ Operator Keyswitch 3 Pos ............................................................ 1 69146 ............................ Operator, Green Pushbutton .......................................................... 1 80025 ............................ Circuit Breaker 20 Amps ............................................................... 1 51913 ............................ P-Pull Button, Emergency Stop ..................................................... 1 51914 ............................ Contact Block, NC ........................................................................ 1 52029 ............................ Contact Block, 2NO WlBase ........................................................ 1 34383 ............................ Contact Block, INO ...................................................................... 1 52672 ............................ Contact Block, 1 NO W/Base ....................................................... 1 67760-002 ..................... Toggle Switch, 3POS 2MAN IMOM ........................................... 1 58292 ............................ Wire, 18 GA White Unless Noted Otherwise ............................. 16 66652-001 ..................... Plug, Male 16 Contacts #1-16 ....................................................... 2 66652-003 ..................... Plug, Male Contacts #17-32 .......................................................... 2 66653-001 ..................... Receptacle Female 16 Cont #1-16 ................................................ 2 66653-003 ..................... Receptacle Female 16 Cont # 17-32 .............................................. 2 66654-032 ..................... Base, Panel Mounted 32 Contacts ................................................. 2 BVDO 1030 .................... Socket ............................................................................................ 1 BVDOI031 .................... Lamp .............................................................................................. 1 72885 ............................ Lens Green Jeweled ...................................................................... 1 71664 ............................ Cover, Lower Control Board ......................................................... 1 65273 ............................ Slope Sensor .................................................................................. 1 71663 ............................ Panel, Lower Control Board .......................................................... 1 71724 ............................ Plug, Female Pins (A) .................................................................... 1 71725 ............................ Plug, Female Pins (B) .................................................................... 1 71727 ............................ Pins, Female Crimp ...................................................................... 80 67125 ............................ Seal Switch (Jib) ............................................................................ 6 67125 ............................ Seal Switch (N"on-Jib) .................................................................... 5 206-00001-00 ................ Diode ............................................................................................. 1 71793 ............................ Resistor 36 OHM 2 Watt .............................................................. 2

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 40

DESCRIPTION

QTY

ITEM

MANUAL 92376-003 JUNE 1998

G

•

FIGURE 4.17: Lower Control Box Assembly

42 RED

1,----------4---------...1 ;

/

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1

\

CL TO Pl-35

42

OPG

TO Cl-22 lA

C1-19 TO Cl-16

42

5

o

.o,

THIS IS THE FUEL SELECTIOI>J S'/iITCH REFER TO D'-.!'lG :::i71-97 FOR SOLENOID HOOKUP

TO Cl-19

TO Cl-q9.-1 '.-22, I,.JUMPEREDJ 5 12AWG

1-22.Pl-17,P2-1S

60''::2308~·

5A 51

TO P2-31

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SLOPE SENSOR TO Cl-05

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FIGURE 4.17: Lower ControlBoxAssembly OUTSIDE CONNECTOR PIN II C1-01 CI-02 CI-03 CI-Q4 C)-OS CI-06 CI-07 CI-08 CI-09 C1-10 C1-11 C1-12 CI-13 cr-14 C1-15 CI-16 CI-17 C1-18 CI-19 CI-20 CI-21 CI-22 CI-23 C)-24 CI-25 CI-26 CI-27 CI-28 CI-29 CI-30 C)-31 CI-32 C2-01 C2-02 (2-03 (2-04 [2-05 C2-06 C2-0?

(2-08 C2-09 (,2-10 (2-11 (2-12 C2-13 C2-14 C2-15 (2-16 (,2-17 C2-18 C2-19 C2-20 (2-21 (2-22

CIRCUIT II 61 .3 D2

D1 I I I SPARE 5 5B AS lS SP I 5T SPARE 5 TOS 42 12 OPB OPG 13 14 25 8L 8H )

2 2 2 ~I

Ul 68 16 15 27 26 24 23 17 18 22 21 TLI Tl2 19 20 34 35 10 9 62

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C2-28 (2-29 [2-30 C2-31 (2-32

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CABLE BC BC BC BC BC BC BC TlS AlS ASC , LSC ASC&lSC ASC&lSC TlS EC EC EC EC EC EC EC EC EC EC EC EC EC EC EC EC 'IH' VH v'H VH VH VH VH

VH VH '/H \/1f

VH VH ",'H 'JH VH SR SR SR SR SR SR SR OC OC OC

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COLOR GRII RED YEl 'w'HT BlK BLU SHIELD BlK BlK GRN 'w'HT RED&BlK BlK&RED BlK BlU'BlK BlK,\.;'HT GRU 'riHT BlK BlK ORWBlK ORII 'iHL BlK GRII 'BLK RED BlK GRiI RED .~'HT BlU. ,!HT BlK GRII. 'BLK BlU .m ',:HT BlU BlU Bll< ORII ORII 'BLK BlK RED "HT REDBlK RED BlK BlK "HT GRII ',:HT GRII '"HT GRIl BlY. GRN ,:HT 'BLI< . ORII. BlK RED 'BLK GRIIBLK ~'HT

BlU ORII RED BlK ·,.HT GRII BlK ',:HT.

FUlICTIDtI EMERG PUMP S\{ITCH SIGNAL 12'1 PO'.o'ER 10 Pl TFRM DATA TRAI'ISMIT TO Pl TFRM DATA RECEIVE FROM PlTFRM GROUrlD TO Pl TFRM GROUHD TO PlTFRM SHIELD GROUND - BOOM CABLE SPARE POIlER TO BOOM LIMIT SWITCHES SIGNAL RETURI~ FRDM BM LIM Siv' SIGUAL FRDM ANGLE SENSOR SIGtlAl FRDM lENGTH SENSOR POIiER TO AI~G/lNGTH SENSORS GRIID TO lNGTH/ANG SEI~SORS TELESCOPE LIMIT S'rIITCH SPARE PO't/ER TO PUMP SEIlSOR TEMP/OIL PRESSURE SIJITCHES HIGII~E IGNITIOI'I SIG~lAl RETURN FROM PUMP SENSOR DIl PRESSURE SENSOR SPLICED TO DPB DRIVE REVERSE DRIVE FDR\yARD START EI'IGIIIE LO',: SPEED THRIlTTLE HIGH SPEED THROTTLE GROUIID FROM BATTER', PO';iER PO'.'ER PO,;ER CHOKE OR GlO'.PlUG UlIlOADER VALVE PUll EI~ERGEIIC. PUI~P STEER RIGHT STEER lEFT PLATFDRI~ RIlTATIDII RIGHHCCd PLATFDRM RIlTATIDII lEFTlC',<) PLATFDRH lE','EL UP PLATFDRI4 lEVEL DO~,II BOOl~ UP BOOM DO ,III S:,I1IG RIGHHCC\\) S :,IIlG lEFHC',,) TELESCOPE SPLICED TO TLI BOOM Ei TEriD BOOM RETRACT H"LE lOCK I VALVE A:'LE lOCK 2 VALVE STEER VALVE 1 STEER ','Al'/E 2 BP.AKE '/Al .... E PO."ER TO ;..l[ PRU;I1m. 'S"dT(H SIGIIAl RETURII A.U PRO, S'.ITCH DRI IE SEP.IES PARAllEL. ..'ril" E l'lDTlDlI ALARM (OPTIDJI) SIGIIAL HOPIJ(OPTIDJI) LIGHT: (oPTIDIJ) JIB UP ,T ~6J T66J Olll L' JIB. DOdl \146J T66J Olll.; H. D Dll Tn!p (oPTIDII> FUEL lE\!EL (OHIDIIJ_ :,:THI VOLTAGE (oPTlOII;

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(HO ()-28 Cl-O) C1-02 C)-03 C)-09 (1-38 CI-36 CI-H CH5 C1-4o& CH7 CH8 CH9 (I-52 CI-53 CI-54 CI-55 C)-56 Cl-57

CH.O (1-61 (1-62 CI-63 Cl-6~

C1-65 CI-67 CI-;(1-l'3 ·(H3 CHI (H2

CH7 16 16':'

I'IDTES: I, DISREGARD COLOR DESIGIIATIDII BEC;:'U:E '!'ll THE dRlIlG III THE BO' E :;HIlE. MANUAL 92376..oc13 JlINE 1998

I,,'AS pmll

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• PHB PH9 » PI-20 P1-21 PI-22 PI-23 PI-24 PI-25 PI-26 P1-2B PI-3i) Pi-31 PI-32 • . PI-34 PI-35 PI-J6 PI-37 PI-38 PHO ~ P2-01 » P2-02 P2-03 P2-04

V>

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P2-06 P2-0B P2-09 1'2-10 P2-1I P2-12 1'2-13 P2-14 P2-IS P2-16 1'2-17 P2-IB P2-19 P2-20 P2-21 P2-22 1'2-23 1'2-24 P2-25 1'2-26 P2-27 P2-28 P2-29 1'2-30 P2-31 P2-32 P2-33

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FIGURE 4.11: Lower Control Box Assembly

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COLOR '.;HT \iHT .. HT ',HT "..HT '.!HT RED '.!HT .. HT ',HT ',HT RED GRtl ,'HT "HT ·.HT RED ',HT '.HT ·.. HT ".HT RED RED iEl RED ',HT ,'HT RED ',HT ',HT ',HT ',HT ··,'HT BlK

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BlU fiLU BlV: GPII GRII GRII BlU BlU BLU fiLU BlIJ RED RED GRII GRII GRII BtU BtU fiLU fiLU BlU ElU BlIJ ,jRII' GRII GRII GRIJ. GRII GRII GRII GRII GRiI GJ111 1jJ1J1 GRII GRII

FUIICTlDlI SOUIID mTlDlI ALARM (DDS> RUn STARTER RELAY <Doo) RUti STEER VALVE 2 <Dll2ll RDTATE Pli.TfORH RIGHT <D0I3) RUU EtlGlIlE (D1I5) RUII lO:" SPEED THROTTLE <D(6) +12VDC'DDB-1l RUII BRAKE VALVE (DIl23) PlATFDRI,' lEVEL UP CD0I5) RUII HIGH SPEED THROTTLE (007) STEER lEfT (D0I2) +12VDCI 000-3 IllUMItlATE A~LE LIGHT (D017> SDUIlD SIGIIAL HDRII (D09) RUIl EMERG, PUMP(DOIl GLO'NPlUG RELAY (ISUZU ONl Yl +12VOC;'D020-23 RUII AilE lOCK VALVE 2 (DIIl9) ST[[R RIGHT (DOm RUII LIGHTS (D03> PLATfORM lEVEL 00"11 (D016) +12VDL S', STEM +12I;DC.D016-19 DATA RECEIVE FROM Pl TFRII +12'1D(:D04-7 DRIVE SEP., Pt;R, VAL ,'E (0010) DATA TRAlill1T Til Pl TFRM . +12VDC. 0012-15 RUII STEEP, VALVE I <D020) RUII U1ll0ADER VALVE (004) RUII A'LE lOCK VALVE I 'DDlS) IllUMllIATE CALlBRATlOII LIGHT (D022) ROTATE PLATfORM lEFT (DIIl4) +SV DC F[]p. 5EIISDRS GROUIID GROUIID A'lE PRO', S~ITCH SIGIiAl /IIPUT (DI2) JIB UP ~IGIiAL IIIPUT (DB) BOON UP ']GIIAl IIIPUT <D~) START ~IGIR IIIPUHDO) DIL. TE~P SdTCH ("3; liP-OUIiD LIFT BOOfl W,,'HITi TELESCOPE (P'."I13T> E'TEIID BoOI·1 'P'"l~5n CHt.SSIS TILT 'EIISDP. SIGII~l IIIPUT (D)3) JIB DO',d I SIGllhl IIIPUT (09) Boofl 00 "I SIGIiAl H1PUT (oS) HITHRDTTlE SIGNAL IIIPUT (DI> PUI~P SPEED SEIISOR SIGIiAl IIIPlIT (A2) +12\; DC 1',110-2 +12VDC 1"" H3-5 lll.'ER BIIOH (P,d~IB) TElESUJPE W,f13B) RE TRAe T BOON (p:,14SB) TELESCOPE WilT S'. ITCH ';JGIIAl IIIPUT (DI~) IfIERGEIIC\ PU~IP SIGII~l IIIPUT (DIO) ~ dliG RIGHT (CU) ;IGIIAl /IIpUT (D6> BOOfl E' TElID SIGIiAl /IIPUT <D2) AIiGlE ~EIJSOR SIGllAl IIIPUT (All H, D, DIl TEHp (AS) S,STEH ',oLTAGE , ..7) DRI'IE FOR .,;'RD 'I' "I~Qn ~dllG RIGHT ICC,) W"M2T> JIB UP GPOUIID EIJG/lIE 011 80[)J.l LlJ.I/T ; I, ITCH GJ10UIJ[1 ;dllG GRoUl1D BOOI,I RETR':'O lEllGTH SEIJ:OP EiIG/lIE OIL PRESSURE FUEL lE !El DRI\'E RE.'EP.~E >,IIIG LEFT JIB DO'"II

•

COIR·IECT TO: C2-25 CI-2S C2-20 C2-OS CR5 RElM COil CI-26 SEE 71046 SHT 2 or 3 C2-21 C2-07 CI-27 C2-04 SEE 71046 SHT 2 or 3 A:<lE lOCK LIGHT C2-26 C2-02 C2-3O SEE 71046 SHT 2 or 3 C2-IB C2-03 C2-27 C2-0B .SEE 71046 SHT 2 OF 3 SEE 71046 SHT 2 OF 3 CI-04 SEE 71046 SHT 2 OF 3 C2-24 CI-03 SEE 71046 SHT 2 OF 3 C2-19 C2-01 (2-17 CALIBRA TlOIi LIGHT (2-0f.

CH3 SEE 71046 SHT IOF 3 StE 71046 SHT I or 3 (2-23 JIB LIFT S','ITCH (n BOOM UFT S. ITC H ([) STAP,T .,ITCH (3) CI-I13 $[[ 71046 SHT I OF 3 e2-09 C2-13 C2-15 SLOPE SEIISOR ',HTl JIB LIFT hITCH (3) BOOI,I LIFT S··.. ITCH \3> CHOKE S'.JTCH (3) C1-20 SEE 71046 SHT 2 OF 3 SEE 71046 SHT " OF 3 [2-10 C2-14 C2-16 CI-IS 5T HAIII. EMERG PUMP h (3) SdllG S"ITCH m TElES(IIf>E S, ITCH (» CHI C2-30 C2-32 CI-24 <lHRU A 36 OHII 2. 1i[;ISTOR) [2-11 [2-29 GROUi'lD. PlATFOF.'I1 S,')TCH 4 t EHERGEIJI:, PlJflP S,JT(H & START. CHDt·E hITCH [1-10 S','/lIG S'dTCH 3 TELESCOPE S'"ITCH 3 CI-I2 CJ-21 C2-31 CI-23 <THRU " 3f. OHM 2', RESETOR) C2-12 C2-29

MANUAL 92376-003

JUNE 1998

4~2

•

FIGURE 5.1:CounterweightAssembly

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MANUAL 92376-003

ruNE 1998

FIGURE 5.1:CounterweightAssembly DESCRIPTION

QTY

ITEM

PART NUMBER

Ref. 1 2 3 4 5 6

71391 ............................ CounterweightAssy ................................................................. Ref. 71391-Dwg ................... Dwg, Counterweight Assy ............................................................ 1 71391-Hw ..................... Hardware Kit ................................................................................ 1 71855 ............................ Cover Weldment, Cover T40 ........................................................ 1 71339 ............................ LevelingBlockCounterweight ...................................................... 1 71341 ............................ Block Plate Counterweight ............................................................ 2 71839 ............................ Shroud,NissanEngine ................................................................... 1

Ref. 1 2 3 4 5 6 7

71391-Hw ..................... Hardware Kit ........................................................................... Ref. 71391-Dwg ................... Dwg, Counterweight Assy ............................................................ 1 BOW46146 ................... Bolt, Hex lID 3/4-IOUNC x 3"L GR8 .......................................... 2 BOW32278 ................... Nut, 3/4-10UNC Jam .................................................................... 2 BOW36718-lID ........... Washer, 3/4 lID ............................................................................ 4 BOW39178 ................... Bolt, Hex lID 3/4-10 x3 112" L GR8 ........................................... .4 BOW30002 ................... Bolt, .25-20UNC x .750 Hex ......................................................... 4 BOW31401 ................... Washer, .25 ID x .63 OD Flat ...................................................... .4

o

Indicates call out pieces for the Hardware Kit.

- Indicates items not shown.

MANUAL 92376-003 JUNE 1998

8)

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FIGURE 6.1 :BoomlSkirtInstallation; T40 •

DESCRIPTION

QTY

ITEM

PART NUMBER

Ref. 1 2 3

710 13-T401146J ............. Boom Installation T40/46J ....................................................... Ref. 71013-T40/46J .............. Dwg, Boom Installation T40/46J .................................................... 1 71013-HW .................... Hardware Kit, T40/46J .................................................................. 1 02430 ............................ StraightMJ04 MB04 (T40) ........................................................... 6 02430 ............................ Straight MJ04 MB04 (46J) ............................................................ 8 71017 ............................ SkirtAssembly ............................................................................... 1 71563 ............................ Jib/SkirtAssembly ......................................................................... 1 71641 ............................ Main Boom AssemblyT40/46J ..................................................... 1 71437 ............................ Pin, Base Boom Pivot T40/46J ...................................................... 1 71446 ............................ Pin, T40 Master CyllBase Boom ................................................... 1 71450 ............................ Pin, T40 Lift CyllBase Boom ........................................................ 1 71838 ............................ Cover, T40/46J Boom Pivot Upr ................................................... 1 71837 ............................ Cover, T40/46 Boom Pivot Lower ................................................. 1 71473 ............................ Hose Carrier Installation, T40146J ................................................. 1 71853-T40 ..................... Hose Kit, Boom T40 ...................................................................... 1 71853-T46J ................... Hose Kit, Boom T46J .................................................................... 1 71854-T40 ..................... Electrical Cable Assembly, T40 ..................................................... 1 71854-T46J ................... Electrical Cable Assembly, T46J ................................................... 1 71528 ............................ Boom Pivot Cover ......................................................................... 2

4 5 6 7 8 9 10 11 12 13 14

-Indicates Items Not Shown

o

Indicates call out pieces for the Hardware Kit

MANUAL 92376-003 JUNE 1998

•

FIGURE 6.2:MainBoomAssemblyT40

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MANUAL 92376-003 .. JUNE 1998

--I

FIGURE 6.2:MainBoomAssemblyT40 • DESCRIPTION

QTY

ITEM

PART NUMBER

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

71641 ............................ Boom Assy, T40/46J ................................................................ Ref. 71641-DWG ................. Dwg, Boom Assy Dwg, T40/46J ................................................... 1 71641-HW .................... Hardware Kit, ................................................................................ 1 71641-FTG .................... FittingKit ....................................................................................... 1 71419 ............................ Boom Weldment, T40/46JBase .................................................... 1 71415 ............................ Boom Weldment, T40/46JTip ....................................................... 1 81587-003 ..................... Bearing Pad, Adj 2 5/8 Long ........................................................ .4 71305 ............................ Wear Pad, Mid/Tip Bottom ........................................................... 1 71304 ............................ Wear Pad, Mid/Tip Top ................................................................. 1 71452 ............................ Wear Pad, TiplBase T40 ............................................................... 2 71146 ............................ SlavelLevel Cyl, Telescope ........................................................... 1 71488 ............................ Cap, Slave Cyl Pin Retainer .......................................................... 1 71444 ............................ Pin Weldment, Slave CyllBoom .................................................... 1 71324 ............................ Cylinder, Boom Extend T40/46J .................................................... 1 71460 ............................ KeeperBlock, Extend CylinderT4 0/46J ....................................... 2 71457 ............................ Pin, T40ExtCylinder

- Indicates Items Not Shown

MANUAL 92376-003 JUNE 1998

•

FIGURE 6.3: Base Boom Assembly

This Page is intentionally left blank.

MANUAL 92376-003 JUNE 1998

FIGURE 6.4:HoseCarrierinstallation

: I'). REF

u SECTION 8-8

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DESCRIPTION

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l~~-_

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------'"

QTY

ITEM

PART NUMBER

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

71473 ............................ Hose Carrier T40/46J ............................................................... Ref. 71473-DWG ................. Dwg, Hose Carrier Installation Dwg T40/46J ............................... 1 71473-HW .................... Hardware Kit ................................................................................ 1 71474 ............................ Hose Carrier Tube Weldment, Tip ................................................ 1 71476 ............................ Hose Carrier Tube Weldment, Base ............................................. 1 71433 ............................ Wear Pad, Tip Hose Tube ............................................................. 2 CLV01233-001 ............. Pipe, 114 SCH 80 PVC x 5.13L ................................................... .4 71471 ............................ Spacer, Catrack Mounting ............................................................. 1 71477 ............................ Frame, Hose Track Cover ............................................................. 1 71479 ............................ Hose Carrier Track T46/66J ......................................................... 1 71480 ............................ Cover, Hose Track ........................................................................ 1

- Indicates Items Not Shown

MANUAL 92376-003 JUNE 1998

8>

1------'5.""----1

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t - - - - - - - - I J•.t1II------C,I::;.

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CYLINDER EXTENDED STROKE RETRACTED BORE O.D. TUBE D.O. ROD O.D. ROD LD. INORKING PRESSURE

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SPEC'S , 209.00 202.50±.13 650±.13 3.00 3.38 2.47 1.88 3000 PSI

FIGURE 6. 6: Cylinder, Boom Extend DESCRIPTION

QTY

ITEM

PART NUMBER

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

71143 ............................ Cylinder,BoomExtend ............................................................. Ref. * .................................... Wiper ............................................................................................. 1 * .................................... O-Ring ........................................................................................... 1 * .................................... Back Up ........................................................................................ 1 * .................................... AQ Seal ......................................................................................... 1 * .................................... O-Ring ........................................................................................... 1 * .................................... O-Cup (Dual Lip) .......................................................................... 1 * .................................... O-Cup Green Tweed ..................................................................... 1 * .................................... Wear Ring ..................................................................................... 4 71143-101 ..................... 55A Seal Kit (indicated by *) ........................................................ 1 71143-102 ..................... Setscrew ........................................................................................ 1 71143-103 ..................... PortPlug ........................................................................................ 2 71143-104 ..................... Port Plug ........................................................................................ 2 71143-105 ..................... Counterbalance Valve ................................................................... 1 71143-106 ..................... Cartridge Valve ............................................................................. 1 71143-107 ..................... TubeAssembly .............................................................................. 1 71143-108 ..................... Rod-TubeAssembly ...................................................................... 1 71143-109 ..................... Head .............................................................................................. 1 71143-110 ..................... BearingSleeve ............................................................................... 1

- Indicates Items Not Shown

Note:

Item numbers 1-8 will be included in seal kit SK16305.

MANUAL 92376-003

JUNE 1998

G

•

FIGURE 6.9: Slave Cylinder Assembly

This Page was Intentionally Left Blank.

MANUAL 92376-003 JUNE 1998

FIGURE 6.10:SlaveLeveICylinder •

@ /

DESCRIPTION

/

QTY

ITEM

PART NUMBER

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

71146 ............................ SlaveLeveICylinder ................................................................. Ref. 71146-101 ..................... Wiper ............................................................................................. 1 71146-102 ..................... Seal ................................................................................................ 1 71146-103 ..................... 0-Ring ........................................................................................... 1 71146-104 ..................... Back-Up ........................................................................................ 1 71146-105 ..................... O-Ring ........................................................................................... 1 71146-106 ..................... O-Ring ........................................................................................... 1 71146-107 ..................... Seal ................................................................................................ 1 71146-108 ..................... Wear Ring ..................................................................................... 1 71146-109 ..................... Wear Ring ..................................................................................... 2 71146-110 ..................... Seal Kit .......................................................................................... 1 71146-111 ..................... Locknut .......................................................................................... 1 71146-112 ..................... PortPlug ........................................................................................ 4 71146-113 ..................... Bushing .......................................................................................... 4 71146-114 ..................... Counterbalance Valve ................................................................... 2 71146-115 ..................... TubeAssembly .............................................................................. 1 71146-116 ..................... RodAssembly ............................................................................... 1 71146-117 ..................... Head .............................................................................................. 1 71146-118 ..................... Piston ............................................................................................. 1

- Indicates Items Not Shown MANUAL 92376"()()3 JUNE 1998

•

FIGURE 6.12:SkirtInstallation

:,.~

NOTES:

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1.

2.

.~-

_

" •.:'15 USED TO CJ.LL OUT FIECE F!.PTS F·JP THE H':"PDO'.';F.E 1m.

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MANUAL 92376-003 JUNE 1998

IJSED TO Ct..LL OUT FIECE ·P':'F.TS F·JF. THE FITTIII':; VolT .

FIGURE 6. 12:Skirtlnstallation

DESCRIPTION

QTY

ITEM

PART NUMBER

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

71017 ............................ Skirt Installation ........................................................................ Ref. 71017-DWG ................. SkirtlnstallationDrawing .............................................................. 1 71017-HW .................... Hardware Kit ................................................................................ 1 71017-FTG .................... FittingKit ....................................................................................... 1 71439 ............................ Pin,BoomTip ................................................................................ 1 71464 ............................ Pin, Slave Cylinder/Skirt ................................................................ 1 71022 ............................ SkirtWeldment .............................................................................. 1 35460 ............................ Actuator ......................................................................................... 1 71215 ............................ Lower Skirt Bracket Weldment .................................................... 1 71219 ............................ Upper Skirt Bracket Weldment ..................................................... 1 71515 ............................ Spacer, SkirtlRotator ..................................................................... 1 81399 ............................ Shim ............................................................................................... 1 71621-STD ................... Hose Kit, Skirt ............................................................................... 1 71554 ............................ Dual P.O. Check Valve ................................................................ 1 81368-36-16 .................. Gar-Max2.00"IDx2.50"ODx 1.00"L. ......................................... 1 71733 ............................ Skirt Stop Weldment LH ............................................................... 1 71732 ............................ Skirt Stop Weldment RH ............................................................... 1

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

71017-HW .................... Hardware Kit ........................................................................... Ref. BOW39011 ................... Bolt, .25-20 UNC x 2.75 Gr 8 Hex ................................................ 4 BOW34272 ................... Nut, .25-20 UNC Nylon Lock ....................................................... 8 BOW39012 ................... Bolt, 1/4-20 x 3.00 Gr 8 Hd Hex .................................................. .4 BOW39105 ................... Bolt, 112-13 x 1114 Gr 8 Hd Hex ................................................. .4 BOW31329 ................... Washer, .50 Gr 5 Split Lock .......................................................... 4 BOW39060 ................... Hex Hd Bolt 3/8-16 x 2 112 Gr 8 ................................................... 1 BOW34274 ................... Nut, .3/8-16 UNC Hex Lock ......................................................... 1 BOW33979 ................... Keystock, .500 x .500 ............................................................ 21LF. BOW36102 ................... Screw, .50-13 UNC .750 Hex Cap .............................................. .4 BOE30030 .................... Bolt, 5116-18 UNC x 1.25 Gr 5 Hex .............................................. 2 BOW34273 ................... Nut, 5116-18 UNC Nylon Lock ..................................................... 2

1 2 3 4

71017-FTG .................... FittingKit .................................................................................. Ref. 00456 ............................ Straight, MJ04 M006 .................................................................... 2 04630 ............................ Elbow, 45° MJ04 M006 ................................................................ 2 02236 ............................ Elbow, 90° MJ04 M004 ................................................................ 4

- Indicates Items Not Shown

MANUAL 92376-003 JUNE 1998

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FIGURE 7.1 :PlatformInstallation • DESCRIPTION

QTY

ITEM

PART NUMBER

Ref. -1 2 3 4

71513 ............................ PlatformInstallation .................................................................. Ref. 71513-DWG ................. Installation DWG, Platform 36 x 60 .............................................. 1 71513-HW .................... Hardware Kit, Platform Installation .............................................. 1 71025 ............................ Platform Weldment; 36 x 60 .......................................................... 1 66095-021 ..................... Glides, Load-Bearing 1.25 OD ..................................................... 1

Ref. 1 2 3

71513-HW .................... Hardware Kit, Platform Installation ......................................... Ref. BOW39055 ................... Bolt 3/8-16 xl 1/4" Hex HD ......................................................... 8 BOW36713-HD ........... Washer, .375 SAE ....................................................................... 16 BOW34274 ................... Nut, 3/8-16UNC Hex Lock ........................................................... 8

- Indicates Items Not Shown

MANUAL 92376·003 JUNE 1998

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~ FIGURE 7.2:PlatfonnElectricalInstallation

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PART NUMBER

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71019-001 ..................... Platform ElectricaIInstallation(T46J) ...................................... Ref. 71019-002 ..................... Platform Electrical Installation (T40)...................................... Ref. 71630-Dwg ................... ElectricaIPlatform Installation Dwg(T40/46J) ............................. 1 71630-Hw ..................... Hardware Kit ................................................................................ 1 71638-001 ..................... Platform Box Assy, 2WD, 2STRIJib (T40) ................................... 1 71638-002 ..................... Platform Box Assy, 2WD, 2STRlNon Jib ..................................... 1 71570 ............................ 110V Platform Assy, T-Series ...................................................... 1 66751 ............................ FootswitchW/Guard+Cable ........................................................ 1

1 2 3 4 5 6

71630-Dwg ................... Electrical Platform Installation Dwg .............................................. 1 BOW41235 ................... Capscrew, .25-20UNC x 1.75 SOC ............................................. .4 BOW31411 ................... Washer, .25 ID x .75 OD Flat ....................................................... 6 BOW31238 ................... Nut, .25-20UNC Hex Keps ........................................................... 6 BOW30004 ................... Bolt, .258-20UNC x 1.00 ............................................................... 2 BOW31411 ................... Washer, .25 ID x .75 OD Flat ....................................................... 2

1 2 3

- Indicates Items Not Shown

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Indicates Call Out Piece Parts for the Hardware Kit. MANUAL 92376·003 JUNE 1998

FIGURE 7.3:11OVPlatformAssembly, T-Series

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

71570 ............................ 110V Platform Assembly, T-Series .......................................... Ref. 71570-DWG ................. Assembly DWG, 110V IN Platform ............................................. 1 40956 ............................ Box, Rain Tight Single-Gang ......................................................... 1 66357 ............................ Receptacle, Ground Fault .............................................................. 1 66358 ............................ Cover, Weatherproof ..................................................................... 1 66136-003 ..................... Strain Relief45°-1I2-.375 .............................................................. 2 67123-001 ..................... Seal, Connector Electronical1/2" .................................................. 2 BOW31362 ................... Washer, Split Lock # 10 ID ........................................................... .4 BOW23075 ................... Connector, Butt 12-10GA Wire ..................................................... 5 BOW31146 ................... Screw, Slot, Round #10-32UNF x 1.00 ......................................... 4 BOW31430 ................... Washer, Flat #10 ID .................................................................... 16

- Indicates Items Not Shown

MANUAL 92376-003 JUNE 1998

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DESCRIPTION

QTY

ITEM

PART NUMBER

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

71368-002 ..................... Platform Control Box Assembly ............................................... Ref. 71592 ............................ Upper Control Box Mach .............................................................. 1 ...................................... Screw ............................................................................................ 4 71501 ............................ Joystick, Single Axis ...................................................................... 1 71502 ............................ Joystick, Single Axis wlRocker ..................................................... 1 71503 ............................ Joystick, Dual Axis ........................................................................ 1 50075 ............................ Switch (Ref PIN 67760) ................................................................ 2 69145 ............................ Operator, Yellow Push Button ...................................................... 1 51913 ............................ Operator, Red Push-Pull ................................................................ 1 71533 ............................ Platform Control Board ................................................................. 1 67760-003 ..................... Toggle Switch 2 Pos Maintain ....................................................... 1 67760-001 ..................... Toggle Switch 3 Pos 2 Pole Man .................................................. 1 67760-002 .................... Toggle Switch 3 Pos 2 Man 1 Mom .............................................. 1 34644 ........................... Alarm ............................................................................................. 1 52672 ........................... Base + 1 NO Contact .................................................................... 1 51914 ........................... Base + 1 NC Contact .................................................................... 1 54257-005 .................... Light, Red Indicator ....................................................................... 1 71710 ........................... 6 Pin Plug For Female Pins ............................................................ 2 71711 ........................... 8 Pin Plug For Female Pins ............................................................ 2 71712 ........................... 10 Pin Plug For Female Pins .......................................................... 2 71713 ........................... Female Crimp Pin For Plugs ........................................................ 48 54910-104 .................... Connector Mounting Base; Ag Panel ............................................ 1 58257 ........................... Wire, 18 Ga White .......................................................................... .

71740 ........................... Seal, Switch .................................................................................... 7

40 41 42 43 44 45 46 47 48 49 50

67760-003 .................... Toggle Switch 2 Pos Maintain ....................................................... 1 34863 ........................... White Push Button ......................................................................... 1 52672 ........................... Base + 1 NO Contact .................................................................... 1 ..................................... Push Button .................................................................................... 1 ..................................... Base w/Contact ............................................................................. 1 69146 ........................... Green Push Button ......................................................................... 1 52672 ........................... Base + 1 NO Contact .................................................................... 1 ..................................... Computer Board Led Readout. ...................................................... 1 ..................................... Cable Ribbon .................................................................................. 1 67758 ........................... Toggle Switch 3 Pos Maintain ....................................................... 1 54257-005 .................... Light, Red Indicator ....................................................................... 1

- Indicates Items Not Shown

MANUAL 92376·003 JUNE 1998

This Page is Intentionally Left Blank

MANUAL 92376-003 JUNE 1998

.I!llIlE:. '" I1BIS f8 .. f8 NEEDS 10 BE REPlACED TOGElHER.

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FIGURE 7.5.:FootSwitchInstallation

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QTY

ITEM

PART NUMBER

Ref. -2

66751 ............................ Foot Switch w/Guard + Cable ....................................................... 1 34667 ............................ Retainer, Foot Switch 7 7/8 ........................................................... 1

DESCRIPTION

- Indicates Items Not Shown

MANUAL 92376-003 JUNE 1998

FIGURE 8.1:ChassisCover Assembly •

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DESCRIPTION

,:. )IS USED T0 C;"LL OUT PIECE P,l.FTS F·jF. THE H':'PD;,:'PE I'IT. -'

QTY

Ref. -1 2 3 4 5

71451 ............................ Chassis Cover Assembly ...............................................;............ Ref 71451-DWG .................. Chassis Covers Drawing ................................................................. 1 71451-HW .................... Hardware Kit, Chassis Covers ...................................................... 1 71340 ............................ Cover, Chassis Side ....................................................................... 2 71338 ............................ Cover, Chassis Rear ....... :.............................................................. 1 71337 ............................ Cover, Chassis Front ..................................................................... 1

1 2

71451-HW .................... lIardware Kit, Chassis Covers ....................................................... .

71451-DWG ................. Dwg, Chassis Covers .................................................................... 1 BOW91666 ................... Nut, .25-20ZincPLTAcom ............ ~ ........ ~ ................................. 20

- Indicates Items Not Shown

MANUAL 92376-003

JUNE IIi98

•

FIGURE 9.1 :FiberglassDoorAssembly

A.

ITEM

PART NUMBER

DESCRIPTION

Ref. -1 -2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 -19

71392 ............................. FiberglassDoor Assembly ........................................................ Ref. 71392-DWO ........•........ Fiberglass Door Assembly Drawing .............................................. 1 71392-HW .................... IIardware Kit .....................................................:........ ~ ................. 1 71198-1 ......................... Turret Cover, Left Side ................................................................. 1 71198-2 ......................... Turret Cover, Right Side ................................................................ 1 71773 ............................ Weldment, Turret Cover Mount Lower RH .................................. 1 71772 ............................ Weldment, Turret Cover Mount Lower LH .................................. 1 71771 ............................ Weldment, Turret Cover Mount Upper RH .................................. 1 71770 ............................ Weldment, Turret Cover Mount Upper LH .................................. 1 71275 ............................ Oas Shock Assembly, Cover .................................... ;.................... 4 71741 ............................ Hinge,CoverDrilled ..................................................:................... 4 71039 ............................ Turret TraylDoor Latch Plate ....................................................... 1 71774 ............................ Latch Bracket, Engine Side ........................................................... I 71750 ............................ Bracket, Cover Mount RH ............................................................ I 71742 ............................ Bracket, Cover Mount LH ................ ,............ ~ .............................. 1 71580 ............................ BoltPlate,'Hinge ............................................................................ 4 71581 ............................ Gasket, Bolt Plate .......•.................................................................. 4 71756 ............................ Ouard, Turret RH .......................................................................... 1 71757 ......................•..... 0u8rd, Turret LH .......................................................................... 1 71779 ............................ Cup Latch, Mod ............................................................................. 1 MANUAL 92376-003 JUNE 1998

Q'iY

FIGURE 9.2:GasCoverShockAssembly . ,

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= /A·:M;;STEP C'>'PF = FI ~ED F·JRCE GAS SPRJI-IG

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= STEEL BALL Jo:'IIH = :=;;465K46 '.~ REO'O:; = ME FEM;"LE = "712-5-002

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ITEM

PART NUMBER

DESCRIPTION

Ref. -1 -2 -3

71275 ............................ Gas Cover Shock Assembly ..................................................... Ref. 71275-DWG ................. Gas Shock Assembly Drawing, Cover .......................................... 1 71275-001 ..................... Gas Shock, 200LBS wlMale Ends ................................................. 1 71275-002 ..................... EndFittings, Female Attachment .................................................. 2

- Indicates Items Not Shown

MANUAL 92376-003 JUNE 1998

QTY

•

FIGURE lO.l:ManuallnstaUation·

MANUAL 92376-003 iuNB 1998

FIGURE lO.l:ManuaIInstallation

DESCRIPTION

QTY

ITEM

PART NUMBER

Ref. 1 2 3 4 5

71639 ............................ ManuaIInstallation, T40-0IlT46-01 .......................................... Ref. 71639-Dwg ................... Manual Installation Dwg; T40/T46J-Ol ......................................... 1 71639-Hw ..................... Hardware Kit, T40/T46J Manuals ................................................. 1 54699 ............................ Container, Manual Storage ............................................................ 1 A630-T46J-01 ............... Manual M-T40/T46J-Ol OIMIP .................................................... 1 92376-001 ..................... Operator's Manual M-T40/46J-Ol ................................................. 1

Ref 1 2 3

71639-Hw ..................... Hardware Kit, Manual Inst ...................................................... Ref. 71639-Dwg ................... Manual Installation Dwg, T40/46J ................................................. 1 BOW39000 ................... Hardware Kit, Manual Installation ................................................ 2 BOW3140 1 ................... Container, Manual Storage ............................................................ 2

- Indicates Items Not Shown

MANUAL 92376-003 JUNE 1998

G

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92376-003 JUNE 1998

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FIGURE 11.1:Decal Kit, T40-01 • DESCRIPTION

QTY

ITEM

PART NUMBER

Ref.

25 26 *27 *28 29

71632 ............................ DecaIKit, T40-01 ...................................................................... Ref 71640 ............................ Decal Kit, T46J-Ol ................................................................... Ref. 71632 ............................ Decal Kit, M-T40-01 Essential ...................................................... 1 71640 ............................ Decal Kit, M-T46J-Ol Essential .................................................... 1 71632-DWG ................. InstallationDWG,DecaIM-T40-01 .............................................. 1 67938-080 ..................... Decal, 80 PSI Tire Pressure ......................................................... .4 67938-075 ..................... Decal, 75 PSI ................................................................................ 4 54984-004 ..................... Decal, Lift And Tie Down ............................................................. 4 56023 ............................ Decal, 7.00" High Arrow Gray ...................................................... 2 56024 ............................ Decal, 2.50" High" Forward" Gray .............................................. 2 21882-001 ..................... Decal, EI Hazard Keep Clear ........................................................ 2 21849 ............................ Decal, Unleaded Gas Only ............................................................ 1 15376-012 ..................... Decal, Diesel ................................................................................. 1 54984-007 ..................... Decal, Hydraulic Fluid ................................................................... 1 71618 ............................ Decal,LowerCautionBoom ......................................................... 2 54984-006 ..................... Decal, 110 Volt EXT To Platform ................................................. 1 21079 ............................ Decal, Lube Fitting ........................................................................ I 71795 ............................ Decal, T40 Transportation ............................................................. 1 71614 ............................ Decal, Boom Upper Caution ......................................................... 1 37958-500 ..................... Decal, 500 LB Rated Work Load ................................................. 2 56034-500 ..................... Decal, 500LBS Rated Work Load ................................................ 1 71615 ............................ Decal, Panic Stop .......................................................................... 1 38550 ............................ Decal, Platform Fall Arrest ........................................................... 2 71369 ............................ Decal, Platform Control Box ......................................................... 1 71370 ............................ Decal, Lower Control Box ............................................................ 1 71589 ............................ Decal, Error Code Turret .............................................................. 1 71617 ............................ Decal, Ground Board Lights .......................................................... 1 56033 ............................ Decal, 3.5" High Twin Stripes ........................................... 12.23LF 71763 ............................ Decal, T40 Gray ............................................................................ 2 71764 ............................ Decal, T46J-Ol Gray ..................................................................... 2 55941-017 ..................... Decal, 17x2.5" Condor Bird ........................................................ 1 55940-060 ..................... Decal, Condor 9 x 60 Gray ............................................................ 1 71768 ............................ Decal, Boom Ext. .......................................................................... 1 71767 ............................ Decal, Boom Raised Fully ............................................................. 1 71785 ............................ Decal, Rotation Stop ...................................................................... 2

-50 51

15843 ............................ Nameplate, Boom Identification ............................................... Ref. 56022 ............................ Decal, 4 x 4 .............................................................................. Ref.

-* 1 -*2 -*2 *3 *4 *5 *6 *7 *8 *9 *10 *11 *12 *13 *14 *15 *16 *17 *18 *19 *20 *21 *22 *23 24

- Indicates Items Not Shown *Indicates Items In Essential Decals

MANUAL 92376-003 JUNE 1998

•

FIGURE 11.1:Decal Kit, T40-01

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FIGURE 11.1:Decal Kit, T40-01 • DESCRIPTION

QTY

ITEM

PART NUMBER

Ref.

25 26 *27 *28 29

71632 ............................ Decal Kit, T40-01 ...................................................................... Ref 71640 ............................ Decal Kit, T46J-Ol ................................................................... Ref. 71632 ............................ Decal Kit, M-T40-01 Essential ...................................................... 1 71640 ............................ Decal Kit, M-T46J-Ol Essential .................................................... 1 71632-DWG ................. InstallationDWG, DecaIM-T40-01 .............................................. 1 67938-080 ..................... Decal, 80 PSI Tire Pressure ......................................................... .4 67938-075 ..................... Decal, 75 PSI ................................................................................ 4 54984-004 ..................... Decal, Lift And Tie Down ............................................................. 4 56023 ............................ Decal, 7.00" High Arrow Gray ...................................................... 2 56024 ............................ Decal, 2.50" High" Forward" Gray .............................................. 2 21882-001 ..................... Decal, EI Hazard Keep Clear ........................................................ 2 21849 ............................ Decal, Unleaded Gas Only ............................................................ 1 15376-012 ..................... Decal, Diesel ................................................................................. 1 54984-007 ..................... Decal, Hydraulic Fluid ................................................................... 1 71618 ............................ Decal, Lower Caution Boom ......................................................... 2 54984-006 ..................... Decal, 110 Volt EXT To Platform ................................................. 1 21079 ............................ Decal, Lube Fitting ........................................................................ 1 71795 ............................ Decal, T40Transportation ............................................................. 1 71614 ............................ Decal, Boom Upper Caution ......................................................... 1 37958-500 ..................... Decal, 500 LB Rated Work Load ................................................. 2 56034-500 ..................... Decal, 500LBS Rated Work Load ................................................ 1 71615 ............................ Decal Panic Stop ........................................................................... 1 38550 ............................ Decal, Platform Fall Arrest ........................................................... 2 71369 ............................ Decal, Platform Control Box ......................................................... 1 71370 ............................ Decal, Lower Control Box ............................................................ 1 71589 ............................ Decal, Error Code Turret .............................................................. 1 71617 ............................ Decal, Ground Board Lights .......................................................... 1 56033 ............................ Decal, 3.5" High Twin Stripes ........................................... 12.23LF 71763 ............................ Decal, T40 Gray ............................................................................ 2 71764 ............................ Decal, T46J-Ol Gray ..................................................................... 2 55941-017 ..................... Decal, 17 x2.5" Condor Bird ........................................................ 1 55940-060 ..................... Decal, Condor 9 x 60 Gray ............................................................ 1 71768 ............................ Decal, Boom Ext. .......................................................................... I 71767 ............................ Decal, Boom Raised Fully ............................................................. 1 71785 ............................ Decal, Rotation Stop ...................................................................... 2

-50 51

15843 ............................ Nameplate, Boom Identification .................................................... I 56022 ............................ Decal, 4 x 4 ................................................................................... 2

-*1 -*2 -*2 *3 *4 *5 *6 *7 *8 *9 *10 *11 *12 -*13 *14 *15 *16 *17 *18 *19 *20 *21 *22 *23 24

- Indicates Items Not Shown *Indicates Items In Essential Decals

MANUAL 92376-003 JUNE 1998

•

FIGURE 12.1:A506NissanLP/GasDualFuel(Liquid)

~

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MANUAL 923'7fH1113 JUNE 1998

'---._--/ EIIGINE FR'JIH " IE .'.

Pl'MF J':-CKET

"

FIGURE 12.1:A506NissanLP/GasDualFuel(Liquid) •

DESCRIPTION

QTY

ITEM

PART NUMBER

Ref. 1 2 -3 4 5 6 -7 8 9 10 11 12 l3 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

71729 ............................ A506 Nissan LP/Gas Dual Fuel (Liquid) ................................... Ref 51630 ............................ FilterLock FL-218 LP-Gas ............................................................ 1 68097 ............................ Valve, Gasoline ShutOff............................................................... 1 71725 ............................ lnstallationDwg, Tank Assembly, LPLiquid ................................ 1 52029 ............................ Base + 2 NO Contacts .................................................................. 1 52670 ............................ Operator, 3 Pos Rot. ...................................................................... 1 71526 ............................ HHFC Installation, A506 Nissan ................................................... 1 71729-DWG ................. lnstallationDrawing,A506-TNSSN-l ........................................... 1 02453 ............................ Tee, FP6 FP6 FP6 ......................................................................... 1 BOWlllOl-X ............... Elbow, Street 90° Brass 3/8 NPT ................................................. 3 04727 ............................ Straight, MS06 MP04 .................................................................... 2 02795 ............................ Connector, Male 114 NPT x 3/8 HC ............................................. 1 BOW24110 ................... Clamp, Hose 5/16-718 Dia ............................................................. 8 BOW36001 ................... Bolt, Hex .25-20 UNC x %/8 Lg ................................................... 2 BOW31201 ................... Nut, Hex .25-20 UNC ................................................................... 2 BOW36725 ................... Washer, Split Lock .251D .............................................................. 2 BOWI1099-2 ................ Nipple, .125 NPT x2.00 Brass ...................................................... 1 37084 ............................ Bracket Weldment, LP/Fuel Tanks ............................................... 1 BOW31144 ................... Screw, Socket Rd #10-32 UNF x .50 ........................................... 1 BOW13350 ................... Bushing, 3/8 x 1/4 .......................................................................... 1 BOW00282 ................... Connector, T 25 x .18 x .18 ........................................................... 1 BOW09757 ................... Tubing, Vacuum .25 ID Low Pressure ................................... lLF. BOW11573 ................... Hose Barb, 114 NPT x 114 ID ....................................................... 1 BOWI1100 ................... Street Elbow, 114 NPT .................................................................. 1 02458 ............................ Tee, MP04 FP04 FP04 .................................................................. 1 BOWI0838 ................... Elbow, 45° . 125NPT Street Brass ................................................. 1 BOWI3348 ................... Bushing, 114 x 118M ...................................................................... 1 67957 ............................ Filter,FuellnlineBubble ................................................................ 1 02699 ............................ Straight, MP06-MP06 .................................................................... 1 38501-076.00 ................ Hose Assembly, #06 04167 LPG .................................................. 1 66818 ............................ Hose, Bulk #10 LPG .......................................................... 2.33LF. 66833 ............................ LP Kit, Nissan H15 ....................................................................... 1 38708 ............................ Clamp, Loom 1..50 Dia.5 Hole ..................................................... 1 67280 ............................ Bosch Relay .................................................................................. 1 BOW31233 ................... Nut, Keps #10-32 UNF ................................................................. 1

51 52 53 54 55 56 57 58 59 60 61

66833-026 ..................... Switch, Vacuum Dual FueL ..................................................... Ref. 66833-010 ..................... Vaporizer Regulator Liquid ...................................................... Ref. 66833-029 ..................... Hose Barb, #06 x Male 114-19 HS ........................................... Ref. 66833-013 ..................... Clamp, Hose 3/4 to 13/4 Dia ................................................... Ref. 66833-005 ..................... Hose, 3/8 ID Fuel Line ............................................................. Ref. 66833-005 ..................... Hose, 3/8 ID Fuel Line ............................................................. Ref. 66833-023 ..................... Carburator Adapter, LPG ......................................................... Ref. 66833-012 ..................... Clamp, Hose 2 ID to 2.25 ID ................................................... Ref. 66833-007 ..................... Hose Barb, #10 x 3/8 NPT ...................................................... Ref. 66833-027 ..................... Elbow, Male 1/4 NPT x 3/8 HC ............................................... Ref. 66833-030 ..................... Hose Barb, #06 x Male MI0-1.25 JIS ..................................... Ref.

- Indicates Items Not Shown MANUAL 92376-003 JUNE 1998

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1 OF 1

CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm.

WARNING: Battery posts, terminals, and related accesories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

_DE_T_R_O_IT_D_IE_S_E_L____ ~ CORPORATION

\..\....~

CALIFORNIA PROPOSITION 65 INFORMATION TO CALIFORNIA CUSTOMERS AND TO COSTOMERS SELLING DIESEL ENGINE EQUIPMENT INTO OR FOR USE IN CALIFORNIA Proposition 65, a California law, requires warnings on products which expose individuals in California to chemicals listed under the law, including certain chemicals in diesel engine exhaust.

Obligations of Manufacturers of Diesel-Powered Off-Road Equipment. The California Superior Court has approved either of the following two methods of compliance with Proposition 65 requirements by manufactures of off-road equipment containing diesel engines. (The court order containing these provisions may be furnished on request.)

1.

On-Equipment Warning. Place the warning pictured in attachment 1 on all equipment shipped by you into or for sale in California after January 1, 1996. The warning must be in a location where it is easily visible to the operator of the equipment when (s)he is operating the equipment. The warning must be secured to the equipment. If warnings or operating instructions are provided through a digital display, you may use that method of providing the warning.

2.

Operator Manual Warning. When the operator manual is next revised or by December 31, 1995, whichever is earlier, place the warning in attachment 2 in the operator manual. The warning may be either printed in the manual or a sticker.

The warning must appear in one of the following locations. * Inside the front cover

* * * *

Inside the back cover Outside the front cover Outside the back cover As the first page of text

Under either alternative, the warning must appear in the same size, print and format as the attachment selected or be of equally conspicuous size and format. If the warning is provided in an on-screen display, the warning must contain the language in the attachment and must be provided at the time of or in connection with ignition in the same manner as other safety warnings electronically communicated on screen.

Obligation of Resellers of Diesel Engines. This letter must accompany any loose diesel engine sold in California.

Should you have any questions, please call Detroit Diesel Corporation, Mr. John F. Farmer on (313) 592-7111, Fax (313) 592-5014.