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A div.

of TIME Manufacturing Company


SELF-PROPELLED
ELEVATING WORK PLATFORM

MODEL V2033XL, V2033


Serial Number X935-97051

OPERATOR'S, MAINTENANCE,
ANO PARTS MANUAL

SHIPPING ADDRESS MAl LING ADDRESS

CONDOR® CONDOR®
A DN. OF TIME MFG. CO. A DN. OF TIME MFG. CO.
8300 IMPERIAL DRIVE P.O. Box 21447
WAco,TEXAs76712 WAco,TEXAs76702-1447
(817) 420-5200 (817) 420-5200

MANUAL 92350
JANUARY 1997
SIN X935-9705 I

" ,
A div. of TIME Manufacturing Company

SELF-PROPELLED
ELEVATING WORK PLATFORM

MODEL V2033XL, V2033


Serial Number X935-97051

OPERATOR'S MANUAL
~\ \ \

SHIPPING ADDRESS MAILING ADDRESS

CONDOR® CONDOR®
A DIV. OF TIME MFG. co. A DIY. OF TIME MFG. co.
8300 IMPERIAL DRIVE P.O. Box 21447
VVACO, TEXAS 76712 VVAco,TEXAS 76702-1447
(817) 420-5200 (817) 420-5200

MANUAL 92350.001
JANUARY 1997
SIN X93S-970S 1
i

INTRODUCTION

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

THIS MANUAL MUST BE RETAINED ON THE CONDOR® ATALL TIMES.

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

It is YOUR RESPONSIBILITY to follow procedures while operating this CONDOR®. The


manufacturer of this CONDOR® cannot control the wide range of applications that may be
carrying out a variety of jobs. Therefore, IT IS THE USER'S RESPONSIBILITY to .
personnel when making decisions regarding the intended use of this CONDOR®.

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

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

DO NOT ALTER OR MODIFY THIS CONDOR® WITHOUT PRIOR WRI7TEN


APPROVAL FROM THE MANAGEMENT OF CONDOR Div.

SERVICE ~ MAINTENANCE

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

MANUAL 92350-001
JANUARY 1997
SIN X935·97051
ii

A div. of TIME Manufacturing Company


CONDOR® SERVICE INFORMATION

1. If you need assistance or have any service or maintenance questions, CONDOR®


service and parts personnel are always available by phone or fax. The telephone
numbers are:

(817) 420-5200 Telephone


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

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

3. Service and maintenance are not a substitute for trained, qualified service technicians.
CONDOR® conducts service schools on a continuing basis. Call any of our service or
sales persons for a schedule. Remember, training of mechanics is the responsibility of
their employer, but CONDOR® Service Schools help you provide this training.

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

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

MANUAL 92350-001
JANUARY 1997
SIN X935-97051
iii

TABLE OF CONTENTS

INTRODUCTION •.•••••.••.•••••••••••••••••••••••••••.••.•.••••••••••••••••••••••••••••••••••••••••.•••••••••••••••••••••••••••••••••••••••••••••••••• ;
SERVICE IN'FORMATION •.••••••••••••••••••••••••••••••••••••••••••••••••.••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• u
TABLE OF CONTENTS •••••••••••••••••.•••••••••••;•••••.••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• _••••••••••_•••• iii

I. P"REPARATION, IN'SPECTION,AND MAIN'TENANCE •••••••••••••••••••••••••••••••••••••••••.•••••••••••••••••••• 1

A. Overall Machine Condition ....................................................................................................... 1


B. Lower Control Station ............................................................................................................... 1
C. Emergency Lowering ................................................................................................................ 1
.D. Platfonn and Upper Control Station .......................................................................................... 2
E. Hydraulic System ...................................................................................................................... 2
F. Batteries ..................................................................................................................................... 2

II. MACHIN'E OPERATION •••.•••.••.••••••••.••••••••.•••...•••••.•••••••••••••••••••••.•••••••••••••••••••••••••••••••••••••••••••••••••••• 2

A. Rated Work Load ............................... :...................................................................................... 2


B. LowerControls .............................. :........................................................................................... 2
C. Upper Controls ........................................................................................................................... 3
D. Emergency Lowering ................................................................................................................ 3
E. Lift-up Entry Gate ..................................................................................................................... 3
F. Deck Extension ......................................................................................................................... 5
G. Removable Upper Control Box ................................................................................................. 5

m. MO'VING FR.OM JOB-SITE T.O JOB-SITE ••••.•••••••••••••••••.•••••~•••••••••••••••••••••••••••••••••••••••••••••••••••••••• 5


A. Loading and Unloading ............................................................................................................. 5
B. Ramp Method .............................................................................................................................. 5
C. Forklift Loading and Unloading Method .................................................................................. 5
D. Transporting .............................................................................................................................. 6
E. Freewheel Operation ................................................................................................................. 6

IV. STORAGE •••••••••••••••••.•.•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• _•••••••••••••••••••••••••••••••••••••••••• 6

APPENDJ:X.: DECALS ILLUSTRATION .••••••••••••••••••••••••.•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 8

ANSIISIA A92.6 -1990 MANUAL OF "RESPONSmILITIES

MANUAL 923S0'()()1
JANUARY 1997
SIN X9JS-97OS 1
IMPORTANT: A COPY OF THE ANSI/SIA A92.6 - 1990 MANUAL OF RESPONSmILITIES IS
ATTACHED TO TmS OPERATOR'S MANUAL. IT CONTAINS IMPORTANT OPERATING
INFORMATION FOR TmS CONDOR®. READ IT BEFORE OPERATING TmS CONDOR®.

I. PREPARATION. INSPECTION. AND
MAINTENANCE STEERING:

The condition of this CONDOR® is very


important, as it directly affects the operator as D Check steering link to knuckle
connections and steering cylinder for
well as others. The operator must perform a proper and secure mounting.
thorough walk-around inspection each day prior to
operating the CONDOR®. Any damage or faulty BRAKES:
operation should be reported immediately.
A DO NOT OPERATE tag outlining the
problem should be attached to the lower control D Check for abnormal wear between
deadbolts and hubs, and for loose or
station and any discrepancies should be corrected missing bolts, nuts, and pins.
before operating this CONDOR®.
DECALS:
KNOW TmS CONDOR® AND ITS
CAPABILITIES. REPORT ANY UNUSUAL
OPERATION, SUCH AS ERRATIC SWAY OR D Check that all decals and warning
signs are in place and are clearly
MOTION OF THE ARMS OR PLATFORM. legible.

Some major areas to check daily are:


CAUTION
A. OVERALL MACmNE CONDITION Defective components, structural damage,
missing parts, and equipment malfunction
MISSING, BROKEN, OR DAMAGED jeopardize the operator and other
PARTS: personnel and may cause excessive
damage to the unit. A poorly maintained

D Check cylinder mounting pins, pivot pins,


pin retainers, bearing pads, bolts, and nuts.
CONDOR® could become the greatest
operational hazard you may encounter.

STRUCTURAL: .

D Check for damaged or cracked welds


on structural components-arms, platform,
B. LOWER CONTROLS

chassis.
D Check that all functions operate
properly, that switches return freely
TIRES AND WHEELS: to neutral position. Do not operate
the CONDOR® with sticking controls

D Check for cracks, tears, cuts, or missing or


loose lug nuts (a rust line running down the
rim from the lug nut indicates a loose lug C. EMERGENCY LOWERING
nut).
D Check emergency lowering
function by pulling red T -handle.

MANUAL 92350-001
JANUARY 1997
SlNX93S-970SI
• D. PLATFORM AND UPPER
CONTROL STATION
D Keep battery tops clean and dry.
D Check that lift-up entry gate is functional
and that chain is secure. D Keep vent caps tightly in place.

D Re-check the structural condition of the D Check that battery cable connections are
tight and clean and free of corrosion.
platfonn-pins, railings, and floor.

D Check for missing bolts & nuts - Replace D Make sure the battery charger and the
indicator lights and meter are not dam-
before operating.
aged.

D Check that extension deck is locked in


place.

o Check function of red button. It disconnects


power to the controls and, when pushed,
ll. CONDOR® OPERATION

CAUTION
stops all powered functions. CONDOR® MUST BE OPERATED
ON FIRM, LEVEL GROUND ONLY.

D Check that drive control lever returns freely


to neutral. A. RATED WORK LOAD

The platform will support a combined weight


E. HYDRAULIC SYSTEM equal to the unit's rated work load-including
personnel, tools, and equipment-throughout the
D Check the hydraulic tank fluid level with
the platform all the way down. Fluid must
working envelope of the CONDOR®.

be visible in sight glass. Add Shell Tellus Rated work load, on extension deck only, is not to
T-32 Hydraulic Fluid if required. Ensure exceed 250 lbs. (113 kg) including one occupant.
that the breather cap is clean and in place Total rated work load is not to exceed 750 Ibs.
on the tank. (340 kg) including two occupants.

D Check for hydraulic leaks at all fittings B. LOWER CONTROLS


and valves.
CAUTION
D Check all hydraulic hoses and tubes for
damage and kinks.
ARM STAND MUST BE USED WIlEN
MAINTENANCE PERFORMED ON
CONDOR® REQUIRES SCISSOR
F. BATTERIES ARM'S TO BE RAISED.

CAUTION 1. To engage arm stand, raise platform,


Keep flame, sparks and metal away then rotate stand until it hangs vertically.
from the batteries. Lower the platform until the arm stand rests
on the cross tube on the frame. Maintenance
D Check Electrolyte level daily in each cell.
Ifnecessary, add clear, odorless, mineral
can now begin.

free water to bring the level to 112" above


the top of the separators, or to the Level
Indicator (if equipped), in each cell. Only
add water after charging cycle is complete.

MANUAL 923S()'()()1
JANUARY 1997
SIN X93S·970S 1
2. To store arm stand, raise platform so that Select desired drive speed with the "high/low!
arm stand can be rotated until it rests on the creep" switch. (A limit switch automatically cuts
stop provided on the scissor arms. drive speed to "creep"as the platform is raised.)

Tum "controls" switch to "lower" position, to To drive forward or reverse, squeeze lever switch
operate from ground. on handle, and push or pull handle in the intended
direction of travel. Release lever switch to stop
In an emergency, push red button. To operate, movement. Letting go of handle also will stop
button must be pulled out. (Also, if applic- movement.
able, battery disconnect switch must be "on" to
operate.) Brakes are automatically released whenever the
drive handle is moved. Let go of the handle to
Push "raise" or "lower" switches to move automatically set the brakes.
platform.
To improve drive traction, depress and hold
Tum switch to "upper" position, to operate "positraction" switch. (This will automatically
from platform. cut-out high drive speed.)

To steer left or right, squeeze lever switch on


C. UPPER CONTROLS handle, and depress rocker switches on top of
handle in the intended direction oftravel. Steering
Turn "controls" switch, on lower control panel, to is not automatically self-centering. Be sure the
"upper" position to operate from platform. steering wheels point in the direction you want
before letting go of the steer switch.
NOTE;
Chain should be snapped in place across entry. D. EMERGENCYLOWERlNG
Gate should be lowered and closed when operating
CONDOR® from upper controls. For emergency lowering, grasp the
Tee-handle located below the rear bumper.
In an emergency, push red button. To operate from Gently pull to lower the platform. Release
platform, both red buttons, on lower and upper handle to stop lowering.
controls, must be pulled out.

To raise and lower platform, push and hold the E. LIFT-UPENTRYGATE


green "power" button, and push the "raise" or
"lower" button. Release buttons to stop movement. To load 4' wide sheets, lift entry gate up until
lockpins snap in place. After loading, pull at
both lockpins, to let gate fall into place. Keep
gate down, except for loading and unloading.

MANUAL 92350-001
JANUARY 1997
SIN X93 5-9705 1
.. LOWER CONTROLS

RED EMERGENCY
STOP BUTTON ----~-
RAISEILOWER

-+-_~
BUTTONS
OPERATING _ _ _
INSTRUCTIONS I .

CONTROL STATION_--.2::::,~--'::::':'--!~
SELECTOR SWITCH
CONTROL
CIRCUIT
BREAKER

upPER CONTROLS
RIGHTILEFT
STEER
ROCKER
SWITCH

POSITRACTION
SWITCH DRIVE
CONTROL
HANDLE

REDEMERGENCY_---+-~~~~~~
STOP BUTTON

~
'i RAISEILOWER
~Ii~ BUTIONS
! HI!
:t/~'Vl!
! II!

~ ,
HIGHILOW/CREEP
DRIVE SPEED
SELECTOR POWER
SWITCH BUTTON

MANUAL 92350-001
JANUARY 1997
SIN X93S-970SI
F. DECK EXTENSION

Lift lockpin, at right side of deck, and push


B. RAMP METHOD

Ensure that the ramp is sufficiently strong to



extension deck forward (or out). When fully support the weight of the CONDOR®.
extended, lockpin will automatically lock. To
retract, lift lockpin and pull extension deck all the The ramp should be set, not steeper than this
way back untillockpin automatically locks CONDOR®'s rated gradeability, which for Model
extension deck in place. V2033/XL is 14° or 25%, or a rise of30 inches in
a run of 10 feet.
CAUTION
Do not lower extension deck onto Before driving the CONDOR® on a ramp, lower
people or any objects! the platform completely, test the drive/steer
controls and the brake system.

G. 'REMOVABLE' UPPER CONTROL CAUTION


BOX Select "low" drive speed,
not "high" and not "creep".
Unsnap overcenter latch at bottom of upper control
box and pull plug out of receptacle. Bend cable so The front of the CONDOR® should be uphill,
that plug faces down. Snap cover onto receptacle meaning: Drive forward uphill and reverse
at bottom of box. Lift box and store it in a secure down.
place to prevent unauthorized use of the
CONDOR®. Keep CONDOR® in alignment with the ramp
during loading and unloading procedures.

III. MOVING FROM JOB-SITE TO


JOB-SITE C. FORKLIFT LOADING AND
UNLOADING METHOD
A. LOADING AND UNLOADING
Ensure that the forklift has sufficient capacity to
Although this CONDOR® is somewhat small handle the weight of this CONDOR®.
compared with larger construction equipment, it (SEE III. A. )
requires the same care and attention in loading,
transporting, and unloading. At no time should its This CONDOR® can be lifted from the rear,
size,or weight be under estimated. Before using the forklift pockets provided.
loading or unloading, inspect the CONDOR® for
any physical damage or defects. NOTE THAT THE CENTER OF GRAVITY
IS 50 INCHES FROM THE END OF THE
The means by which you load or unload the CONDOR®.
CONDOR® should be of sufficient strength to
withstand its weight. The CONDOR® should only be raised to a height
sufficient to clear any obstructions.
MODEL WEIGHT(#) WEIGHT(KG)
2633 3,3001bs. 1496 kg' Keep forklift travel to a minimum, carry
CONDOR® as close as possible to the ground,
and set it down gently.

MANUAL 92350-001
JANUARY 1997
SIN X935-9705 1
• D. TRANSPORTING

This CONDOR® can be easily transported


between job-sites if the following rules and
procedures are followed:

Block all wheels to prevent forward and reverse


motion.

Tie down the CONDOR® with chains or cables,


running them through the tie-down holes only. Do
not tie down over the guardrails or entry steps.

Always tum the power off at the lower control


station.

E. FREEWHEEL OPERATION

CAUTION
This CONDOR® must be on firm, level
ground when releasing the parking brakes.
To put the CONDOR® into freewheel mode,
use the brake release handles on the rear axle.
One handle is on the front side of the axle and
the other is on the rear side of the axle. Tum
each release handle 900 and at the same time,
slightly rotate it. The brakes are now released.
(Released brakes will automatically reset the
next time forward or reverse drive is used,
then will engage when drive is stopped;)

Never exceed 5 mph when moving the


CONDOR® in the freewheel mode.

IV. STORAGE

When you get out of the platform, leave it all the


way down.

CAUTION
Never park the CONDOR®
with platform raised.

MANUAL 92350-001
JANUARY 1997
SIN X93S-970S 1
NOTES •

MANUAL 92350-00 1
JANUARY 1997
SIN X935-97051
.. APPENDIX: DECALS IllUSTRATION

WI,-----IJli SEC71C~ a-2


PARTIAL
SECTION A-A

22 23

FRONT

13

14~ ,
I ., •

~~8
il~!
LJ J
BACK

MANUAL 92350-001
1ANUARY 1997
SIN X935·97051
APPENDIX: DECALS ILLUSTRATION
.,
ITEM PART NUMBER DESCRIPTION QTY

Ref 55487 ............................ Decal Installation ...................................................................... Ref.


*1 54984-00 I ..................... Decal, Upper Oper. Instructions " .................................................. 1
*2 54652-001 ..................... Decal, Itemized Caution Notes ...................................................... 1
*3 54984-002 ..................... Decal, Rated Work Load ............................................................... 2
*4 55480-002 ..................... Decal, Lower Oper. Instructions ................................................... 1
*5 54652-003 ..................... Decal, Guardrail/Chain Caution .................................................... 1
6 54984-007 ..................... Decal, Hydraulic Fluid .................................................................. 1
*7 54652-002 ..................... Decal, Arm Stand Caution ............................................................. 1
*8 54984-005 ..................... Decal, Rear Bumper ...................................................................... 1
*9 66973 ............................ Decal, Electric Hazard Keep Clear ................................................ 2
10 54984-006 ..................... Decal, 110 Volt Ext. To Platform .................................................. 1
11 69473-002 ..................... Decal, Die-Cut, CONDOR 3.45 x 23 ............................................ 2
12 54985 ............................ Decal, Die-Cut ............................................................................... 2
13 55291 ............................ Tape,OrnlRed3" .............................................................. 17.75LF.
* 14 55480-001 ..................... Decal, Lower Controls .................................................................. 1
15 53259 ............................ Tape, Non-Skid 6"W Black ................................................ 1.67LF.
16 66921 ............................ Coating, Non-Skid Jet Black ................................................ 27GL.

21 ...................................... Nameplate, Scissors Ident. ....................................................... Ref.


*22 54976-001 ..................... Decal, Upper Control Box Top ..................................................... 1
*23 54976-002 ..................... Decal, Upper Control Box Front ................................................... 1
* 55487-001 ..................... Decals, V2033 Essential ........................................................... Ref.

- Indicates Items Not Shown


*Indicates Included In Essential Decals

MANUAL 92350-001
JANUARY 1997
SIN X93S·970S 1
APPENDIX: DECALS ILLUSTRATION

1 i OPERA TING INSTRUCTIONS


,.+:I :NU:~ "~\;~;;~~~~~, S~'~~~,\~; ~~:~r:~~.C~~~~~~R:~~~;~;~~ ~~:~;~~\/J3S~~;~R~~ ~~~~~\~~. "~0~O~\~::~7":;RV.
AND ON ~::>"ER CONTROLS, 'lUST BE PUL'-.::: Oi..'~.
I.... _ . . .......... ~ ~"....... ,.....,....~_ .. ~" ,,_..,...~.
J. 10 RAISt.. ...:..ND
I .,..-.....
Lv',\!::"'K
....
Pt...A p-
..........
J!"(:VI. r-'u~H Ai\:.; '-'UL....
_.r-
. .... ::,. u+<r..:.~
_,.....H
i-""O'.. c.""( Bu!. '....... , .:.~c ;:: . . 5....; iHE
.,
RA..S:::
..

I OR "lO'::::q" BUTTON. RELE.A.5E BU"TTONS TO S,OP V;OVt:MEN~.


ll. SELECT JRVE SPEED v'iITf-! TH:: "HiGH/LOt//eR::::?" s;·,nCH.
A liMIT S:.. TCH AUTOMA TICALl Y CUTS BACK Tri~ SpEED AS Ti-IE PLA T;ORM /S q:. SED.


,
TO DRIVE "JRWARD OR REvERSE, SQUEEZE
IN THE '.. -~NDED DIRECTION OF 7RAVEl.
~.EVER
S:ir,CH ON HANDLE, A.ND ;::\.:5- OR C\.;,,_ YANDLE

, RELEASE _:::VER SW:TCH TO STOP MOVEMENT. _:::TT:NG GO O=- HANDLE ALSC;,:,-_ STOP V::: '::::V:ENT.

• BRAKES "RE AUTOMAT/CALLY RELEASED WHENEVER 7HE DRIVE HANDLE :S 'lOVE:).


lET GO ::::- THE HANDLE TO AUTOMA TICALl Y SET T;-,t: BRAKES.
• TO IMPRC'/E DRIVE TRACTION. DEPRESS AND HOLD "cOS/TRACT'ON" S:,:TCH.

! THIS WILL A.UTOMA TICALL Y GuT-OUT HIGH S;::::E9.


• TO STEER :..EFT OR RIGHT, SQUEEZE lEVER S:·.nCH SN hANQlE. AND DEPRESS =:::;::;KER S:. ~::;HES
ON TOP CO' HANDLE iN THE iNTENDED DIRECi:ON C= TRAVEL..
STEERING S NOT AUTOMA TiOAlL Y SELF -CE~iTERING. 3E SURE THE S-:-t:i::RiNG :.'-::::::_S PO.\ T
I, iN THE J ~~CTION YCU .\i~.NT 3E;:-CRE L.E:TT!NG GO J; 7:-:E ST::t:R S":;:-:-CH.

2 Iit, CAUT~ON I
1. DO NOT~AjfE:';iS CONDOR" UNTIL YO:.; CiAVE BEEN PROPERLY TRAINED AND HAVE
COMPLETELY READ AND UNDERSTOOD THE OPERATOR'S MANUAL THAT IS LOCt..~ED 0\ -:-:"'S CONDO,,:"
2. PRIOR TO EACH DAY'S 'JSE. CHECK TO MA'<E SJRE ALL FUNCTIONS ARE C=:::R4 T'NG "'RC"ERL Y.
=:ERFORM ALL iNSPECTIONS REQUIRED BY S:::C;:ON 6 OF TriE ANSI 92.5 S-!"V)ARD.
3. DO \0'" uSE THE CONCOR"'. ':- T IS MALi'":';\C;:'JNING OR OAMAGED iN A",v :.~ v,
OR ,:- :HE WIND 8LO::S OVER i 5 MPH.
4. DO \)OT DRIVE ON A SLOPE UNLESS THE PL.ATFORM IS FULLY LO.vERED.
5. RAISE THE PLA TFORM ONLY WHEN THE CO\:DOR'" IS ON FIRM. lEVEL GROUNLi.
6: ALI'IA YS LOOK IN THE DIRECTION IN '/IHICI-i ThE PLATFORM IS MOVING.
\"ATC!-i FOR, AND AVOID, OVERHEAD 06STRUCT'ONS AND ANYTHING ELSE TCiAT MAY STRXE
DlA TFORM, PERSONNEL, OR CONTROLS.
7. THIS ::ONDOR'" IS NOT ELECTRICALLY iNSULA TED.
MAINTAIN SAFE CLEARANCES FROM ElECTR!CAl POWER LINES.
8. FOLL(W INSTRUCTIONS IN OPERA TOR'S MANUAL WHEN SERVICING 6A TTERiES.
EACH REPLACEMENT 8ATTERY \1UST i'lEIGH Ai LEAST 55 Ibs. DRY AND 66 1::5. ,VET.
9. REPc..A.CEMENT TIRES MUST BE SAME AS FACTORY ORIGINALS.
10. iN CASE OF A.N EMERGENCY. PUSH THE ;:(E!:) ":::V,ERGENCY STCP" BUTTON.

MANUAL 92350-001
JANUARY 1997
SIN X93S·970S 1
APPENDIX: DECALS ILLUSTRATION

3
RA TED WORK LOAD
;: (""I:: =-X~::-N:'C::;·"N,: j'.:-;"/ ,"'.\': v
JI\J _ 11-' ....... ,'-..,.;, -',-,-",r'\ '-"i\JI...- ~

I;S 25CLas :J~ C>~E JCC~:::A.\JT.


TO~A~ RAT~D !.ORK ~JAJ
:S -::-SOL8S OR T'i.'O OCCUP.L\NTS.

.
GLARDRAILS AND SAFETY
C:-iil,INS IvlUST BE SECl..;KED
~~D USED AT ALL TIVES
5 4 552-CC.3

6
HYDRAULIC
FLUID 7
54984-CD7i
!~ Cfo\UT~ON I
STAND CLEAR
UNLESS ARM STAND
is !\i PLACE
54652-CC2

8
FORKLIFT EMERGENCY LOWERING BRAKE RELEASE FORKLIFT
;>ULL T-HANDLE. TO LOWER PLA TFORM. ONLY ON FiRII. LEVEL GROUND.
POCKET RELEASE HANDLE TO STOP MOVEMENT. ROTATE BOTH LEVERS TO RELEASE BRAKES. POCKET
Icr:p,

MANUAL 92350-001
JANUARY 1997
SIN X93S-970S1
APPENDIX: DECALS ILLUSTRATION

ELECTROCUTION HAZARD
KEEP CLEAR
DEATH OR SERIOUS INJURY CAN RESULT FROM
CONTACT WITH THIS EQUIPMENT OR VEHICLE
IF IT SHOULD BE ELECTRICALLY CHARGED.
21882-001

THIS MACHINE IS NOT INSULATED


ELECTROCUTION HAZARD
MAINTAIN SAFE CLEARANCES FROM ELECTRICAL LINES AND
APPARATUS. YOU MUST ALLOW FOR BOOM SWAY, ROCK OR
SAG AND ELECTRICAL LINE AND LOAD SWAYING.

THIS AERIAL WORK PLATFORM DOES NOT PROVIDE


PROTECTION FROM CONTACT WITH OR PROXIMITY TO AN
ELECTRICALLY CHARGED CONDUCTOR.

YOU MUST MAINTAIN A CLEARANCE OF AT LEAST 10 FEET


BETWEEN ANY PART OF THE WORK PLATFORM OR LOAD AND
ANY ELECTRICAL LINE OR APPARATUS CARRYING UP TO
50,000 VOLTS. ONE FOOT ADDITIONAL CLEARANCE IS
REQUIRED FOR EVERY ADDITIONAL 30.000 VOLTS OR lESS.
DEATH OR SERIOUS INJURY WILL RESULT FROM CONTACT OR
INADEQUATE CLEARANCE.

MANUAL 92350-001
JANUARY 1997
SIN X935-970SI
APPENDIX: DECALS ILLUSTRATION

10 110 VOLT
EXTENSION TO j
170PERAT1NG iNSTRUCTIONS)
PLATFORM
.7CJ"N "CONTRD,-S" S1i;TCH is "~::.::,," :>:;S·7:D:\; •.
549r!4-CC6~
-0 OPERATE ;:-:;:;::;)/. GROUND.
•• N AN EMERGE"GY, F'USH REO "\J~~S".
, -:-0 C~ERA TE. 50 "'!"TON MUST 8E PUL_::O C>"::.
'ALSO, iF APPU:AtlLE. BA TTERv D:S::::',,;::::
SWITCH MUST B[ "eN" TO DP~RA TE.~

'.• PUSH "RAISE" SR "LOWER" 81.: 7 '01\S


i TO MOVE PLA TFDRM.
i. 'uRN SWiTCH TO "UPPER" POS!7ION
,0 OPERA TE rRC~~ PLATFORM.

21 8300 ;;VDERIAL DR'VE o


WACC, -:::::XAS 76 7~ 2

I MANUFACTL:RED !N U.S.A. I ! SER!AI 0,10.


;=1 C=O=N=D=O=R==M=O=D=E=L==2=5=3===3====::::! i RATE':) WORK· OA:: 750#

! PLATFORM Ht.IGHT 20'-0" i H':"D. DRES:::,0R=- 2.700 DS!


I SYSTEM VOL IAGE 24 V. DC
Tf-!,S UNIT IS NOT ELECTRICA:....L Y INSULA -'-E::.
THIS SELF-PROPELLED ELEVATING WORK PLAT::-ORM CON=-2RMS
o TO ALL APPLICABLE REQUIREMENTS OF ANSi A92.6-1990 0
51.340

IpOSITRACTION I

22
EMERGENCY

0~
23

10
I

I
I EMERGENCY
'I
I

~
, --------,\
~ (F~D "; I

~IGH IJ~~Rli
PLATFORM

I RAISE
i
I

I
\ i "C/ \ I
) lOW

ILOWERI
! ~CREEP \ REVERSE) I
,
I
I
I
IDRIVE SPEED ,.".-01,,1
CONTROLS I
/\UPPER I i POWER RAISE
24
I OFF! '.

\ / I
I ~LOWERi
I
i
I f'\
1...,.-001 i i \J
I
15.4976-002
LOWER

MANUAL 92350-001
JANUARY 1997
SIN X93S·970S 1
A div. of TIME Manufacturing Company

SELF-PROPELLED
ELEVATING WORK PLATFORM

MODEL V2033XL, V2033


Serial Number X935-97051

MAINTENANCE MANUAL

SHIPPING ADDRESS MAILING ADDRESS

CONDOR® CONDOR®
A my. OF TIME MFG. co. A DN. OF TIME MFG. CO.
8300 IMPERIAL DRIVE P.O. Box 21447
VVAco,TEXAs76712 VVAco,TEXAs76702-1447
(817) 420-5200 (817) 420-5200

MANUAL 923S0-002
JANUARY 1997

SIN X93S-970S I
i
INTRODUCTION

The primary purpose ofthis manualis to provide the user with a thorough understanding ofthe proper
operating procedures necessary to comply with the intended use of the CONDOR®, and to provide the
infonnation necessary to maintain and service the CONDOR®.

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

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

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

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

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

DO NOT ALTER OR MODIFY THIS CONDOR® WITHOUT PRIOR WRITI'EN APPROVAL


FROM THE MANAGEMENT OF TIME MANUFACTURING-CONDOR DIVISION

SERVICE & MAINTENANCE

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

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

A div. of TIME Manufacturing Company


~, ••
CONDOR®SER~CEThWORMATION

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

(817) 420-5200 Telephone


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

2. There are numerous written Maintenance Procedures available for this CONDOR®.
These procedures are available through the Condor Division Service Department to anyone
who requests them.

3. Service and maintenance are not a substitute for trained, qualified service technicians.
Calavar conducts service schools on a continuing basis. Call any of our service or sales
persons for a schedule. Remember, training of mechanics is the responsibility of their
employer, but Condor Division Service Schools help you provide this training.

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

CONDOR DIVISION

8300 IMPERIAL DRIvE. P.o. Box21447, WAco,TExAs 76702-1447-817-420-5200, 817-666-4544 FAX


iii

A div_ of TIME Manufacturing Company

Condor® Self-Propelled Booms and Scissors


WARRANTY

Time Manufacturing (Condor Division) warrants to the purchaser that each new aerial work platform made
by Condor Division is free from defects in material and workmanship arising under normal use and servi~
in the case of major weldments, (chassis, turret, and booms), for a period of five (5) years after the original
shipment of the aerial work platform from Condor Division's plant; and in the case of all other parts, for a
period of one (1) year after the aerial work platform is placed in service or two (2) years after the original
shipment of the aerial work platform from Condor Division's plant, whichever comes first.

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

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

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

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

This Warranty is in lieu of all other warranties, expressed orimplied, including but not limited to warranties
of merchantibility and fitness for a particular purpose. Any applicable implied warranty shall be limited in
duration to the warranty period.

8300 ImperillDrive, P.O. Box 21447, Waco, Texas 76702-1447-817-666-4S4S,817-666-4S44 FAX

Form No.S13-3M-392 Effective Dale 9/1190


Printed in U.S.A
EffectiyeJaDuaryl,1993

WARRANTYPRQGBAM

Warranty is a function of a manufacturing company to back up the product it manufactures. It is a


guarantee against defects in design and workmanship ofcomponents utilized in the product, and is offered
for a fixed period of time following the purchase of the product by a customer.

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

A. WARRANTY PERIOD

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

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

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

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

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

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

The submittal of a warranty claim against a stock machine constitutes it as being "in
service," initiating the warranty period.
B. PRE-DELIVERY INSPECTION SHEET (p.D.I.)

1. Each Self-Propelled Boom or Scissor CONDOR® shipped from Time Manufacturing-


Condor Division's facility will have a Pre-Delivery Inspection (P .0.1.) sheet enclosed in
the Safety Manual holder tube.

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

3. Failure to complete the P .0.1. sheet and return itto Condor Division within the time frame
given will result in voiding the Warranty on the CONDOR® .

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

C. ITEMS NOT COVERED UNDER WARRANTY

Some components are used on the CONDOR® which are not warranted by Condor Division.
However, these are warranted by the component manufacturer. Some of these are:

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

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

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

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

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

6. Troubleshooting: Troubleshooting is not covered or reimbursable. However, Condor


Division Warranty will cover reasonable labor charges for the removal and replacement
of defective components.
D. PROCESSING OF WARRANTY CLAIM

During the Warranty Period, should a component failure be encountered within the guidelines of
the Condor Divison Warranty Policy, the following procedure is to be followed:

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

a. Issuing an order to our Parts Department through normal channels, which


entails your being invoiced.

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

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

c. Although not recommended, you may purchase the part locally. When this is
done, a copy of the purchase order or receipt MUST accompany the claim.
Condor Division has the option to ship a replacement part at no charge ifthe local
cost would be greater, in lieu of issuing credit for locally purchased parts.

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

2. Complete the Warranty Claim as noted in the "Warranty Claim Procedure" section.
Provide as much information as possible to enable Condor Division to thoroughly
evaluate the claim and process it in the shortest amount oftime possible.

NOTE;
WARRANTY CLAIMS Wll..L NOT BE ACCEPTED BY CONDOR DIVISION
AFTER 45 DAYS AFTER FAILURE

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

E. RETURN AUTHORIZATION

1. If a component is found to be defective within the normal guidelines ofthe Warranty, a


Warranty Claim Form must be completed.

2. It will be necessary for you to call the Condor Division Service Department and ask to
be issued a Return Authorization (R/A) number. You will be asked for a Dealer Claim
Number. As noted in Section 2, Item A, ofthe Warranty Claim Procedure, this isanumber
assigned by the dealer for the purpose of tracking the claim, as there may be more than
one claim for the same CONDOR®. The R/A number issued must be logged in the
appropriate section of the claim form, and the gold copy (RIA) of the form must be
returned with the parts being returned.
NOTE:
DO NOT SHIP ANY RETURN PARTS WImOUT
A RETURN AUTHORIZATION (RIA) NUMBER

Doing so may result in parts getting lost in the system and may delay processing the claim,
or may cause denial due to the time element of the claim.

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

4. All parts claimed under Warrrantywill be required to be shipped back to Condor Division
FREIGHT PREPAID. No freight collect shipments will be accepted.
CONDOR® Model V2033XL, V2033

NUUNTENANCENL\NUAL

TABLE OF CONTENTS

INTRODUCTION ..................................................................................................................... i
CONDOR® SERVICE INFORMATION .............................................................................. ii
SELF-PROPELLED W ARR.AN"TY ........................................................................................ iii

Table of Contents ...................................................................................................................... 1

Specifications ............................................................................................................................ 3

Recommended Tool List ........................................................................................................... 4

Serial Number Location ............................................................................................................ 5

Serial Number To Model Designation ...................................................................................... 6

Hydraulic System Description .................................................................................................. 7

Pressure Adjustment Procedures ............................................................................................ 11

Electrical System Description ................................................................................................. 15

Machine Options Description ................................................................................................. 19

Assembly Diagrams Section .........................: ......................................................................... 23

Battery Service ........................................................................................................................ 45

Preventive Maintenance ........................................................................................................... 53

Hydraulic Fluid Specifications ......................................................................... ;..................... 63

Battery Charger Troubleshooting Guide .............................................................. ;................. 65

Bolt Torque Chart ................................................................................................................... 75

MANUAL 92350-002
JANUARY 1997
SIN X935·9705 I
• NOTES

MANUAL 92350-002
JANUARY 1997
SIN X935-9705 I
SPECIFICATIONS
SPECIFICATIONS

V2033XL

Maximum Working Height 26 ft.
Platform Height 20 ft.
Stowed Platform Height 39.5"
Overall Length 93"
Overall Width 33"
Overall Height 79"
Overall Height With Rails Removed 50"
Platform Size 92.5" x 30"
Platform Capacity 7501bs.
Gross Weight 3,3610Ibs.
Power System 24 volt DC
Battery Capacity 235 amp hour
Number of Batteries 4
Battery Voltage 6 volt
Battery Charger 25 amp
WheelBase 75"
Tires 16x5
(Solid Rib)
Inside Turning Radius 24"
Drive Speed .7511.5/3 mph
Gradeability 25%/14°
LiftlLower Time 35/30 sec

OPTIONS

* Battery Condition Indicator * MotionIMovement Alarm


* Strobe Light * Descend Alarm
* 250 Amp Hour Deep Cycle Batteries * 5° Slope Alarm
* Hour Meter * Low Volt Waming/Interrupt Battery
* Travel Alarm Protection System
* Key Switch

The CONDOR® Model V20331XL is designed and built to conform to Condor Div. understanding
and interpretation of all applicable OSHA rules and regulations as well as ANSI standards:

ANSI Standard A92.6 - 1990 ................... Self Propelled Elevating Work Platform

CAUTION

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

MANUAL 923S0-002
JANUARY 1997
SIN X93S-970S I
• RECOMMENDED TOOL LIST

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

1 each Volt/Ohm Test Meter


1 each Hydraulic Flow Meter, 0-10 GPM
1 each Hydraulic Flow Meter, 0-50 GPM
1 each Hydraulic Quad Meter Pressure Gauge
1 each Battery Hydrometer
1 each Battery Load Tester
1 each 112" Drive Torque Wrench, 0-250 ftIlbs
1 each Pry Bar
1 each Strap Type Filter Wrench
1 each Grease Gun
1 each Hammer, 24 oz.
1 each Vice Grip Pliers
1 each Combination Wrench Set, 114" to 1-112"
1 each 3/8" Drive Socket Set, 114" to 3/4"
1 each 112" Drive Socket Set, 3/8" to 1-112"
1 each Hex Key (allen wrench) Set, up to 112"
1 each Screwdriver Set, Phillips Tip & Slot Tip
1 each Punch Set; Drift, Lineup and Straight
1 pair Wire Stripping Pliers
1 pair Wire Crimping Pliers
1 pair Wire Cutting Pliers
1 pair Needle Nose Pliers
2 pair Jumper Wires with Alligator Clips

NOTE: This list is not intended to be all inclusive ofthe tools required to perform every maintenance
function that may be required on this specific CONDOR® model. However, these tools will greatly .' '
assist in troubleshooting problems and conducting routine maintenance on the equipment.

MANUAL 92350-002
1ANUARY 1997
SIN X935·97051
Serial Number Location •

1
2

The CONDOR® Model V20331XL Serial Number is stamped in two locations on the machine.

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

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

MANUAL 92350-002
JANUAB.Y 1997
SIN X935-970SI

MANUAL 92350-002
JANUARY 1997
SIN X93S-97051
HYDRAULIC SYSTEM DESCRIPTION •
The following is a detailed description of the hydraulic system used on the CONDOR® model
V2033IXL scissor, and how it designed to operate. To assist in understanding the system, this description
should be used in conjunction with the hydraulic schematics found at the end of this section.

GENERAL

The hydraulic system on the CONDOR® model V20331XL consists primarily of a single
manifold assembly, used to control all the hydraulic functions through the use of hydraulic cylinders and
motors. The system is electric over hydraulic, meaning that the hydraulic valve assembly is activated by
electrical signals from the function controls. The system is also of the open-center valve type, meaning
that the hydraulic fluid circulates back to the tank when the pump is running and no functions are being
operated. All lift and drive functions can be performed from the platform console, while ONLY lift
functions are available from the lower control console.

HYDRAULIC TANK

The hydraulic tank is an "L" shaped


weldment having a fluid capacity of 7 US gal-
lons. The main portion of the tank is located
between the batteries in the belly pan, with the
smaller portion extending outward to the right
side ofthe unit (See FIG. 1) nextto the hydraulic
pump. A filler neck and cap, and a sight glass are
provided at the extended section of the tank for
checking and maintaining the fluid level. Filtra-
tion ofthe hydraulic oil is provided through a 10 Ball
micron spin-on return filter, and a 100 mesh, 10 Valve

GPM, tank-mounted strainer. The filter, and


strainer are located at the end of the tank, just
behind the pump. The use of a tank strainer and
shut-off valve (ball valve) for the tank has been
discontinued. Although the tank configurations
differ between models, the attaching compo-
FIG. 1
nents are identical.

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

DO NOT MIX HYDRAULIC FLUIDS.

MANUAL 92350-002
JANUARY 1997
SIN X935-97051
• PUMPIMOTOR

The pump and motor assembly is lo- HYDRAULIC TANK


cated in the right side of the belly pan, between
the tank and the fixed axle (See FIG. 2). A 24
volt DC motor drives a tandem pump, which
consists of two separate pumps drivenfrom the
same shaft. Both sections have a size of .194
cubic inch per revolution, which equals to 2.7
GPM of hydraulic flow at 3600 rpm. One
section of the pump is only used for drive, while
the other pump section supplies fluid for steer- PUMP/MOTOR CONTACTDR

ing, lift, or to increase the drive speed when FIG. 2


directed to the drive circuit.

MAIN VALVE ASSEMBLY

Located in the left side of the belly pan Batteries


between the batteries and battery charger is the
main valve assembly which performs all of the
hydraulic functions ofthe machine (See FIG. 3).
This assembly includes three directional control
valves and a variety ofcartridge valves to achieve
the operation ofthe cylinders and motors for the
Main Valve Battery Charger
machine functions. These individual functions Assembly
are described in detail below. FIG. 3

MACIDNE FUNCTIONS

The hydraulic functions of the CONDOR® model V2033IXL includes: forward and reverse
drive with three selectable speeds at limited height, spring applied/hydraulicallyreleased brake cylinders,
left and right steering, and platform raising or lowering. Each of these functions are performed by the
main valve assembly via electrical control signals. A detailed description of the electrical controls and
their circuits can be found in the Electrical System Description of this maintenance section.

DRIVE FUNCTION

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

MANUAL 92350-002
JANUARY 1997
SIN X93S-97051
~------------~~----------------------~~
Drive Directional
Control Valve

Creep Speed
Solenoid Valve
0,------,/

Flow Divider/Combiner Creep Speed


Needle Valve
FIG. 4

DRIVE FUNCTION (cont'd)

Pump flow circulates through the main valve assembly and back to tank if no functions are
activated when the pump is running. _Once the directional control valve shifts, fluid is directed to one
of the load control valves in its free-flow direction, and then to the normally open positraction valve.
Fluid flows through the positraction valve cartridge, then to both drive motors which each have an 11.9
cubic inch per revolution displacement and are located on the steer axle. When the positraction button
is depressed at the upper control box, the 4-way normally open positraction valve closes, blocking the
flow of fluid through it, but forcing the fluid through the flow divider/combiner to enhance tire traction.

The deceleration valve is utilized to cushion the braking action of the drive circuit. This is
accomplished by letting fluid by-pass between the two drive motors. Since the deceleration valve is a
2-way normally open spool valve, it allows fluid to flow through it at all times. When the drive control
handle is actuated, energizing the drive circuit, the deceleration valve becomes energized and closes,
blocking the flow of fluid through it. When the drive handle is released (circuit de-energized), the
deceleration valve opens, and lets the drive pressure by-pass to the opposite drive motor, allowing the
two drive motors to continue to roll momentarily without creating a hydrostatic lock in the circuit. A
0.040 dia. orifice, located under the deceleration valve, is used to control the amount of by-pass that
occurs which affects the deceleration of the machine.

The V2033IXL has a creep speed which is either automatically activated at platform heights
above seven feet by a limit switch, or is operator selectable at heights below seven feet. Creep speed is
a situation in the drive circuit whereas when the creep speed solenoid valve is energized, some ofthe drive
flow is diverted back to the tank. The speed at which the machine travels when in creep, is controlled
by the creep speed needle valve (See FIG. 4). The creep speed is factory set to obtain a travel speed of
80-100 sec/88 feet, on firm, level ground; (Ref..75/.6 mph), (see note #2 on schematic at end ofhydraulic
section).

MANUAL 92350-002
JANUARY 1997
SIN X93S-970S1
• DRIVE FUNCTION (cont'd)

When the speed selector switch is in the


high position, the drive speed increases by the
Select Directional Steer Directional
Control Valve Control Valve
addition of the P2 pump's fluid displacement (between drive and steer)
(steerllift pump) being diverted to the drive
circuit. This is accomplished by activation of
the select directional control valve. The hydrau-
lic pump contains two individual pump sections,
one of which is used solely for the drive circuit.
The other pump section supplies fluid for the
operation of lift and steer, and will supply fluid
to the drive circuit when the machine is in high
speed. A check valve cartridge is used to isolate Check Valve
the drive-only pump flow for use in the drive Cartridge
Creep Valve
circuit (See FIG. 5).
FIG. 5

STEERING FUNCTION

Steering is accomplished with a cylin-


der, knuckle, and connecting arm arrangement,
which in its configuration provides a tight turn-
ing radius. The drive motors are mounted to the
steering knuckles, thus enhancing driveability.
The steering cylinder, located just behind the
front bumper plate of the chassis, is controlled
by the steer directional control valve on top of
the manifold assembly (See FIG. 5&6).
Connecting Arm
Steer Cylinder

FIG. 6
LIFT FUNCTION

Lifting of the platform is accomplished


by energizing the select directional control valve.
This will direct fluid from the P2 pump to the Cylinder
base end of the lift cylinder, with the rod end of
Manifold
the lift cylinder being vented back to the tank.
Coil
Located on the cylinder body (See FI G. 7), is the
holding valve, which consists of a manifold Cable
body, a 2-way normally closed cartridge with a
manual override, and an electric coil. Attached
to the cartridge is a cable assembly used for
FIG. 7
manually lowering the platform via aT-handle
located at the rear ofthe machine, under the rear
bumper plate. Descent speed is controlled by a flow control valve (See FIG. 3), in which clockwise
rotation decreases descent speed, while counterclockwise rotation increases the descent speed.

MANUAL 92350-002
JANUARY 1997
SIN X935-97051
PRESSURE ADJUSTMENT PROCEDURES
NOTES: All pressure adjustments are to be made with the pump motor running, and with the hydraulic
fluid at operating temperature. Ensure that the tank is filled to its recommended level, and that the
batteries are fully charged. To simplify the adjustment procedure, install a pressure gauge at the "01"
port, and install another pressure gauge at the "02" port, which are both located at the creep valve end
of the main valve assembly. All reliefvalves adjust in the same manner: clockwise increases pressure
setting, and counterclockwise decreases pressure setting. All flow control cartridges adjust in the same
manner: clockwise decreases flow, and counterclockwise increases flow. Refer to FlO. 8 for
adjustments.

Drive Pressure Adjustment

1. Chock both drive wheels to prevent them from spinning in the forward drive direction.
2. With the drive speed selector in the low position, activate forward drive with the drive controller.
3. While drive is activated, adjust "RVI" to 2700 psi while observing the gauge reading from the
"01" port.·
4. After setting, lock the adjustment screw with the jam nut.

High Drive Pressure Adjustment

1. Select high speed at upper control box.


2. Observe the pressure reading at the "01" port while climbing a grade, and note pressure reading
at which the high drive shifts to low.
3. Adjust the "SEQ" valve until the pressure reading is 1100 psi when high drive shifts to low.
4. After setting, lock the adjustment screw with the jam nut.

NOTE: The load control valves, "CB 1" and "CB2", are factory set. Ifthey are not functioning properly,
they must be replaced; DO NOT ATTEMPT ADmSTMENT.

Lift PressurelDescent Speed Adjustment

1. With pump running, and platform raised completely (cylinder bottomed out), observe the
pressure reading on the gauge connected to the "02" port. Adjust "RV2" to 2700 psi.
2. Adjust "FC}" to obtain a 25-35 second descent from a fully raised position.

MANUAL 92350-002
JANUARY 1997
SIN X93S-970S 1
To aid troubleshooting, some of the valves and cartridges are identical to others and can be swapped to
help determine faulty components:

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

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

3. "CBI" and "CB2" are identical-- DO NOT ADJUST!

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

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

"G2" Gauge Port


1-+----- (Reads Steer/Lift!
High Drive Pressure)

"G1" Gauge Port


(Reads Drive Only
Pressure)

"FC1" - Controls Platform


Descent Speed

"RV2" Relief For Steer/Lift


("G2" Gauge Port)

"RV5" Secondary
Lift Relief
Creep Speed
Adjustment

"SEQ" (Sequence) Valve "RV1" Relief For Drive Only


Controls High Drive Shifting ("G1" Gauge Port)

"CB1" and "CB2" Load


Control Valves
(DO NOT ADJUST)

FIG. 8

MANUAL 92350-002
JANUARY 1997
SIN X935·97051
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MANUAL 92350-002
JANUARY 1997
SIN X935-97051
ELECTRICAL SYSTEM DESCRIPTION
The following is a detailed description of the electrical system used on the CONDOR® model
V20331XL scissor, and how it designed to operate. To assist in understanding the system, this description
should be used in conjunction with the electrical schematics found at the end of this section.

GENERAL

The CONDOR® model V20331XL uses a 24 volt direct current (DC) electrical system
consisting of four, 6 volt DC batteries, an electric motor to drive the hydraulic pump, and various
electrical controls to operate the system. Included in this system description is a Machine Options
section, describing options which are available on the model V20331XL. All of the options contained
in this description are electrical only, and do not affect the hydraulic performance of the machine.

BATTERIES

The model V20331XL scissor uses four, 6 volt DC batteries, each having a235 amp hour capacity.
There are two batteries on each side ofthe belly pan nearestthe steer axle. The four batteries are connected
in series, combining their voltage, to make up the 24 volt DC system. The batteries are of the wet-cell
type, and when filled with electrolyte, each battery weighs 66 lbs. More information on batteries in
general can be found in the Battery Service Section beginning on page 47.

BATTERY CHARGER

The battery charger has a 25 amp @ 24


Main Manifold Ground Controls
volt DC nominal rating, and operates off ofaIlS
Assembly
volt alternating current (AC), 160 Hz, 8 amp
input. The charger features contains an ammeter
for reading the DC amp output, and two LED
status indicator lights; a red LED indicates the
charger is on, charging, while a green LED indi-
cates the charging is complete. The charger- is
located on the left side of the belly pan, between
the main valve assembly and the fixed axle (See
FIG. 9). More detailed information ofthe charger
can be found in the Battery Charger Trouble-
shooting Guide beginning on page 67. .

CIRCUIT BREAKERIFUSE

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

MANUAL 92350-002
JANUARY 1997
SIN X93S-9705 I
• PUMP MOTOR

The CONDOR® model V2033XL uti- PumplMotorContactor


lizes a pump motor which is a 24 volt DC unit,
rated 6hp@3600rpm. SincethemodelV2033XL
utilizes a gravity lowering system, the motor does
not run while the lowering function is activated.

FIG. 10

LOWER CONTROL FUNCTIONS

Located above the left rear wheel is the


lower control box, which provides a junction
Emergency Stop Button
connection through the use oftwo terminal strips,
for the limit switch cable, the hydraulic valve
cable, the pump motor contactor cable, and the Platform Lift Control
cable to the upper controls. At the lower controls
are switches (see FIG. 11), to provide operation
of the lift function only; drive is not available Control Selector Switch ---n;.+4~!""J
from this control box. The lower control box I
_ I

15 Amp Circuit Breake~IF use ---!<H--@


I
contains an emergency stop button which must be I
___________ .J
I

pulled out to supply power to both control boxes.


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

UPPER CONTROL FUNCTIONS

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

MANUAL 92350-002
JANUARY 1997
SIN X93S-970S I
UPPER CONTROL FUNCTIONS (cont'd)

Positraction Button
(black) Cut-Away View
ofSlip-Fit Insert
Emergency Stop Button

rr----------------------------\
Lift Controls
Drive Controller
w/Steer Rocker
Switch

Power Button Drive


(green) Speed
Selector

Cable Hamess
Plug Hidden View of
Slip-Fit Insert

FIG. 15

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

MANUAL 92JS()"oo2
JANUARY 1997
SIN X9JS-970S1
• NOTES

MANUAL 92350-002
JANUARY 1997
SIN X935·970S I
MACHINE OPTIONS DESCRIPTION
The following descriptions are intended to be used with wiring diagrams at the end of this
electrical section.

STROBE LIGHT (OPTION)

This option is to indicate that the machine is on or ready to operate. The strobe has: a plug-in
flash tube for easy replacement, an energy output of2 joules, a power output of 3 watts, and a flash rate
of 60 + 10 flashes per minute. The strobe is energized whenever the control selector switch is in the
"UPPER" or "LOWER" position and the lower control emergency stop button is pulled out.

5°SLOPE ALARM (OPTION)

This option sounds an alarm when the V20331XL is 5° or more outoflevel. A 5° omni-directional
sensor is mounted in the belly pan to sense a 5° out-of-Ievel condition. In this situation, a fast pulse/loud
tone alarm at the upper control box (See FIG. 13), is activated until the machine is returned to a less than
5° condition. This serves as a warning, and does not inhibit any functions. The sensor is mounted on a
spring loaded base which is adjustable to allow leveling. Testing of the system is accomplished by
manually tilting the sensor against its spring tension mount, to physically put the sensor in a 5° out-of-
level condition, causing the alarm to sound. Power is supplied to the sensor, and the alarm, only when
the machine is in the "UPPER" control position. When the sensor is activated (5° or greater), the sensor's
white wire (connected to the alarm), becomes grounded after a few second delay, through circuits inside
the sensor.

BATTERY CONDITION INDICATOR (OPTION)

This option is to monitor the batteries' S\opeAIann


state-of-charge, (See FIG. 13). The indicator is Battery
Condition
wired directly to the batteries with the 15 amp Indicator
circuit breaker, or fuse, included in the circuit.
Consisting of an analog 10-LED bar display, the
indicator provides a visual reference for reading
properly charged batteries (top LED lit), batteries
at 70% depth-of-discharge (second from bottom
LED flashes), and when the batteries have reached
an 80% depth-of-discharge (bottom two LED's
flash alternately).

FIG. 13

SIGNAL HORN (OPTION)

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

MANUAL 92350-002
JANUARY 1997
SIN X93S-97OSI
• LOW VOLTAGE BATTERY
PROTECTION SYSTEM (OPTION)

This option prevents operation when the


batteries are in a low voltage condition. It be- Low Volt Override Pushbutton ignal Horn
comes energized whenever the control selector (w/Amber Indicator Lamp) Pushbutton
switch is in either "UPPER" or "LOWER" posi- (white)

tion (lower emergency stop button must be pulled


out). While energized, the module monitors the
batteries'voltage level, and will prevent the pump
motor contactor from being activated once the
battery voltage reaches 12.5% undervoltage, or
approximately 21 volts~ This condition must be Slope ~~~- Cable Harness Plug
Alarm
present for 21 seconds to activate the interrupt FIG. 14
system. Terminals 3 & 4 of the module are
normally closed contacts which complete the
pump motor contactor circuit, and it is these contacts which are opened during a low voltage condition.
Terminal 7 of the module is the battery input voltage, while terminal 6 is machine ground. Terminals 1
& 2 are normally open contacts which close during a low voltage condition and turns on an amber
indicator light (pushbutton) at the upper control box. The system can be overridden by pressing the
pushbutton on the side ofthe upper control box (See FIG. 14), which energizes terminalS ofthe module.
However, the override will only allow three repeated by-pass cycles of2 minutes 30 seconds each. The
LVI module will reset when the battery voltage reaches approximately 25.5 volts during re-charging.
Once the batteries have been properly charged and the LVI module has automatically reset, the
CONDOR® can be operated once again.

TRAVEL ALARM (OPTION)

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

DESCEND ALARM (OPTION)

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

MOTION ALARM (OPTION)

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

HOUR METER (OPTION)

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

MANUAL 923SO-OO2
JANUARY 1997
. SIN X93S-970SI
BATTERY SERVICE
BATTERY SERVICING TOOLS
Use proper tools when performing battery service to prevent damage to battery, cables, terminals
and hold-downs, and to save time and energy.

Suggested battery tools and their use are described below.

FILLING DEVICES

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

SCRAPER AND WIRE BRUSH

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

BATTERY CARRIER

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

SERVICE PROCEDURES

The user should realize that the battery is a perishable item and requires periodic attention. With a
reasonable amount of care, the life of the battery can be appreciably extended. Neglect and abuse will
invariably cause shorter life.
CAUTION
Low battery voltage (discharged) requires highercurrentdrawto do the same
work. This high current draw WILL DAMAGE the electric motor, relay
contacts and the batteries. DO NOT OPERATE the CONDOR® with a
battery DISCHARGED or that has a specific gravity of 1.130 or LESS.

Routine servicing of the battery should proceed as follows:

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

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

MANUAL 923S()'oo2
JANUARY 1997
SIN X93S-970S I
Next, wipe with a cloth with clear water. After rust is removed from a part with a wire brush,
rinse with clear water, dry and paint with an acid-resistant paint.

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

The second item in routine servicing of conventional batteries is to check the electrolyte level in
all cells. Ifnecessary, add clear, odorless, mineral free water to bring the liquid level to the level indicator
in all cells. If the battery does not have a level indicator, bring the level to 112" (l3mm) above the tops
of the separators. Do not overfill any cell. When a cell is overfilled, the excess electrolyte may be
forced from the cell by the gas formed in the battery. This will cause excessive corrosion of adjacent
metal parts, reduced performance and shorter life.

BATTERY TESTING

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

STEP 1 - VISUAL INSPECTION

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

STEP 2 - HYDROMETER TEST

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

DANGER

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

MANUAl.. 92350-002
JANUARY 1997
SIN X93S-970S1
The average state ofcharge ofthe cells in a battery can be determined by measuring the stabilized.
voltage of the battery. The voltage is stabilized if the battery has been on open circuit overnight or for
a period of several hours. A voltage reading of 12.4 (6.2 on a 6 volt battery) is equivalent to a specific
gravity of 1.225. The disadvantage of measuring the open circuit voltage is that a lower voltage cell can
be masked by the remaining cells. Ifthe cell connectors are accessible for voltage measurements, a range
of 0.05 volts between the highest and lowest cells corresponds to a 50 point variation in specific gravity.
A cell voltage of 2.07 is equivalent to a specific gravity of 1.225.

STEP 3 - ADJUSTABLE LOAD TEST

The following instructions are intended as guidelines. When available, the instrument
manufacturer's instructions should be followed. Follow all precautions.

A. Disconnect battery cables starting with ground cable.

B. Measure temperature of a center cell. If instrument has an integral temperature


compensator, use attached probe.

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

D. Connect current transducer (if necessary) to appropriate lead.

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

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

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


Figure x.

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

I. , If test voltage is below minimum, replace battery.

TESTING WIm FIXED LOAD TESTER AND OPEN CIRCUIT

For testing batteries with a fixed load tester and an open circuit voltmeter, refer to "Battery Testing Chart"
Figure Y.

STEP 1 - VISUAL INSPECTION

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

MANUAL 92350-002
JANUARY 1997
SIN X935-9705 I
. S T E P 2 -FIXED LOAD TEST

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

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

A. Disconnect battery cables starting with ground cable.

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

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

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

E. Apply test load for 15 seconds.

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

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

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

STEP 3 - OPEN CIRCUIT VOLTAGE TEST

If the battery failed the load test, the state of charge must be checked. If a hydrometer is not
available, the stabilized open circuit voltage can be used to indicate the state of charge. Allow at least
10 minutes after the load test for the voltage to stabilize, then measure and record the open circuit voltage..
Determine the approximate state ofcharge from the following chart (Battery temperature 60-100 degrees
F.)

OPEN CIRCUIT VOLTS PERCENT CHARGE


12.6 or greater 100%
12.4 - 12.6 75-100%
12.2 - 12.4 50-75%
12.0 - 12.2 25-50%
11.7 - 12.0 0-25%
11.7orless 0%

The change of voltage with state of charge is small and must be measured accurately using a
digital meter or an analog meter with an expanded scale. If the state of charge is 75% or greater and the
battery failed the load test, it should be replaced. Ifthe state of charge is less than 75%, the battery should
be charged at the recommended rate and time, and the load test repeated. If the battery passes the load
test, return it to service. If it fails the load test again, replace it and refer to the next chapter to determine
the cause offailure.
MANUAL 92350-002
JANUARY 1997
SIN X93S-97051
DETERMINING CAUSES OF BATTERY !AllJURE

Whether the battery passes or fails either of the above tests, the results must be believed. If the battery
passed the load test only after a recharge, the cause of the discharge condition should be determined.
Ifthe battery has been returned previously or is otherwise still questionable, one final test should be made.
Fully charge the battery and place it on open circuit stand for three days. If the loss in specific gravity
of any cell is greater than 35 points or the open circuit voltage drops by more than 0.20 volts, replace the
battery. If not, return the battery to service and determine the cause for the discharged condition.
The following should be checked:

1. Corroded Battery Terminals or Connectors

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

2. Electrical Circuit Leakage

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

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

B. Ohmmeter - Disconnect the positive cable at the battery. Connect an ohmmetertothe


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

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

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

3. Charging System

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

MANUAL923SG-002
JANUARY 1997
SIN X93S-970SI
• STEP 1
FIGURE: X
BATTERY TESTING CHART

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

I OBVIOUS DAMAGE I I NO OBVIOUS DAMAGEj


IREPLACEBATTERVI I CHECK ELECTROLYTE LEVEL I
BELOW TOP OF PLATES IN ONE OR
MORE CELLS
I ELECTROLYTE LEVEL ABOVE TOP OF
PLATES IN ALL CELLS - PROCED TO
ADD WATER TO JUST ABOVE SEPA- STEP 2
RATORS. CHARGE FOR 15 MINUTES
AT15-25AMPS. PROCEED TO STEP 2

STEP2 I HVDROMETERTEST I

I I
SPECIFIC GRAVITY LESS THAN 1.225 SPECIFIC GRAVITY 1.225 OR GREATER
OR CELL VARIATION 50 POINTS OR OR CELL VARIATION LESS THAN 50
GREATER. POINTS.
I I
I RECHARGE I:DISCHARGEAT 150 AMPS FOR 151
SECONDS
I
SPECIFIC GRAVITY LESS THAN 1.225 I
OR CELL VARIATION 50 POINTS OR
GREATER.
I CONTINUE TO STEP 3 I
I
IREPLACEBATTERVI

STEP 3 I LOAD TEST I


I
1. PLACE THERMOMETER IN CENTER CELL
COVER BATTERVWITH A DAMP CLOTH.
2. CONNECT VOLTMETER AND AMPERE LOAD
EQUAL T0112THECOLDCRANKINGAMPERES
AT O°F (-18°C) RATING OF THE BATTERV FOR
15 SECONDS.
3. OBSERVE VOLTAGE AT 15 SECONDS WITH
LOAD ON.
4. REFER TO VOLTAGE CHART BELOW.
I
I
IVOLTAGE BELOW CHART VALUE t
I
I I
VOLTAGE EQUAL TO OR ABOVE CHART
VALUE - RETURN TO SERVICE
I
I REPLACE BATTERV I

VOLTAGE CHART

ESTIMATED ELECTROLYTE TEMPERATURE MINIMUM REQUIRED VOLTAGE UNDER 15 SEC. LOAD


(USE 1/2 THESE VALVES FOR 6-VOLT BATTERIES)

70°F (21°C) & ABOVE 9.6


60°F (16°C) 9.5
50°F (10·C) 9.4
40°F (4°C) 9.3
'30°F (-1°C) 9.1
20°F (-7°C) 8.9
10°F (-12°C) 8.7
O°F (-18°C) 8.5

MANUAL 923SO-OO2
JANUARY 1997
SIN X93S-970S 1
FIGURE: Y
SATTERY TESTING CHART

STEP 1 VISUAL INSPECTION


CHECK FOR OBVIOUS DAMAGE SUCH AS
CRACKEDORBROKENCASETHATSHOWS
LOSS OF ELECTROLYTE. ALSO CHECK
FOR TERMINAL DAMAGE.

I
I I
IOBVIOUS DAMAGE! NO OBVIOUS DAMAGE I
I I
IREPLACE BATTERY I CHECK ELECTROLYTE LEVEL. ADD
WATER IF NECESSARY. PROCEED
TO STEP 2.

STEP 2 ! FIXED LOAD TEST!


I
1. ATTACH TESTER CLAMPS TO BATTERY TERMINALS IN CORRECT
POLAITY - USUALLY RED TO POSITIVE (+) AND BLACK TO NEGATIVE (-).
2. SET SELECTOR SWITCH ON LOAD TESTER TO 112 CRANKING AMPERAGE
RATING OF BATTERY (AT O"F, -1S"C).
3. IF TESTER DOES NOT HAVE AN AUTOMATIC BATTERY TEMPERATURE
COMPENSATOR, PLACE A THERMOMETER IN CELL, READ AND SET TEMP-
ERATUREDIALONTESTER. WITHOUT ANY TEMPERATURE CORRECTION,
MAKE LOAD TESTS ONLY ON BATTERIES ABOVE SO"F (1S"C).
4. APPLY LOAD FOR 15 SECONDS AND READ LOAD TESTER JUST BEFORE
RELEASING THE LOAD.

I
I I
! BATTERY FAILS LOAD TEST
I
I I BATTERY PASSES LOAD TEST]
RETURN TO SERVICE.
IPROCEED TO STEP 3 I

STEP 3 ! OPEN CIRCUIT VOLTAGE TEST!


I
1. ALLOW 10 MINUTES FOR BATTERY VOLTAGE TO STABIUZE
AFTER LOAD TEXT.
2. READ OPEN CIRUITVOLTAGE.
I
I
UNDER 12.4 VOLTS-BATTERY SHOULD 12.4 VOLTS OR ABOVE - IF BATTERY
BECHARGEDAND LOAD TESTED AGAI N DID NOT PASS THE LOAD TEST, IT
(REPEAT STEP2). IF BATTERY AGAIN SHOULD BE REPLACED - THEN PRO-
FAILS THE LOAD TEST, REPLACE IT. IF IT CEED TO STEP 4.
PASSES, RETURN TO SERVICE AFTER
PROCEEDING TO STEP 4.

STEP 4 CAUSES OF BATTERY FAILURE:


1. CORRODED BATTERY POSTS OR CONNECTORS -ALWAYS CLEAN THE BATTERY POSTS OR
SIDE TERMINALS AND THE BATTERY CABLE CONNECTIONS WHEN CHARGING OR REPLACING
A BATTERY.
2. ELECTRICAL LEAKAGE - CHECK FOR ELECTRICAL LEAKAGE WITH ALL ACCESORIES TURNED
OFF:
A) DISCONNECT THE BATTERY GROUND CABLE AND CONNECT A SUITABLE VOLTMETER
BETWEEN DISCONNECTED BATTERY POST AND GROUND (A READING OVER S VOLTS
INDICATES AN EXCESSIVE LEAK).
OR
B) DISCONNECT THE BATTERY CABLE THAT GOES TO THE STARTER AND CONNECT AN
OHMMETER BETWEEN THE CABLE AND THE GOUND (A RESISTANCE OF UNDER 100 OHMS
WILL DRAIN THE BATTERY).
3. CHARGING SYSTEM SHOULD ALWAYS BE CHECKED AFTER CHARGING OR REPLACING A
BATTERY.

MANUAL 923S0-002
JANUARY 1997
SIN X93S-97OS 1
• NOTES

MANUAL 92350-002
JANUARY 1997
SIN X935-970S 1
PREVENTIVE MAINTENANCE
In conjunction with the pre-operation inspection, a good preventive maintenance program will ensure
a properly operating CONDOR®. This section is directed toward those items of maintenance which
the operator should be aware of, and which may be accomplished prior to the operation of the equip-
ment. Refer to the "Preventive Maintenance Daily Inspection" and the "Preventive Maintenance 50
Hour Inspection" for detailed inspection procedures. Included in this section are checklists, for the
Daily and 50 Hour Inspections, to assist in maintaining the CONDOR®. Please note that on the 50
Hour Inspection, some items may be stated as 500 Hours, where applicable.

LUBRICATION

NOTE: Recommended lubrication intervals are based on normal use in


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

1. Wheel Bearings

Lubricant: Wheel bearing grease.

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

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

IMPORTANT: If damage is evident, remove the CONDOR®


from service until the spindle assembly is replaced, and contact
the Condor Div. Service Department to report the damage.

Repack cone bearings using fresh wheel bearing grease, install


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

MANUAL 92350-002
JANUARY 1997
SIN X93S-970S I
• 2. Hydraulic System

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

Return Filter: Replace filter element after first 50 hours of operation. There-
after, replace filter element every 500 hours of operation.

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

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

Suction Strainer-
MDL, MDt, AND MDC: Drain oil from tank and replace strainer annually. If operating
in dusty or harsh conditions, inspect filter more frequently and
replace if necessary.

DO NOT MIX DIFFERENT HYDRAULIC FLUIDS

3. Battery Servicing

FOR PROTECTION WHEN SERVICING BATTERIES,


ALWAYS WEAR A FACE SHIELD AND DO NOT SMOKE!

Visual Inspection: Inspect for defective cables, loose connections, corrosion,


cracked or swelling cases or covers, loose hold downs, and loose
or deformed terminal posts.

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

Electrolyte Level: Check electrolyte level daily in each cell. Ifnecessary, add clear,
odorless, mineral free water to bring the level to 112" above the
top of the separators, or to the level indicator (if equipped), in
each cell. Only add water after the charging cycle is complete.

MANUAL 92350-002
JANUARY 1997
SIN X935-9705 I
PREVENTIVE MAINTENANCE INSPECTION
This field inspection list provides for a systematic inspection of the CONDOR®. The items listed to be
inspected or checked daily will ensure proper unit performance prior to operation. By following the daily inspec-
tion procedure on a regular basis, any potential malfunction will be identified before it can become a major
problem. The 50 Hour Inspection will detect any defective, damaged, or improperly secured part. The 50 hour
Inspection also includes items requiring attention at 500 hours or yearly which, are indicated where applicable.

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

DAILY INSPECTION

A. VISUAL INSPECTION

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

Tire Condition: Inspect tires for wear, cuts, and abrasions.

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

Hydraulic Fluid
Leaks: Inspect to ensure that there is no evidence of leaking hoses or fittings.

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

B. FLUID LEVEL CHECK

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

Battery Electrolyte
Level: For protection, wear a faceshield. Check electrolyte level in each cell.
If necessary add electrolyte or clear, odorless, mineral free water as required
to bring the level to 112" above the tops of the separators or to the level
indicators (if equipped), in each cell. Add only after the charging cycle is
complete.

MANUAL 92350-002
JANUARY 1997
SIN X93S-970S 1
• C. OPERATIONAL TEST

Instrument Check

Hour Meter: Ensure that meter is recording properly.

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

Lower Controls
Operation Check

Emergency Stop Button: Ensure that machine will not operate with button pushed in.
Check that button maintains its in or out position.

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

Lift Control Buttons: Check that buttons and toggle switch return to their normal
position when released. and that buttons and toggle switch
properly operate the lift function.

Upper Controls
Operation Check

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

Lift Control Buttons: Check that buttons return to their normal position when
released. and that buttons properly operate the lift function.
Make certain that lift function does not operate unless green
power button is depressed.

Drive/Steer Functions: Squeeze handle grip and operate drive and steer functions.

Drive Speed Selector: Ensure that each speed selection works properly while driving.

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

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

MANUAL 92350-002
JANUARY 1997
SIN X93S-97051
PREVENTIVE MAINTENANCE
DAILY INSPECTION

MON TUES WED THURS FRI SAT SUN

ITEM I
VISUAL INSPECTION
12/ / V / / / /
HOURS

Overall Condition

Tire Condition

Battery Cable Connections

Hydraulic Fluid Leaks

Battery Electrolyte Level


Verify Legibility of Decals & Placards

OPERATIONAL TEST
Hour Meter

Battery Condition Indicator

LOWER CONTROLS
Emergency Stop Button

Control Selector Switch

Lift Control Buttons

UPPER CONTROLS
Emergency Stop Button .

Lift Control Buttons

Drive/Steer Functions

Drive Speed Selector Switch

Positraction Button

Slope Alarm

MANUAL 92350-002
JANUARY 1997
SIN X935·970S I
• PREVENTIVE MAINTENANCE INSPECTION
50 HOUR INSPECTION

A. CHASSIS

Visual Inspection: Inspect for cracks in welds, dents or bends in material.

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

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

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

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

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

Brake Cylinders: Check hydraulic lines for leakage. Check for proper brake
operation. Check for proper brake release lever operation.
Inspect cylinders and retaining bolts for damage and proper
installation.

Hydraulic Hoses
and Fittings: Inspect for leaks, cuts, and abrasions. Check fittings for tightness.

Tires: Inspect for excessive or abnormal wear, cuts and abrasions.

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

Battery Charger: Inspect for damage. Verify proper charging operation.

Wiring and Electrical


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

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

MANUAL 923S()"()()2
JANUARY 1997
SIN X935-970S 1
B. ARMSTACK

Visual Inspection: Inspect for cracks in welds, dents or bends in material.



Lift Cylinder Hoses
and Fittings: Inspect for leaks, cuts, and abrasions. Check for tightness and
proper routing.

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

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

Lift Cylinder Pins and


Retaining Bolts: Inspect cylinder pins and retaining bolts for security.

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

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

Armstack Bearing Pads


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

C. PLATFORM

Visual Inspection: Inspect for cracks in welds, dents or bends in material.

Platform Pivot Shafts and


Retaining Bolts: Inspect security of retaining bolts and pin.

Platform Bearing Pads: Inspect for binding, cracking, pitting, or abnormal wear. Clean
any dirt or debris from pad slide area. Ifbinding or chatter is
present during movement, lubricate sliding surfaces with anti-
sieze compound.

Platform Entrance Lift Gate


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

MANUAL 923S0-002
JANUARY 1997
SIN X93S-970SI
• C. PLATFORM (cont'd)

Extension Deck and Latch


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

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

D. LOWER CONTROL BOX

Yisual Inspection

External: Inspect for proper mounting, damage to enclosure or controls,


Ensure that enclosure lid seals watertight and that controls are
secure.

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

Manual Tube Holder


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

E. UPPER CONTROL BOX

Visual Inspection

External: Inspect for proper operation of electrical cable quick discon-


nect plug. Inspect for damage to enclosure or controls. Ensure
that box fits snugly onto mounting posts and that controls are
secure.

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

MANUAL 923S0-002
JANUARY 1997
SIN X93S-970S I
PREVENTIVE MAINTENANCE
50 HOUR INSPECTION

MON TUBS WED THURS FRI SAT SUN

ITEM I
CHASSIS
Z / 1/1/1// 1//
HOURS

Visual Inspection

Steering Cylinder

Steering Connecting Arm

Steering Knuckles

Wheels
Drive Motors

Brake Cylinders

Hydraulic Hoses and Fittings .

Tires

Belly Pan

Battery Charger

Wiring and Electrical Connections

Electric Motor and Pump

ARMSTACK
Visual Inspection

Lift Cylinder Hoses and Fitting

Electrical Cable

Lift Cylinder

Lift Cylinder Pins and Retaining Bolts

Limit Switch

UpperlLower Electrical Junction


Armstack Bearing Pads (chassis)

PLATFORM
Visual Inspection

MANUAL 92350-002
JANUARY 1997
SIN X935-97051
• PREVENTIVE MAINTENANCE
50 HOUR INSPECTION
(cont'd)

MON TOES WED THURS FRI SAT SUN

ITEM I
PLATFORM (cont'd)
IZ:/1/V / V / /
HOURS

Platfonn Pivot ShaftslRetaining Bolts f'

Platfonn Bearing Pads

Platfonn Entrance Lift GatelLatches f..

Extension Deck and Latch Assembly


~,

Electrical Cable . r<l


fe
Manual Storage Container
MOL, MOl and MDC Models

LOWER CONTROL BOX


Visual Inspection--External
Visual Inspection--Internal
Manual Tube Holder i
MOD Models

UPPER CONTROL BOX


Visual Inspection--External
Visual Inspection--Internal

't

MANUAL 92350-002
JANUARY 1997
SIN X935-9705 I
HYDRAULIC FLUID SPECIFICATIONS
FOR
CONDOR® AERIAL WORK PLATFORMS

Shell Tellus - T32 Hydraulic Fluid

Viscosity
SUS @ 100° F 155
SUS@210°F 47

Viscosity Index 154

Flash Point OF 325°

Pour Point of -54°

COLD TEMPERATURE OPERATION

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

A) Conoco DN-600 Antiwear Hydraulic Fluid


Manufacturer: Continental Oil Co., Houston, Texas

B) Sun Low Temperature No.3 Hydraulic Fluid


Manufacturer: Sunoco, Inc., Toronto, Ontario, M5S 2S4, Canada

C) Fluids Conforming to MIL-H-5606C Specifications.


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

CAUTION

DO NOT MIX DIFFERENT FLUIDS

MANUAL 923S0-002
JANUARY 1997
SIN X93S·970SI
NOTES

MANUAL 92350-002
JANUARY 1991
SIN X935·91051
115 VAC BATTERY CHARGER
TROUBLESHOOTING GUIDE

To be able to use the troubleshooting guide effectively, it is important to read this guide
completely before beginning any tests.

II
. REPAIRS BY QUALIFIED
CA1fDONPERSONNEL ONLY. I
NOTE: Modifying this charger for use other than that for which it was intended, repairs by persons
not qualified, or not using original equipment replacement parts will void the warranty and Lester
liability.

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

SECTION 1 - CHARGER DOES NOT TURN ON

In nonnal operation the charger DC output must be connected to the batteries in order to turn the
charger on. A time delay of2 to 5 seconds is provided to allow adequate time to make a secure connection
before the charger turns on. After this time delay the power relay closes and an audible "click" should
be heard. When the relay closes, AC power is supplied to the transformer primary coil. If operating
properly, the transfonner should hum and the ammeter should indicate the charge rate. If the charger
does not turn on properly, refer to Part A, B, or C for specific test procedures.

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

MANUAL 923S()'oo2
JANUARY 1997
SIN X93S-970S1
• PART A-RELAY DOES NOT CLOSE,NO TRANSFORMER HUM AND AMMETER
DOES NOT REGISTER.

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

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

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

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

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

MANUAL 92350.002
JANUARY 1997
SIN X935-97051
CAUTION
DO NOT charge batteries with the Electronic Timer Kit bypassed. The charger
will remain on as long as the power supply cord is connected to an outlet.

Severe overcharging and eventual damage to batteries will result.

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

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

Check to be sure the power supply cord is securely connected to a live AC outlet. When three-prong
to two-prong adapters are used, they tend to work loose resulting in a poor connection. Check the AC line fuse
or circuit breaker and, if possible, measure the AC line voltage at the outlet to be sure AC power is present.
If necessary, connect a functioning charger, utility light or other electrical appliance to the outlet to verify the
presence of AC power.

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

PART C-RELAY CLOSES AND TRANSFORMER HUMS BUT AMMETER DOES-NOT REGIS-
TER

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

1. Connect the tester leads to the charger I?C output connector and note the reading. Reverse the tester leads
and check the output connector again. The circuit should be complete in only one direction. Ifthe circuit does
not conduct in either direction and the fuse is good, individually check the continuity ofthe DC output cord,
ammeter, diodes and all connections. Ifthe circuit conducts in both directions, a "short" exists in the charger
DC circuit. First check the DC output cord for a "short" between the two wires. It is more likely that one or
both diodes have "shorted." Refer to Section 2 -"Charger Fuse Blows" for continuity test of diodes.

MANUAL 923S11-OO2
1ANUARY 1997
SIN X93S-970SI
• 2. Ifthe charger DC circuittest is good, a check ofthe capacitoris necessary. Disconnect the power supply
cord from its outlet and the DC output connector from the battery connector. Then disConnect
both transformer coil leads from the capacitor terminals. Use care when disconnecting the capacitor
leads so the wires do not break. Using an ohmmeter, set the scale to R X 10K ohms and test the capacitor as
follows:

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

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

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

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

CAUTION
Use only a 6 Mfd, 660 volt AC rated capacitor for replacement (part No. 02390S).
The use of a different value capacitor may result in improper charging, capacitor
failure, transformer burnout and/or battery damage.

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

-PART D -ELECTRONIC TIMER KIT REPLACEMENT

The Electronic Timer Kit should always be replaced as a complete assembly.. The tools required
are: a Phillips head screwdriver, 3/8" and 11132" wrenches, and pliers. No soldering is required. To
replace the kit, follow the step-by-step procedures listed below.

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

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

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

MANUAL 92350-002
JANUARY 1997
SIN X93S·970S I

~- .......
Connect the black lead of the power supply cord to terminal # 1 on the Electronic Timer Kit
and the white lead of the power supply cord to terminal #2.
Connect the red wire of the Electronic Timer Kit along with the white lead of the DC cord to
the Heat Sink Assembly. Connect the black wire of the Electronic Timer Kit along with the black lead of

the DC cord to the ammeter post. Do not allow the ammeter post to turn when tightening the nut. Recon-
nect the green wire of the Electronic Timer Kit along with the transformer secondary lead to the diode
lead terminal.

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

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

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

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

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

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

SECTION 2 - CHARGER FUSE BLOWS

The charger fuse assembly consists of a dual element fuse link under a transparent cover mounted
on the charger front panel. Each fuse· element is electrically connected in series with a rectifier diode to
provide protection for the transformer in the event of a diode failure. Visually inspect and electrically
test the fuse to determine ifone or both fuse links are blown and refer to Part A or PartB for test procedures.
LOCATE AND CORRECT CAUSE OF TROUBLE BEFORE REPLACING BLOWN FUSE. DO
NOT attempt to repair the fuse link as inadequate protection will result.

MANUAL 92350-002
lANUAllYlm
SIN X935-910S I
PART A - SINGLE FUSE LINK BLOWS

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

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

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

PART B - BOTH FUSE LINKS BLOW

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

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

MANUAL 923S0-002
JANUARY 1997
SIN X93S·970S1
SECTION 3 - AMMETER READS 30 AMPS FOR MORE THAN 30 MINUTES

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

CAUTION

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

SECTION 4 - CHARGER OUTPUT IS LOW

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

CAUTION

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

SECTION 5 - CHARGER TURN OFF MALFUNCTIONS

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

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

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

MANUAL 92350-002
JANUARY 1997
SIN X935-970S I
• PART A - CHARGER TURNS OFF TOO SOON

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

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

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

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

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

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

PART B - CHARGERDOES NOT TURN OFF

New batteries with all good cells should rise to at least 2.5 volts per cell. This will allow the finish
charge rate to taper below 8 amperes. As batteries age, individual cells may weaken and these cells may
not reach 2.5 volts. This will result in finish charge rates greater than 8 amperes, and less time will be
required for the batteries to reach full charge. At a finish charge rate of8 amperes or less the charge time
should not exceed 18 hours. At a finish charge rate greater than 8 amperes the charge time should not
exceed 14 hours.

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

MANUAL 92350-002
JANUARY 1997
SIN X93S·970S I
Ifthe charger remains on longer than the maximum time specified and the two to five second delay

is present, verify that the green wire from the Electronic Timer Kit and the secondary transformer coil lead
are securely connected to the diode lead as shown. The charger will NOT tum offifthe green wire is loose
or disconnected. Ifthe green wire is securely connected, the Electronic Timer has malfunctioned and the
complete Electronic Timer Kit must be replaced.

If a precision digital type DC voltmeter is available, a test to verify that the Electronic Timer has
malfunctioned can be made. Connect the charger to the batteries and allow to charge normally. After the
charge rate has tapered to its lowest point, measure the battery terminal voltage using a DC voltmeter
capable of reading in increments of .00 1 volts. Continue charging and check the battery voltage reading
every hour. lithe battery voltage increases less than .012 volts, or ifthe battery voltage decreases between
successive hourly readings, the charger should turn off. If the charger does not tum off, the Electronic
Timer has malfunctioned and the complete Electronic Timer Kit must be replaced.

PART C - CHARGER RUNS TOO LONG BUT DOES TURN OFF

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

SECTION 6 - AC LINE FUSE OR CIRCUIT BREAKER BLOWS

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

SECTION 7 - TRANSFORMER SHORT OR BURNOUT

Failure of the transformer can be the result of natural aging, premature shorting of adjacent coil
turns or overheating damage. The most common cause oftransformer overheating and premature burnout
is the result of misuse, connecting the charger to a battery system of lower voltage than specified on the
charger (See Section 3). Darkening of all the transformer secondary coil windings is an indication of
possible overheating damage. A low or complete lack of output would be observed on the ammeter,
however, the transformer may hum or the AC line fuse or circuit breaker may blow when the charger is
turned on. To test the transformer, disconnect the power supply cored from its outlet and the DC output
connector from the battery connector. Then disconnect the transformer secondary coil leads # 1 and #4
from the diodeterminals and disconnect the transformer capacitor coil leads from the capacitorterminals.
Use care when disconnecting the capacitor lead so the wires do not break.

MANUAL 92350-002
JANUARY 1997
SIN X93S-970SI
DANGER
IDGH VOLTAGE: With the charger operating, the charger capacitor voltage is
approximately 650 volts AC. Use extreme caution when working near the capacitor
terminals.

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

If the transformer secondary coil voltage and capacitor coil voltage check good, disconnect the
power supply cord from its outlet. Check the capacitor to be sure its rating is 6 Mfd. 660 volts AC, and
then carefully reconnect the capacitor coil leads to the capacitor terminals. Then, take caution when
reconnecting the power supply cord to an outlet and measure the transformer secondary voltage again.
The correct voltage reading is shown in Figure 7. Ifthe transformer secondary voltage reading is the same
as measured with the capacitor disconnected, from Figure 6, the capacitor may be open, the capacitor coil
may be open or the capacitor coil terminals may not be making proper electrical contact. Refer to Section
I, Part C, Item 2 for capacitor test procedures. If the voltage readings are correct, both the transformer
and capacitor are good, refer to Section 1, Part C, Item 1 for further tests of the DC circuit.

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

MANUAL 92350-002
JANUARY 1997
SIN X93S-970S 1
APPENDIX A

A div. of TIME Manufacturing Company

BOLT TORQUE CHART


BASIC ~TRESS TENSILE STRENGTIl (T) MIN
MAJOR !AREA PROOF LOAD (P) SAE GRADE 5 SAEGRADE8
NOMINAL DIA SQ. IN SAEGRAl E(J9S7)
TIlREADS INCH GRADE 5 GRADES icLAMP ASSEMBLY TORQUE CLAMP ASSEMBLYTOROUE
T P T P LOAD R~.200DRY -.ISOLUB LOAD R-.200DRY -.ISOLUB
LBS. LBS.
4-40 .1120 .00604 120KSI aSKSI \sOKSI 120KSI 380 BLB-IN 6LB-1N S40 12LB-1N 9LB-1N
4-411 " .1120 .00661 120KSI 8SKSI ISOKSI I20KSI 420 9LB-1N 7LB-1N 600 13LB-1N IOLB-IN
b-JZ .1380 .00909 120KSI 8SKSI I50KSI I20KSI S80 16LB-1N 12LB-1N a20 23LB-1N 17LB-1N
b-4U .\380 .0101S 120KSI aSKSI lSOKSI 120KSI 640 18LB-1N 13LB-1N 920 2SLB-1N 19LB-1N
S-32 .1640 .01400 120KSI aSKSI ISOKSI 120KSI 900 3OLB-1N 22LB-1N 1260 41LB-1N 31LB-1N
II-Jb .1640 .01474 120KSI aSKSI ISOKSI 120KSI 940 31LB-1N 23LB-1N 1320 43LB-1N 32LB-1N
lU-Z4 .1900 .017S0 120KSI 8SKSI ISOKSI 120KSI 1120 43LB-1N 32LB-1N IS80 6OLB-1N 45LB-1N
JU-JZ .1900 .0200 llOKSI 85KSI 150KSI I2OKS1 I28S 49LB-1N 36LB-1N 1800 68LB-1N 51LB-1N
"1/4-20 .2500 .03180 120KSI aSKSI lSOKSI 120KSI 2020 8LB-Ff 7SLB-1N 2a6O 12LB-Ff 9LB-FT
lI4-ZI1 .2500 .03640 120KSI 8SKSI ISOKSI 120KSI 2320 IOLB-FT 86LB-1N 3280 14LB-FT IOLB-FT
;'/1(HII .3125 .OS24O 120KSl 85KSI ISOKSl 120KSl 3340 17LB-FT 13LB-Ff 4720 2SLB-Ff laLB-Ff
5/16-24 .312S .05800 120KSI 85KSI ISOKSI 120KSI 3700 19LB-FT 14LB-Ff 5220 2SLB-Ff 20LB-FT
3/8-16 .37S0 .077S0 120KSI aSKSI ISOKSI llOKSI 4940 3OLB-FT 23LB-Ff 7000 4SLB-FT 35LB-FT
3/8-24 .37S0 .08780 120KSI aSKSI 150KSI 120KSI S600 3SLB-Ff 2SLB-FT 7900 5OLB-Ff 3SLB-FT
7/17-14 .437S .10630 120KSl aSKSI ISOKSI 120KSI 6aOO SOLB-Ff 3SLB-Ff 9SS0 7OLB-FT 5SLB-FT
7Il6-20 .437S .11670 120KSI aSKSI l50KSI 120KSI 7550 SSLB-FT 4OLB-Ff 10700 8OLB-Ff 6OLB-FT
1/2-13 .5000 .14190 120KSI aSKSI ISOKSI 120KSl 9OS0 7SLB-FT 5SLB-Ff 12750 110LB-Ff 8OLB-FT
112-20 .5000 .15990' 120KSI 8SKSl ISOKSI 120KSI 10700 9OLB-FT 6SLB-Ff 14400 120LB-Ff 9OLB-Ff
9/16-12 .562S .18200 120KSI 8SKSI lSOKSI 120KSI 11600 IIOLB-FT 8OLB-Ff 16400 lSOLB-FT 1I0LB-Ff
9/16-IS .562S .20300 120KSI aSKSI 150KSI 120KSl 12950 I2OLB-Ff 9OLB-FT 182S0 I7OLB-FT 130LB-FT
;'/11-11 .6250 .22600 120KSl aSKSl ISOKSl 120KSl 14400 lSOLB-FT IIOLB-FT 20350 ~ 17OLB-FT
;'/11-111 .62S0 .25600 120KSI 8SKSI ISOKSI 120KSI 16950 180LB-FT 13OLB-FT 23000 240LB-FT 180LB-FT
3/4-10 .7S00 .33400 llOKSI 8SKSI ISOKSl 120KSI 2\300 26OLB-Ff 200LB-FT 30100 380LB-FT 2aOLB-FT
3/4-16 .7S00 .37300 120KSI 8SKSI lSOKSI 120KSI 23800 300LB-Ff 22OLB-FT 33600 420LB-FT 320LB-FT
7/S-9 .87S0 .46200 120KSI 8SKSI ISOKSl llOKSl 29500 S20LB-Ff 39OLB-Ff 41600 6OOLB-Ff 460LB-FT
7/S-14 .87S0 .S09OO 120KSI 8SKSI 150KSI 120KSI 32400 57OLB-FT 43OLB-FT 45800 66OLB-FT 5OOLB-FT
-8 1.000 .60600 120KSI 8SKSI 150KSI 120KSl 38600 77OLB-FT 580LB-FT S4S00 9OOLB-FT 680LB-FT
1-12 1.000 .66300 120KSI 8SKSI l50KSI 120KSI 42300 8SOLB-FT 630LB-FT 59700 lOOOLB-FT 74OLB-FT
IlIS-7 1.1250 .76300 10SKSI 74KSI 150KSI 120KSI 42300 800LB-FT 6OOLB-Ff 68700 128OLB-FT 960LB-FT
1118-12 1.1250 .85600 105KSI 74KSI 150KSI llOKSI 47500 880LB-FT 66OLB-Ff 77000 I44OLB-FT 1000000FT
11l4~7 1.2500 .96900 IOSKSI 74KSI l50KSI 120KSI S3800 1120LB-FT 84OLB-Ff 87200 182OLB-FT 136OLB-FT
11/4-12 1.2500 1.0730 105KSl 74KSI ISOKSI 120KSI S9600 1248LB-FT 920LB-Ff 96600 2000LB-FT ~OOLB-Ff
13/11-6 1.3750 1.1S5O 10SKSI 74KSI 150KSI IlOKSI 64100 1468LB-FT 1100LB-Ff 104000 238OLB-FT 80LB-FT
13/S-12 1.3750 1.3150 10SKSI 74KSI lSOKSI 120KSI 73000 1680LB-FT 126OLB-FT 118400 272OLB-FT 204OLB-FT
II1Z-6 1.5000 1.4050 10SKSI 74KS1 ISOKSI I2OKS1 78000 194OLB-FT I46OLB-FT 126500 316OLB-FT 236OLB-FT
1112-12 1.5000 1.5800 10SKSI 74KSI 150KSI 120KSI 87700 22OOLB-FT 164OLB-FT 142200 3S6OLB-FT 2660LB-Ff

NOTES:

1. THIS CHART SHOWS RECOMMENDED BOLT TORQUES.

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

MANUAL 92350-002
JANUARY 1997
SIN X935-970S I
APPENDIX B

A div. of TIME Manufacturing Company

BOLT TORQUE CHART

FOR METRIC HEX HEAD CAP SCREWS

- RECOMMENDED ASSEMBLY TORQUES IN FOOT-POUNDS


(*VALUES IN LB-IN, OTHERS ARE LB-FT.)

-THE TORQUE VALUES FOR EACH DIAMETER ARE ACCEPTABLE


FOR ANY THREAD PITCH IN THAT DIAMETER.

PROPERTY CLASS 8.8 PROPERTY CLASS 9.8 PROPERTY CLASS 10.9 PROPERTY CLASS 12.9
DIAMETER DRY LUBRICATED DRY LUBRICATED DRY LUBRICATED DRY LUBRICATED
TIlREADS TIlREADS TIlREADS TIlREADS TIlREADS TIlREADS TIlREADS TIlREADS

M4 27.5* 17* 30* 18* 38.5* 24* 53* 32.5*

M5 56.5* 33.5* 61* 37* 78* 47* 107* 65*

M6 95* 57.5* 103* 61* 132* 79* 180* 109*

M8 19 12 21 13 27 16 37 22

MI0 39 23 42 25 53 32 73 44

M12 67 40 73 44 92 55 127 76

M14 107 64 116 69 146 89 203 122

M16 167 100 181 108 230 138 316 190

M20 325 195 352 211 449 269 617 370

M24 562 337 609 386 775 465 1066 640

M30 1117 670 1210 726 1540 924 2188 1271

MANUAL 92350-002
JANUARY 1997
SIN X935-97051
ATTENTION
MANUAL OF RESPONSIBILITIES
for
Dealers, Owners, Users, Operators,
Lessors, Lessees and Brokers
of
ANSIISIA A92.6-2006
Self-Propelled Elevating Work Platforms

WARNING
FAILURE TO COMPLY with your REQUIRED '
RESPONSmILITIES in the use and operation of the Aerial
Platform could result in DEATH OR SERIOUS INJURY.
IMPORTANT
You are required by ANSIISIA A92.6-2006 to read and understand YOUR
RESPONSIBILITIES before you use or operate this Aerial Platform.

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

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

The USER and OPERATOR MUST MAKE DECISIONS nalntenaIllce, use and operation'
of the Aerial Platform with due that the SAFETY OF THE
OPERATOR AND OTHER decisions. FAILURE TO
COMPLY with your REQUIRED and operation of the Aerial
Platform could result in DEATH OR

Refer to the manufacturer's nn<•...,~1n... aerial


platform and

The Self-Propelled
Manual incorporates

Definitions
Responsibilities of Dealers Page 2
Responsibilities of Owners Page 4
Responsibilities of Users Page 6
Responsibilities Page 10
Section 9 Page 13
Section 10 Page 13
Section 11 Page 13
Figure 1 Page 14

Single copy list price $4.95

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

Copyright © 2006 by Scaffold Industry Association, Inc.


All rights reserved.
No part of this publication may be reproduced in any form,
in an electronic retrieval system or otherwise, without the prior written permission ofthe publisher.
Printed in the. United States of America
RESPONSIBILITIES MANUAL Reprint from ANSIISIA A92.6 2006

13. DEFINITIONS Insulated platform. A platform designed and tested to meet the
specific electrical insulation ratings consistent with the
manufacturer's identification plate.
Aerial platform. A mobile device that has an adjustable position
platform, supported from ground level by a structure. Interlock. A control or mechanism that, under specified
Anchorage(s). A secure point of attachment to be used with conditions, automatically allows or prevents the operation of
personal fall protection equipment (PFPE). another control or mechanism.
Authorized personnel (authorized person). Personnel Lessee. A person(s) or entity to whom an aerial platform is
approved or assigned to perform a specific type of duty or duties provided by lease, rental, loan, or other arrangement. A lessee
at a specific location or locations at a work site. may also be a dealer, owner, user or operator.
Base. The relevant contact points of the aerial platform that form Lessor. A person(s) or entity who leases, rents, loans, or
the stability fulcrum (e.g. wheels, casters, outriggers, stabilizers). otherwise provides an aerial platform to another party for the
Broker. An independent business entity or person that arranges a beneficial use of that party (the user). A lessor may also be a
lease or transfer of ownership of an aerial platform, but does not dealer, owner, lessee, user, or operator.
own the aerial platform. If the entity or person is an employee of Maintenance. The act of upkeep such as inspection, lubrication,
the buyer, seller, lessor or lessee of the aerial platform, he shall adjustment and scheduled part(s)
not be considered a broker.
Chassis. The integral part of the aerial platform that provides A document containing the
mobility and support for the elevating assembly. 3) and the requirements mandated in this
Configuration. All positions in which an aerial platfol~ the following entities: Dealers (Section 5); Owners
part thereof can be placed within its intended operating 6); Users (Section 7); (Section 8); Lessors
Critical component(s). Load supporting elements which (Section 11).
or stabilize the platform or aerial platform. makes, builds, or
Dealer. A person or entity
distributor and who !;;<;1.'<;""11. .aximum platform height or the
platforms.
Delivery. Transfer of care, custody of the aerial manufacturer.
platform from one person or entity to another person or entity. modified. To make a change(s) to an aerial
Directional controls. Controls that initiate functions that affects the operation, stability, safety factors, rated
movement of the platform or the aerial platform. or safety of the aerial platform in any way.
Ductile materials. Materials having a mlllllII\un Most adverse stability condition(s). The permitted
10% in 2 inches (50.8mm). configuration of the aerial platform most likely to cause
Elevating assembly. The instability while maintaining stability. Factors to be considered
platform relative to the aerial shall include:
Familiarization. Providing the control (1) With zero load to maximum test load.
functions and safety devices for aerial platform(s) to a (2) Up to and including maximum platform height.
qualified person or operator who controls the movement of the (3) All positions and configurations of the platform(s).
aerial platform(s) being delivered. (4) All wheel and axle positions.
Guardrail system. A vertical barrier primarily intended to (5) Forward and backward configurations of the elevating
protect against personnel falling to lower levels. assembly;
Hazardous location. Any location that contains, or has the (6) All other moveable features which affect the stability of the
potential to contain, an explosive or flammable atmosphere as aerial platform.
defined in ANSIINFPA 505 - 1996, Powered Industrial Trucks. Multiple rating(s), multiple rated loads. Two or more different
Instability. A condition of an aerial platform in which the sum rated work loads based on alternative configurations of the aerial
of the moments that tend to overturn the unit exceeds the sum of platform.
the moments tending to resist overturning. Operation. Performance of functions of an aerial platform
within the scope of its specifications and in accordance with the
manufacturer's instructions, the user's work rules, and applicable
governmental regulations.
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RESPONSIBILITIES MANUAL Reprint from ANSIISIA A92.6 2006

Operator. A qualified person who controls the movement of an Stability/Stable. A condition of an aerial platform in which the
aerial platform. sum of the moments that tend to overturn the unit is less than or
Outriggers. Devices that increase the stability of the aerial equal to the sum of the moments tending to resist overturning.
platform and that are capable of lifting and leveling the aerial Stabilizers. Devices that increase the stability of the aerial
platform. platform but are not capable of lifting or leveling the aerial
Override. To take over aerial platform movement control platform.
functions at the upper control station by those at the lower control Training. Instruction to enable the trainee to become a qualified
station. person regarding the task to be performed, including knowledge
Owner. A person or entity who has possession of an aerial regarding potential hazards.
platform by virtue of proof of purchase. Unintended motion. Motion of the aerial platform or platform
Passive. Under specified conditions, automatically performed without activation of any control.
and not requiring any specific action to accomplish. Unrestricted rated workload. The maximum designed carrying
Platform. The portion of an aerial platform intended to be capacity of the aerial platform allowed by the manufacturer in all
occupied by personnel with their necessary tools and materials. operating configurations.
Platform height. The vertical distance measured from the floor User. A or entity who has care, control and custody of
of the platform to the surface upon which the machine is being the aerial This person or entity may also be the
supported. , a dealer, owner, lessor, lessee, or
Powered functions. Those which control motion of the platform
or the aerial platform and are caused by
hydraulic or pneumatic forces. operating, maintenance, repair and parts
Qualified person. One who, by possession of a recognized A92.6 2006
certificate, or professional standing, or by
training, and experience, has aerial platform
ability to solve or resolve
work, or the project.
Rated horizontal force.
force at the top rail which can be
specified by the manufacturer. OF DEALERS.
Rated work load. The designed carrying capacity of the
platform as specified by the manufacturer.
Rebuild/recondition. The Basic principles. Sound principles of safety, training,
adjustment of an aerial inspection, maintenance, application, and operation consistent
replacement parts and with all data available regarding the parruneters of intended use
beyond the scope of mamtfmatlC and expected environment shall be applied in the training of
standard) in order to restore, to operators, in maintenance, application, safety provisions and
platform or component to manufactured operation of the aerial platform with due consideration of the
specifications. knowledge that the aerial platform will be carrying personnel.
Remanufacture. The modification of an aerial platform, either 5.2 Manuals.
by the original manufacturer or another qualified entity, so that 5.2.1 Machine manual(s). Dealers shall keep and maintain a
the aerial platform will comply with the ANSI Standard in effect copy(ies) of the :
on the date the modification is completed. (1) Operating manual
Repair. The act of restoring to good condition that which has (2) Maintenance manual
been broken, damaged or worn due to use, abuse or other (3) Parts manual
reasons. (4) Repair manual
Shall. The word "shall" is to be understood as being mandatory. The operating manual and maintenance manual shall be provided
Should. The word "should" indicates that the rule is a with each rental, lease or sale delivery and shall be stored in the
recommendation, the advisability of which depends on the facts weather resistant storage compartment on the aerial platform.
in each situation. Manual(s) are considered an integral part of the aerial platform
and are vital to communicate necessary safety information to
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RESPONSIBILITIES MANUAL Reprint from ANSIISIA A92.6 2006

owners, users and operators. In addition, repair and parts (1) identify the weather resistant compartment (for manual
manuals should be provided with each sale delivery. storage).
5.2.2 Manual of Responsibilities. The current Manual of (2) confinn the manuals, as specified by the manufacturer, are on
Responsibilities for Dealers, Owners, Users, Operators, Lessors, the aerial platfonn.
Lessees, and Brokers of Self-Propelled Elevating Work Platfonns (3) review control functions
shall be provided and stored in the weather resistant storage (4) review safety devices specific to the model aerial platfonn
compartment. being delivered.
5.3 Pre-delivery preparation. Aerial platfonns shall be 5.9 Dealer as user. Whenever a dealer directs personnel to
inspected, serviced and adjusted to the manufacturer's operate an aerial platfonn (loading, unloading, inspecting, sales
requirements prior to each delivery by sale, lease or rental. demonstrations, or any fonn of use), the dealer shall assume the
5.4 Maintenance, inspection and repair. responsibilities of users as specified in Section 7 of this standard.
5.4.1 Maintenance. When a dealer accomplishes preventative All personnel authorized to operate the aerial platfonn shall have
maintenance on the aerial platfonn, it shall be in accordance with been:
the manufacturer's (remanufacturer's) recommendations, the (1 ) Trained.
environment, and severity of use. (2) Familiarized with the aerial platfonn to be operated.
5.4.2 Inspection. When the dealer accomplishes frequent and (3) of the responsibilities of operators as outlined in
annual inspections, they shall be accomplished in accordance this Standard.
with the manufacturer's (remanufacturer's) manuals. owners and users. If a dealer is unable to
5.4.3 Repairs. Repairs accomplished to correct LH".lJ.LUl~ or user's question(s} relating to rated capacity,
and problems shall be in accordance with the mamutat1 maintenance, repair, inspection, or operation of the
(remanufacturer's) manuals and instructions. platfonn, the dealer shall the proper infonnation
5.5 Maintenance safety precautions. if the manufacturer
repairs are started on an aerial nlolttn,rm infonnation to the
shall be taken as applicable:
(1) Power plant stopped rendered
inoperative;
(2) All controls in the "Off' years:
secured from inadvertent motion by brakes, blocks, or oth address of the purchaser of each aerial platfonn
means;
(3) Elevating assembly and platfonn lowered to Records of the predelivery preparation perfonned prior to
each delivery.
cribbing to prevent (3) Records of frequent and annual machine inspections
(4) Hydraulic oil pressure accomplished.
before loosening or rprt""''''" (4) Records of repairs accomplished to correct malfunctions and
(2) Safety props or latches problems.
prescribed by the manufacturer. (5) Name of the person(s} trained.
5.6 Replacement parts. When parts or components are (6) Name of the person(s) providing the training.
replaced, they shall be identical or equivalent to original aerial (7) Date of training.
platfonn parts or components. (8) Name of person(s) receiving familiarization with the aerial
5.7 Training. The dealer shall offer appropriate training to platfonn upon each delivery unless this individual has been
facilitate owners, users, and operators to comply with provided with familiarization on the same model, or one
requirements set forth in this standard regarding the inspection, having characteristics consistent with the one being
maintenance, use, application, and operation of the aerial delivered, within the prior 90 days.
platfonn. (9) Name of person(s) providing familiarization with the aerial
5.8 Familiarization on delivery. Upon delivery by sale, platfonn upon each delivery.
lease, rental or any fonn of use, the dealer shall have the 5.11.2 Proof of training. The dealllr should provide trainees
responsibility with the person designated by the receiving entity who successfully complete training a means to evidence they are
for accepting the aerial platfonn to: trained. The dealer shall provide such proof if requested by the
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RESPONSIBILITIES MANUAL Reprint from ANSIISIA A92.6 2006

RESPONSmILITIES OF OWNERS.
trainee. The document evidencing training shall include the
following information:
(1) Name of trainee
(2) Name of entity providing training or retraining.
(3) Name oftrainer(s).
(4) Clear identification that training covered Self-Propelled
Elevating Work Platforms.
(5) Date of training.
5.11.3 Record dissemination. Upon request, the dealer shall
provide the following information:
(1) To the owner of the aerial platform, a copy of frequent or
annual inspections performed.
(2) To the owner of the aerial platform, a copy of repairs
accomplished.
(3) To a user, proof of training for an operator, including name
of trainer and date of training.
(4) To a user, the name of the person(s) receiving familiarization
upon delivery of the aerial platform.
5.12 Modifications. Modification, alteration or ""J"au,...a.,,~
of an aerial platform shall be made only with prior
permission of the manufacturer. Should the
manufacturer no longer exist, a qualified
such modifications. All modltllcatl a copy(ies) of
manufacturer's requirements with each rental, lease,
(Responsibilities of maillutitctur,ers they are properly stored in the
5.13 Manufacturer's
The dealer shall comply with safety an integral part of the aerial platform
"U.''''''':;H:;U

from the manufacturer (remanufacturer). communicate necessary safety information to


5.14 Responsibilities upon sale. When the aerial users and operators, In addition, repair and parts
sold, the dealer: manuals should be provided with each sale delivery.
(1) Shall, upon delivery, ensure the 6.3.2 Manual of Responsibilities. The current Manual of
manuals are conveyed to the Responsibilities for Dealers, Owners, Users, Operators, Lessors,
(2) Shall, upon delivery, provide Lessees, and Brokers of Self-Propelled Elevating Work Platforms
Responsibilities for Dealers, shall be provided and stored in the weather resistant storage
Lessors, Lessees and Brokers compartment.
Work Platforms. 6.4 Maintenance, inspection and repair.
(3) Should, within 60 days of sale, provide repair and parts 6.4.1 Maintenance. The owner of an aerial platform shall
manuals. arrange that the maintenance specified in this standard is properly
(4) Shall, within 60 days of the sale, notify the manufacturer performed on a timely basis. The owner shall establish a
(remanufacturer) or its successor (if existing) of the sale, preventive maintenance program in accordance with the
providing the full name and address of the purchaser. manufacturer's (remanufacturer's) recommendations and taking
(5) Should, if the aerial platform is used, accomplish an annual into account the environment of the work place and severity of
machine inspection prior to delivery and provide a copy to use of the aerial platform.
the purchaser within 60 days of the sale. 6.4.2 Inspection. The owner shall arrange for frequent and
(6) Shall, upon delivery, familiarize the person designated by the annual inspections to be performed in accordance with the
receiving entity with the aerial platform being acquired. recommendations of the manufacturer (remanufacturer). All
malfunctions and problems identified in the inspection shall be
corrected before the aerial platform is returned to service.
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RESPONSIBILITIES MANUAL Reprint from ANSIISIA A92.6 2006

6.4.3 Repairs. When the aerial platform is damaged or in need manufacturer (remanufacturer) for an annual inspection. The
of repair, all malfunctions and problems identified shall be owner shall not place the aerial platform into service until all
corrected before the aerial platform is returned to service. malfunctions and problems have been corrected.
6.5 Predelivery preparation. Aerial platforms shall be 6.8 Maintenance safety precautions. Before adjustments and
inspected, serviced, and adjusted in accordance with the repairs are started on an aerial platform, the following precautions
manufacturer's (remanufacturer's) requirements prior to each shall be taken as applicable:
delivery by sale, lease or rental. (1) Power plant stopped and starting means rendered
6.6 Frequent inspection. The owner of an aerial platform shall inoperative;
ensure that a frequent inspection is performed in accordance with (2) All controls in the "off position and all operating systems
the manufacture's (remanufacturer's) instructions, for the aerial secured from inadvertent motion by brakes, blocks, or other
platform: means;
(1) That was purchased used. This inspection shall be (3) Elevating assembly and platform lowered to the full down
accomplished unless it is determined that the frequent and position, if possible, or otherwise secured by blocking or
annual inspections are current; cribbing to prevent dropping;
(2) That has been in service for three (3) months or 150 hours, oil pressure relieved from all hydraulic circuits
whichever comes first; or removing hydraulic components;
(3) That has been out of service for a period longer than three or latches installed where applicable as
months.
The inspection shall be made by a person qualified as a When parts or components are
on the specific type of aerial platform or one having shall be identical or equivalent to original aerial
design characteristics. The inspection shall be in accordance
items specified by the manufacturer for a shall train their
frequent inspection and shall to the of the
.1i:1HUClJli:1IU;C

following:
(1 ) All functions and their and 6.11 of this standard.
limits of motion;
(2) Lower controls including the for overriding of Whenever an owner directs or
upper controls to operate an aerial platform (loading,
(3) All chain and cable mechanisms for adjustment and inspecting or any form of use) the owner shall assume
damaged parts; responsibilities of the user as specified in Section 7 of this
(4) All emergency and safety devices; standard and shall ensure the person has been:
(5) Lubrication of all (1 ) Trained.
element(s), hydraulic oil, (2) Familiarized with the aerial platform to be operated.
by the manufacturer; (3) Made aware of the responsibilities of operators as outlined in
(6) Visual inspection of structural and other critical Section 8 of this Standard.
components such as fasteners, pins, shafts and locking 6.11.2 Assistance to user. Upon request of the user, when an
devices; owner leases, rents or provides an aerial platform for any form of
(7) Placard, warnings and control markings; beneficial use, the owner at that time shall offer to do training or
(8) Additional items specified by the manufacturer. advise the user where training may reasonably be secured.
The owner shall not place the aerial platform into service until all 6.12 Familiarization upon delivery. Upon delivery for lease,
malfunctions and problems have been corrected. rental or any form of beneficial use, the owner shall have the
6.7 Annual inspection. The owner of an aerial platform shall responsibility with the person designated by the receiving entity
ensure that an annual inspection is performed on the aerial for accepting the aerial platform to:
platform no later than thirteen (13) months from the date of the (1) Identify the weather resistant compartment (for manual
prior annual inspection. The inspection shall be performed by a storage).
person(s) qualified as a mechanic on the specific make and model (2) Confirm that the manuals, as specified by the manufacturer,
of the aerial platform or one having similar design characteristics. are on the aerial platform.
The inspection shall be in accordance with items specified by the
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RESPONSIBILITIES MANUAL Reprint from ANSIISIA A92.6 2006

(3) Review control functions with the operator or person(s) 6.15.3 Record dissemination. Upon request, an owner
designated by the user. accomplishing training and/or familiarization shall provide the
(4) Review safety devices specific to the model aerial platform following:
being delivered. (1) to a user, proof of training for an operator, including name of
6.13 Operation. When an owner operates an aerial platform, trainer and date of training;
the owner shall have the responsibilities of users as specified in (2) to a user, the name of the person(s) receiving familiarization
Section 7 of this standard and his operating personnel shall have upon delivery of the aerial platform.
responsibilities of operators as specified in Section 8 of this 6.16 Modifications. Modification, alteration or remanufacture
standard. of an aerial platform shall be made only with prior written
6.14 Assistance to users and operators. If an owner is unable permission of the manufacturer (remanufacturer). Should the
to answer a user's or operator's question(s) relating to rated manufacturer (remanufacturer) no longer exist, a qualified person
capacity, intended use, maintenance, repair, inspection, or may approve such modifications. All modifications shall meet
operation of the aerial platform, the owner shall obtain the proper the applicable manufacturer's requirements as specified in section
information from the dealer or manufacturer and provide that 4 (Responsibilities of manufacturers) of this Standard.
information to the user or operator. 6.17 Safety Bulletins. The owner shall
6.15 Record retention and dissemination. bulletins as received from the
6.15.1 Record retention. The owner shall date and retain the or the dealer
following records for at least 4 years: Upon sale of the aerial
(1) Name and address of the purchaser of each aerial
by serial number and date of delivery. and maintenance
(2) Written records of the frequent and annual inspections
repairs performed. The record shall current Manual of
found, corrective action Users, Lessors,
the person(s) performing Elevating Work
(3) Written records of
platform. and parts manuals to the new owner.
accomplished and 'u..."'.. u".~."'" the request of the new owner, offer to do training
the repairs. where training may reasonably be obtained.
(4) Pre-delivery preparation performed prior to each
(5) Name of the person(s) trained.
(6) Name ofperson(s) RESPONSIBILITIES OF USERS.
(7) Name of person(s)

on the same model, or one 7.1 Basic principles. The information in this standard must be
with the one being delivered, supplemented by good job management, safety control, and the
(8) Name ofperson(s) providing familiarization upon delivery. application of sound principles of safety, training, inspection,
6.15.2 Proof of training. Owners providing training should maintenance, application, and operation, consistent with all data
provide successful trainees a means to evidence their training and available regarding the parameters of intended use and expected
shall provide such proof if requested by the trainee. The environment. Since the user has direct control over the
document evidencing training shall include the following application and operation of aerial platforms, conformance with
information: good safety practices in this area is the responsibility of the user
(1) Name of trainee and the operating personnel, including the operator. Decisions on
(2) Name of entity providing training or retraining. the use and operation of the aerial platform must always be made
(3) Name oftrainer(s). with due consideration for the fact that the aerial platform will be
(4) Clear identification that training covered Self Propelled carrying personnel whose safety is dependent on those decisions.
Elevating Work Platforms. 7.2 Manuals.
(5) Date of training 7.2.1 Machine manuals. Users shall keep and maintain a
copy(ies) of the operating and maintenance manual(s) in the
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RESPONSIBILITIES MANUAL Reprint from ANSI/SIA A92.6 2006

weather resistant storage compartment provided by the (3) Elevating assembly and platform lowered to the full down
manufacturer. The manual(s) is considered an integral part of the position, if possible, or otherwise secured by blocking or
aerial platform and is vital to communicate necessary safety cribbing to prevent dropping;
information to users and operators. (4) Hydraulic oil pressure relieved from all hydraulic circuits
7.2.2 Manual of Responsibilities. The current Manual of before loosening or removing hydraulic components;
Responsibilities for Dealers, Owners, Users, Operators, Lessors, (5) Safety props or latches installed where applicable as
Lessees, and Brokers of Self-Propelled Elevating Work Platforms prescribed by the manufacturer (remanufacturer);
shall be provided and stored in the weather resistant storage (6) Precautions specified by the manufacturer (remanufacturer).
compartment. 7.4 Replacement parts. When parts or components are
7.3 Inspection and maintenance. Users shall inspect and replaced, they shall be identical or equivalent to original aerial
maintain the aerial platform as required to ensure proper platform parts or components.
operation. The frequency of inspection and maintenance shall be 7.5 Maintenance training. The user shall ensure only qualified
in accordance with the manufacturer's recommendations taking personnel inspect and maintain the aerial platform in accordance
into account the environment of the work place and the severity with the manufacturer's (remanufacturer's) recommendations and
of use of the aerial platform. Aerial platforms that are not in and 7.4 of this standard.
proper operating condition shall be immediately removed from and retraining. Whenever a user directs
service until repaired. Repairs shall be made by a qualified individual to operate an aerial platform the user
person and the repairs shall be in conformance with the
manufacturer's recommendations. being assigned to operate the aerial platform.
7.3.1 Frequent inspection. Users of an aerial PlaUOITI with the aerial platform to be operated.
ensure that frequent inspections Made aware of rp.~l'1on~jhj as outlined in
Section 6.6 of this standard. Section 8 of this
7.3.2 Annual inspection. (4) Retrained, if observation and
ensure that annual
Section 6.7 of this standard. of the trainee's aerial platform
7.3.3 Prestart inspection. by the user for at least 4 years.
beginning of each shift, the aerial shall be given a visua before use. The user shall permit only
inspection and functional test including but not limited to th personnel to operate an aerial platform. The user
following: ensure that before use the operator is familiar with the
(1) Operating and emergency controls. model of the aerial platform to be operated, and specifically:
(2) Safety devices. (1 ) knows where the weather resistant compartment for manual
(3) storage is located.
(4) Cables and wiring (2) knows the operating and maintenance manuals supplied by
(5) Loose or missing parts. the manufacturer (remanufacturer) are stored in the weather
(6) Tires and wheels. resistant compartment and is familiar with the operating and
(7) Placards, warnings, control markings, and operating safety manuals.
manual(s). (3) understands all control functions, placards and warnings.
(8) Outriggers, stabilizers, and other structures. (4) is aware of and understands all safety devices specific to the
(9) Guardrail system. model aerial platform being used.
(10) Items specified by the manufacturer. 7.8 Workplace inspection. Before the aerial platform is used
7.3.4 Maintenance safety precautions. Before adjustments and during use, the user shall check the area in which the aerial
and repairs are started on an aerial platform, the following platform is to be used for possible hazards such as, but not limited
precautions shall be taken as applicable: to:
(1) Powerplant stopped and starting means rendered inoperative; (1) Drop-offs or holes, including those concealed by water, ice,
(2) All controls in the "Off' position and all operating systems mud, etc.
secured from inadvertent motion by brakes, blocks, or other (2) Slope(s).
means; (3) Bumps and floor obstructions.
(4) Debris.
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RESPONSIBILITIES MANUAL Reprint from ANSIISIA A92.6 2006

(5) Overhead obstructions and high voltage conductors. from overhead obstructions and energized electrical
(6) Hazardous locations and atmospheres (reference conductors and parts.
ANSIINFPA 505-1996). (7) Electrocution hazard. All applicable safety related work
(7) Inadequate surface and support to withstand all load forces practices intended to prevent electric shock covered by the
imposed by the aerial platform in all operating Code of Federal Regulations (CFR) 1910.333 shall be
configurations. defined and explained to the operator by a qualified person.
(8) Wind and weather conditions. In particular, such person shall direct the operator,
(7) Presence of unauthorized persons. commensurate with the operator's qualifications, to maintain
(8) Other possible unsafe conditions. the appropriate minimum approach distance (MAD) from
7.9 Determination of hazardous locations. It shall be the energized power lines and parts covered by CFR 1910.333
responsibility of the user to determine the hazard classification of (c).
the intended location of operation. Aerial platforms operated in (8) Personal protective equipment (PPE). The user shall
hazardous locations shall be approved in accordance with, and of direct the operator to ensure all personnel on the platform
the type required, by ANSIINFPA 505-1996. wear personal protective equipment (PPE) as required.
7.10 Operator warnings and instructions. The user shall
direct personnel operating the aerial platform to be in compliance floor while working thereon. Climbing by
with the provisions set forth in section 8 of this standard. The midrail or toprail of the aerial platform is
user shall monitor their performance and supervise their work to of planks, ladders, or any other devices
ensure the use, application and operation of the aerial n1l1lttnrm for achieving additional height or reach is
in conformance with the provisions set forth in this
warn personnel of potential hazards, provide means to When other
against identified hazards, and explain the potentIa
of not following proper operating local ordinances or
guidelines regarding proper the workplace. Warnings
necessarily be limited to the roped off areas, flashing
(1) Fall protection. The be used as appropriate.
provides fall protection. or malfunctions. The user shall direct
required to wear personal fall protection equipment (PFPE), to immediately report to a supervisor any
or malfunction(s) that become evident during
aerial platform manufacturer operation. The user shall ensure all problems and
anchorage( s). malfunctions are repaired prior to continued use.
(2) Slope and grade. The (12) Reporting potentially hazardous locations. The user shall
in any marmer on grades, direct the operator to immediately report to a supervisor any
those for which the aerial potentially hazardous location(s) that become evident during
manufacturer (remanufacturer). operation.
(3) Deployment of stability enhancing means. Outriggers, (13) Hazardous location operation. Operation of aerial
stabilizers, extendible axles, oscillating axles or other platforms not approved and marked for operation in a
stability enhancing means shall be deployed and locked into hazardous location shall be prohibited.
place as required by the manufacturer (remanufacturer). (14) Entanglement. Care shall be taken to prevent rope,
(4) Guardrail system. Guardrails shall be installed and electric cords, and hoses, etc., from becoming entangled in
positioned, and access gates or openings shall be closed per the aerial platform.
the manufacturer's (remanufacturer's) instructions. (15) Capacity limitations. Rated capacities shall not be
(5) Distribution of load. The load and its distribution on the exceeded when loads are transferred to the platform at any
platform and any platform extension(s) shall be in height.
accordance with the manufacturer's (remanufacturer's) rated (16) Work area. The user shall direct the operator to ensure
capacity for that specific configuration. the area surrounding the aerial platform is clear of personnel
(6) Maintain overhead clearance. The operator shall be and equipment before lowering the platform.
instructed to ensure that adequate clearance is maintained
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RESPONSIBILITIES MANUAL Reprint from ANSIISIA A92.6 2006

(17) Fueling. The engine (if applicable) shall be shut down personnel shall be removed from the platform/basket before
while fuel tanks are being filled. Fueling shall be done in a attempts are made to free the platform using lower controls.
well-ventilated area free of flame, sparks, or other hazards (28) Vacating (or entering) an elevated aerial platform. If
that may cause fire or explosion. permitted by the manufacturer, personnel shall only vacate
(18) Battery charging. Batteries shall only be charged in a or enter a raised aerial platform by following the guidelines
well-ventilated area free of flame, sparks, or other hazards and instructions provided by the manufacturer
that may cause fire or explosion. (remanufacturer).
(19) Improper platform stabilization. The aerial platform (29) Modifications. Modification or alteration of an aerial
shall not be positioned against another object to steady the platform or the fabrication and attaching of frameworks, or
platform or improve stability. the mounting of attachments for holding tools or materials
(20) Misuse as a crane. The aerial platform shall not be used onto the platform or the guardrail system shall only be
as a crane. accomplished with the prior written permission of the
(21) Unusual operating support conditions. The aerial manufacturer (remanufacturer). Should the manufacturer
platform shall not be operated from a position on trucks, (remanufacturer) no longer exist, a qualified person may
trailers, railway cars, floating vessels, scaffolds, or similar modifications. All modifications shall meet
equipment unless the application is approved in writing by manufacturer's requirements as specified in
the manufacturer (remanufacturer) or a qualified person. of manufacturers) of this
(22) Travel speeds. The user shall direct the operator to limit
travel speed according to conditions, including the "nTHiitlnn operator. If an operator encounters any
of the support surface, congestion, visibility, slope, malfunction of the aerial platform, or any hazard
of personnel, and other factors leading to hazards which capacity, intended
cause collision(s) or result the operator shall
personnel. request further
(23) Driving requirements.
aerial platform, the user shall Any problem(s) or
(a) Maintain a clear view of
of travel. use of the aerial platform.
(b) Ensure personnel in the worksite area that ,uifprilll!l (larger than the platform.) The user

affected are aware of the movement, cOlnIrmnica ensure that only tools and materials which are evenly
and maneuvering the aerial platform distributed and can be safely handled by a person(s) working
from the platform are transported.
(c) Maintain a safe distance (33) Rated horizontal force. The user shall direct the operator
offs, holes, depressions, not to exceed the manufacturer's (remanufacturer's) rated
ensure safe travel. horizontal force.
(d) Maintain a safe distance obstacles and (34) Bridge cranes. When an aerial platform is to operate within
energized electrical conductors. the area of travel of a bridge crane or similar equipment,
(24) Stunt driving. The user shall inform the operator that stunt steps shall be taken to prevent a collision with the aerial
driving and horseplay are prohibited. platform.
(25) Securing the aerial platform. The user shall direct the (35) Adequate support requirements. The user shall insure the
operator to implement means provided to protect against use support surface is adequate for the aerial platform and the
by an unauthorized person(s). load carried.
(26) Altering safety devices. Interlocks or other safety devices (36) Leveling the aerial platform. Outriggers and leveling
shall not be altered or disabled. devices supplied by the manufacturer (remanufacturer) shall
(27) Snagged platform. If the platform/basket or supporting be utilized to level the aerial platform when provided.
assembly becomes caught, snagged, or otherwise prevented (37) Protecting against unauthorized use. The user shall direct
from normal motion by adjacent structures or other obstacles the operator not to use, rent, lease, or provide the aerial
such that control reversal does not free the platform, all platform for any form of beneficial use unless so authorized.

9
RESPONSIBILITIES MANUAL Reprint from ANSI/SIA A92.6 2006

7.11 User as Operator. If a user is also the operator of an permission of the manufacturer (remanufacturer). Should the
aerial platform, the user shall have the responsibilities of manufacturer (remanufacturer) no longer exist, a qualified person
operators specified in Section 8 of this standard as well as may approve such modifications. All modifications shall meet
responsibilities of users as specified in Section 7 of this standard. the applicable manufacturer's requirements as specified in section
7.12 Shutdown of aerial platform. The user shall authorize 4 (Responsibilities of manufacturers) of this Standard.
and direct the operating personnel to cease operation of the aerial 7.15 Manufacturer's safety bulletins. The user shall comply
platform in case of any suspected malfunctions of the aerial with safety-related bulletins as received from the manufacturer
platform, or any hazard or potentially unsafe condition that may (remanufacturer), dealer or owner.
be encountered, and to request further information as to safe
operation from the owner, dealer, or manufacturer before further
operation ofthe aerial platform. 18. RESPONSIBILITIES OF OPERATORS.
7.13 Record retention and dissemination.
7.13.1 Record retention. The user shall retain the following
records for at least 4 years: 8.1 Basic principles. The information in this standard shall be
(1) Names of the operator(s) trained and retrained. Su}:'pl~:m~:n!~:d by good judgment, safety control, and caution in
(2) Names of operator(s) provided familiarization. situation. Since the operator is in direct control of
(3) The owner (or the entity designated by the owner) is
responsible to ensure frequent and annual inspections are iWV'll,,.VUJ.Y of the operator. The operator shall
conducted and written records are maintained. The on the use and operation of the aerial platform
shall include the date of the inspection, any consideration for the fact that his or her own safety as
found, the corrective action recommended and 1(1entllIc as the safety of other platform is dependent
of the person(s) performing the inspection.
(4)
platform, the user shall
shall include the date manuals are stored in the weather
accomplished, and 1'(lenUIlcl on the aerial platform. The
the repair. InSlldelred an integral part of the aerial platform and
7.13.2 Record dissemination communicate necessary safety information to the
(1 ) When the user directs personnel to accomplish The operator shall be familiar with the manuals and
annual inspections, not later than 60 reference them as required.
inspections. the appropriate 8.2.2 Manual of Responsibilities. The operator shall be
owner of the aerial familiar with the requirements for operators as set forth in Section
(2) 8 of the Manual of Responsibilities for dealers, owners, users,
operators, lessors, lessees, and brokers of Self-Propelling
Elevating Work Platforms. The current Manual of
the owner. Responsibilities for Dealers, Owners, Users, Operators, Lessors,
7.13.3 Proof of training. Users providing training should Lessees, and Brokers of Self-Propelled Elevating Work Platforms
provide successful trainees a means to evidence their training and shall be provided and stored in the weather resistant storage
shall provide such proof if requested by the trainee. The compartment.
document evidencing training shall include the following 8.3 Prestart inspection. Before use each day or at the beginning
of each shift, the aerial platform shall be given a visual inspection
information: and functional test including but not limited to the following:
(1) Name of trainee. (1) Operating and emergency controls.
(2) Name of entity providing training or retraining. (2) Safety devices.
(3) Name oftrainer(s). (3) Personal protective devices.
(4) Clear identification that training covered Self Propelled (4) Air, hydraulic, and fuel systems leaks.
Elevating Work Platforms. (5) Cables and wiring harness.
(5) Date of training. (6) Loose or missing parts.
7.14 Modifications. Modification, alteration or remanufacture (7) Tires and wheels.
of an aerial platform shall be made only with prior written (8) Placards, warnings, control markings, and operating
manual(s).
10
RESPONSIBILITIES MANUAL Reprint from ANSIISIA A92.6 2006

(9) Outriggers, stabilizers and other structures. (1) Drop-offs or holes, including those concealed by water, ice,
(10) Guardrail system.
mud, etc.
(11)Items specified by the manufacturer (remanufacturer).
8.4 Problems or malfunctions. Any problems or malfunctions (2) Slope(s).
(3) Bumps and floor obstructions.
that affect the safety of operations shall be repaired prior to the
(4) Debris.
use of the aerial platform. (5) Overhead obstructions and electrical conductors.
8.5 Training, retraining, and familiarization. (6) Hazardous locations and atmospheres (reference
8.5.1 General training. Only personnel who have received ANSIINFPA 505-1995).
general instructions regarding the inspection, application and (7) Inadequate surface and support to withstand all load forces
operation of aerial platforms, including recognition and imposed by the aerial platform in all operating
avoidance of hazards associated with their operation, shall configurations.
operate an aerial platform. Such items covered shall include, but (8) Wind and weather conditions.
not necessarily be limited to, the following issues and (9) Presence of unauthorized persons.
requirements:
(1) The purpose and use of manuals. (10) Other possible unsafe conditions.
(2) That operating manuals are an integral part of the aerial 8.8 Prior to each elevation. Before each elevation of the
platform and must be stored properly in the weather resistant platform, the operator shall ensure:
compartment when not in use.
(3) A pre-start inspection. '''''V'UL",,,, extendible axles, or other stability
(4) Responsibilities associated with problems or malfunctions are used as required by the manufacturer.
affecting the operation of the aerial platform. and access gates or openings are
Lll<>.all<'U

(5) Factors affecting stability. m~nmp-r'~ (remanufacturer's) instructions.


(6) The purpose of placards and decals. its distribution on the platform and any
(7) Workplace inspection. extension(s) are in accordance with the
(8) Safety rules and regulations. (remanufacturer' rated capacity for that
(9) Authorization to operate. specific configuration.
(10) Operator warnings and instructions. All personnel on the
(11) Actual operation of the aerial platform.
of a qualified person, the .
platform for a sufficient
proficiency in the actual to understand the hazard
8.5.2 Retraining. The OP(:ratlor location of operation according to
directed by the user, based
evaluation of the operator. warnings and instructions. The operator shall
8.5.3 Familiarization. When an operator is directed to operation of the aerial platform is in compliance with
an aerial platform he/she is not familiar with, the
receive instructions regarding the following items: Fall protection. The guardrail system of the aerial platform
(1) The location of the weather resistant provides fall protection. If occupant(s) of the platform are
manual storage). required to wear personal fall protection equipment (PFPE),
(2) The purpose and function of occupants shall comply with instructions provided by the
aerial platform manufacturer (remanufacturer) regarding
(3) Safety devices and operatin~
anchorage(s).
aerial platform. (2) Slope and grade. The aerial platform shall not be operated
8.6 Before operation. Before operator shall: in any manner on grades, side slopes or ramps exceeding
(1) Read and understand the manufacturer's (remanufacturer's) those for which the aerial platform is rated by the
operating instruction(s) and user's safety rules or have them manufacturer (remanufacturer).
explained. (3) Deployment of stability enhancing means. Outriggers,
(2) Understand all labels, warnings and instructions displayed on stabilizers, extendible axles, oscillating axles or other
the aerial platform or have them explained. stability enhancing means shall be deployed and locked into
(3) Ensure all occupants of the aerial platform wear appropriate place as required by the manufacturer (remanufacturer).
(4) Guardrail system. Guardrails shall be installed and
personal protection equipment (PPE) for the conditions,
positioned, and access gates or openings shall be closed per
including the environment in which the aerial platform will the manufacturer's (remanufacturer's) instructions.
be operated. (5) Distribution of load. The load and its distribution on the
platform and any platform extension(s) shall be in
8.7 Workplace inspection. Before the aerial platform is used
accordance with the manufacturer's rated capacity for that
and during use, the operator shall check the area in which the specific configuration.
aerial platform is to be used for possible hazards such as, but not (6) Maintaining overhead clearance. The operator shall
limited to: ensure that adequate clearance is maintained from overhead
obstructions and energized electrical conductors and parts.

11
RESPONSIBILITIES MANUAL Reprint from ANSIISIA A92.6 2006

(7) Electrocution hazard. The operator shall perfonn only that (21) Unusual operating support conditions. The aerial
platfonn shall not be operated from a position on trucks,
work for which he or she is qualified, in compliance with all trailers, railway cars, floating vessels, scaffolds, or similar
applicable safety related work practices intended to prevent equipment unless the application is approved in writing by
electric shock covered by the Code of Federal Regulations the manufacturer (remanufacturer) or a qualified person.
(22) Travel speeds. The operator shall limit travel speed
(CFR) 1910.333. The operator's level of competence shall according to conditions, including the condition of the
be established only by persons qualified to do so. Operators support surface, congestion, visibility, slope, location of
shall maintain the appropriate minimum approach distance personnel, and other factors leading to hazards which may
cause collision(s) or result in potential injury(ies) to
(MAD) from energized power lines and parts covered by personnel.
CFR 1910.333 (c). (23) Driving requirements. Before and during driving the aerial
(8) Personal protective equipment (PPE). The operator shall
ensure all occupants of the platfonn wear personal protective platfonn, the operator shall:
equipment as required. (a) Maintain a clear view of the support surface and route
(9) Personnel footing. Personnel shall maintain finn footing on of travel.
the platfonn floor while working thereon. Climbing by (b) Ensure personnel in the worksite area that may be
occupants on the midrail or toprail of the aerial platfonn is affected are aware of the movement, communicating
prohibited. The use of planks, ladders, or any other devices and maneuvering the aerial platfonn as required to
on the platfonn for achieving additional height or reach is against personal injury.
prohibited~ a safe distance from obstacles, debris, drop-
(10) Precaution for other moving equipment. When other depressions, ramps, and other hazards to
moving equipment and vehicles are present, special travel.
precautions shall be taken to comply with local ordinances a safe distance from overhead obstacles and
safety standards established for the workplace. :nelrgt~ed electrical conductors.
such as, but not limited to, flags, roped off areas, driving. Stunt driving and horseplay are prohibited.
lights, and barricades shall be used as appropriate. Securing the aerial The operator shall
(11) Reporting problems or malfunctions. The operator implement means against use by an
immediately report to a supervisor unauthorized
malfunction(s) that become (26) Altering or other safety devices
operator shall ensure shall not
affect the safety of (27) "nal~gt:u platformibasket or supporting
use. snagged, or otherwise prevented
(12) Reporting potentially by adjacent structures or other obstacles
shall immediately report to supervisor control reversal does not free the platfonn, all
shall be removed from the platformibasket before
hazardous location(s) that become evident during uuo~.al"U1J atte:mpts are made to free the platfonn using lower controls.
(13) Hazardous location operation. Operation Vacating (or entering) an elevated aerial platform. If
platfonns not approved and marked for pennitted by the manufacturer, personnel shall only vacate
or enter a raised aerial platfonn by following the guidelines
hazardous location shall be and instructions provided by the manufacturer
(14) Entanglement. Care (remanufacturer).
cords, and hoses, etc., (29) Modifications. Modification or alteration of an aerial
platfonn. platfonn or the fabrication and attaching of frameworks, or
(15) Capacity limitations. the mounting of attachments for holding tools or materials
exceeded when loads are onto the platfonn or the guardrail system shall only be
height. accomplished with the prior written pennission of the
(16) Work area. The operator shall ensure the area surrounding manufacturer (remanufacturer). Should the manufacturer
the aerial platfonn is clear of personnel and equipment (remanufacturer) no longer exist, a qualified person may
before lowering the platfonn. approve such modifications. All modifications shall meet
(17) Fueling. The engine (if applicable) shall be shut down while the applicable manufacturer's requirements as specified in
fuel tanks are being filled. Fueling shall be done in a well- section 4 (Responsibilities of manufacturers) of this
ventilated area free of flame, sparks, or other hazards that Standard.
may cause fire or explosion.
(18) Battery charging. Batteries shall only be charged in a well- (30) Assistance to the operator. If an operator encounters any
ventilated area free of flame, sparks, or other hazards that suspected malfunction of the aerial platfonn, or any hazard
may cause fire or explosion. or potentially unsafe condition relating to capacity, intended
(19) Improper platform stabilization. The aerial platfonn shall use or safe operation of the aerial platfonn, the operator shall
not be positioned against another object to steady the cease operation of the aerial platfonn and request further
platfonn or improve stability. infonnation from the user.
(20) Misuse as a crane. The aerial platfonn shall not be used as
a crane.

12
RESPONSIBILITIES MANUAL Reprint from ANSIISIA A92.6 2006

(31) Problem(s) or malfunction(s). Any problems or 9.4 Lessor as a user. When a lessor is the user of the aerial
malfunctions that affect the safety of operations shall be platform, the lessor shall have the responsibilities of users as
repaired prior to the use of the aerial platform. specified in Section 7 of this standard.
(32) Carrying materials (larger than the platform.) The 9.5 Lessor as an operator. When a lessor is the operator of the
operator shall ensure only tools and materials which are aerial platform, the lessor shall have the responsibilities of
evenly distributed and can be safely handled by a person(s) operators as specified in Section 8 of this standard.
working from the platform, shall be transported.
(33) Rated horizontal force. The operator shall not permit
personnel on the platform to exceed the manufacturer's 110. RESPONSIBILITIES OF LESSEES.
(remanufacturer's) rated horizontal force.
(34) Bridge cranes. When an aerial platform is to operate within
the area of travel of a bridge crane or similar equipment, 10.1 Basic principles. Sound principles of safety, training,
steps shall be taken to prevent a collision with the aerial
platform. inspection, maintenance, application, and operation consistent
(35) Adequate support requirements. The operator shall ensure with all data available regarding the parameters of intended use
the support surface is adequate for the aerial platform and the and expected environment shall be applied in the performance of
load carried.
(36) Leveling the aerial platform. Outriggers and leveling of lessees with due consideration of the
devices supplied by the manufacturer shall be utilized to the aerial platform will be carrying personnel.
level the aerial platform when provided. a Dealer. When a lessee is also the dealer for the
(37) Protecting against unauthorized use. The operator shall amlfiu;tw:er) of the aerial platform, the lessee
V~<'HnH"'~" of dealers as specified in Section 5
not use, rent, lease, or provide the aerial platform
form of beneficial use to another entity as an Owner. When a lessee is the owner of the
authorization of the user. platform, the lessee the responsibilities of
8.11 Record of training. When provided or when obtained owners as specified in
the operator's request, proof of training 10.4 Lessee as a U
entity should be retained by the platform, the lessee 'U"",nuu,",,, of users as

the following information: specified in


10.5 Lessee a lessee is the operator of the
(1) Name of trainee. have the responsibilities of
(2) Name of entity providing 8 of this standard.
(3) Name oftrainer(s).
(4) Clear identification that
Elevating Work Platforms.
(5) Date of training. OF BROKERS.

9. RESPONSIBILITIES OF 11.1 Responsibilities upon sale. The broker shall:


(1) Upon delivery, ensure the operating and maintenance
manuals are provided to the new owner.
(2) Upon delivery, provide a copy of the current Manual of
9.1 Basic principles. of safety, training, Responsibilities for Dealers, Operators, Users, Lessors,
inspection, maintenance, operation consistent Lessees, and Brokers of Self-Propelled Elevating Work
Platforms to the new owner.
with all data available regarding the parameters of intended use
(3) Maintain records of the. sale for a minimum of four (4) years.
and expected environment shall be applied in the performance of 11.2 Responsibilities with re-rents, leases, or any other form
responsibilities of lessors with due consideration of the of beneficial use. When compensation is received as a result of a
knowledge that the aerial platform will be carrying personnel. re-rent, lease or any form of beneficial use of an aerial platform,
the broker shall:
9.2 Lessor as a dealer. When a lessor is a dealer for the (1) Upon delivery, ensure the operating and maintenance
manufacturer of the aerial platform being leased, the lessor shall manuals are provided to the user.
have the responsibilities of dealers as specified in Section 5 of (2) Upon delivery, provide a copy of the current Manual of
Responsibilities for Dealers, Operators, Users, Lessors,
this standard. Lessees, and Brokers of Self-Propelled Elevating Work
9.3 Lessor as an owner. When a lessor is the owner of the aerial Platforms.
platform being leased, the lessor shall have the responsibilities of (3) Ensure operating personnel are familiarized with the aerial
platform prior to use.
owners as specified in Section 6 of this standard.
(4) Retain records of the transaction for a minimum of four (4)
years.
13
Figure 1 - Typical Examples of Equipment Covered
A div. of TIME Manufacturing Company

SELF-PROPELLED
ELEVATING WORK PLATFORM

MODEL V2033XL, V2033


Serial Number X935-97051

ILLUSTRATED·PARTS MANUAL

SHIPPING ADDRESS MAILING ADDRESS

CONDOR® CONDOR®
A DIV. OF TIME MFG. CO. A DIY. OF TIME MFG. CO..
8300 IMPERIAL DRIVE P.O. Box 21447
VVAco,TEXAS76712 VVAco,TEXAS76702-1447
(817) 420-5200 (817) 420-5200

MANUAL 92350-003
January 1997
SIN X935·97051
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®, and to
provide the information necessary to maintain and service the CONDOR®.

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

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

It is YOUR RESPONSIBILITY to follow procedures while operating the CONDOR®.


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

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

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

DO NOT ALTER OR MODIFY THIS CONDOR® WITHOUT PRIOR WRITTEN APPROVAL


~t, FROM THE MANAGEMENT OF CONDOR Div.

SERVICE & MAINTENANCE

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

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

MANUAL 92350-003
January 1997
SIN X935-97OS 1
ii

A div. of TIME Manufacturing Company

CONDOR® SERVICE INFORMATION

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

(817) 420-5200 Telephone


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

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

3. Service and maintenance are not a substitute for trained, qualified service technicians.
Condor conducts service schools on a continuing basis. Call any of our service or sales
persons for a schedule. Remember, training of mechanics is the responsibility of their
employer, but Condor Service Schools help you provide this training.

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

CONDOR DIVISION

8300 IMPERIAL DRIVE, P.O. Box21447, WACO, TExAs 76702-1447· 817-420-52005, 817-666-4544 FAX
CONDOR® MODEL V2033XL & V2033
ILLUSTRATEDPARTS~AL

TABLE OF CONTENTS

INTRODUCTION ............................................................................................................. i

SERVICE INFORMATION ............................................................................................ ii
SERIAL NUMBER TO MODEL DESIGNATION ....................................................... iii
TABLE OF CONTENTS ................................................................................................. 1
FIGURE DESCRIPTION PAGE

A ............................................... Serial Number Location ............................................. 2


B ............................................... Recommended Spare Parts List ................................. 3
C ............................................... How to Order Parts ................................................. 4,5

1 ............................................... Final Installation ........................................................ 6


2 ............................................... Decal Installation '" .................................................... 8
3 ............................................... Carriage Assembly ................................................... 10
4 ............................................... Hose Installation ....................................................... 12
5 ............................................... Lift Cylinder ............................................................ 14
6 ............................................... Steer Cylinder ................................ ::=; ................... 15
7 ............................................... Brake Cylinder.... ... .... .......... ....... ... ..... .... ................. 16
8 ............................................... Hub Motor Assembly .............................................. 17
9 ............................................... Hub Assembly .......................................................... 18
10 ............................................... Belly Pan Assembly ................................................. 20
11 ............................................... Motor & Pump Assembly ........................................ 24
12 ............................................... Pump Assembly ....................................................... 25
13 ............................................... Motor 24VDC Assembly ......................................... 26
14 ................................................ Manifold Assembly ................................................. 28
15 ............................................... Charger 115V/60HZ-25A124VDC .......................... 30
16 ............................................... Electrical Wiring ...................................................... 34
17 ............................................... Jumper Assembly .................................................... 36
18 ............................................... Cylinder Harness Assembly .................................... 39
19 ............................................... Lower Control Box Assembly ............................ ,.... 40
20 ............................................... Armstack Assembly ................................................. 48
21 ............................................... Armstack Cylinder ................................................... 54
22 ............................................... Manifold Assembly ................................................. 57
23 ............................................... Platform Assembly .................................................. 58
24 ............................................... 110 Volt Extension To Platform .............................. 61
25 ............................................... Upper Control Box Assembly ................................. 62
26 ............................................... Travel Alarm (Option) ............................................. 66
27 ............................................... Motion Alarm (Option) ........................................... 67
28 ............................................... Strobe Light (Option) .............................................. 68
29 ............................................... Descend Alarm (Option) .......................................... 69
30 ............................................... Slope Alarm (Option) .............................................. 70
31 ............................................... Hour Meter (TI-Option) ......................................... 71
32 ............................................... Battery Condition Indicator (TI-Option) ................ 72
33 ............................................... Low-Voltage Warning Interrupt (TI-Option) ......... 73
34 ............................................... Larger Batteries IPOS (TI-Option) ....................... 75

MANUAL 92350-003
January 1997
SIN X93S-970S 1
• FIGUREA-SerialNumber Location

1
2

The CONDOR® Model V2033XL & V2033 Serial Number is stamped in two locations on the machine.

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

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

MANUAL 92350-003
January 1997
SIN X935-97051
FIGURE B-Recommended Spare Parts List •

CONDOR®MODELV2033XL&V2033 (1 UNIT-l YEAR OPERATION)

V2033XL V2033
PARTNUMBER DESCRIPTION QTY QTY

91029 .................................. Nut Lug 1/2" ..................................................... 5 .............................. 5


555636-001 ......................... Stud Wheel 112"-20 x 1 3/4" ............................. 5 .............................. 5
54783 .................................. Cable Assembly, Emergency Lowering ............ 1 .............................. 1
54798 .................................. Couple Nut, 10-32UNF .................................... 1 .............................. 1
55471 .................................. Plunger, Hand Retract Spring ............................ 3 .............................. 3
55241 .................................. Spring Loaded Pull-Up Latch ........................... 3 .............................. 3
54048 .................................. Latch Door ........................................................ 1 ........................ ...... 1
67408 .................................. Element, Hydraulic Filter PIN 33430 ................ 5 .............................. 5
36085 .................................. Fitting, Swivel 90° Elbow 6-6 ........................... 2 .............................. 2
51036 .................................. Switch Limit Body Only ................................... 1 .............................. 1
51037 .................................. Offset Head Limit Switch ................................. 1 .............................. 1
51039-002 ........................... Limit Switch, ArmIShort ................................... 1 .............................. 1
54589 .................................. Controller, Drive/Steer ...................................... 1 .......................... N/A
67939-015 ........................... Fuse, 15Amp ..................................................... 1 .............................. 1
67940 .................................. Fuse Holder ....................................................... 5 .............................. 5
52138 .................................. Solenoid 24V ..................................................... 1 .............................. 1
206-00001-00 ...................... Diode ................................................................. 9 .............................. 9
54438 .................................. Relay, 24V SPDT Bosch ................................... 1 .............................. 1
34547 .................................. Jumper ............................................................... 4 .......................... N/A
34542 .................................. Jumper .......................................................... NIA.............................. 1
55982-002 ........................... Decal Installation .............................................. 1 .......................... N/A
55982-102 ........................... Decal, V2033XLEssentiais .............................. 1 .......................... N/A
55982-001 ........................... DecaIInstallation ......................................... N/A .............................. 1
55982-101 ........................... Decal, V2033 Essentials ............................... NIA.............................. 1
55469 .................................. Hose Kit ............................................................ 1 .............................. 1
55243 ......................... :........ Spring - Deck Latch .......................................... 1 .............................. 1
55333 .................................. Charger .............................................................. 1 .............................. 1
54910-102 ........................... Receptacle ......................................................... 1 .............................. 1
54910-104 ........................... Mounting ........................................................... 1 .......................... N/A
51913 .................................. Operator, Red P-Pull ......................................... 1 .............................. 1
51914 .................................. Base, 1 NC Contact ........................................... 1 .............................. 1
52670 .................................. Operator, 3 Pos Rot ........................................... 1 .......................... N/A
34464 .................................. Base, NOINC Contacts ...................................... 1 .......................... N/A
52669 .................................. Operator, Black P-Button .................................. 1 .......................... N/A
52672 .................................. Base, 1 NOContact, .......................................... I .......................... N/A
69146 .................................. Operator,GreenP-Button ................................. 1 .......................... N/A
54913 .................................. Operator BlackIBlack Double P-Button ............ 1 .......................... NIA
52029 .................................. Base, 2 NO Contacts ......................................... 1 .............................. 1
50075 .................................. Switch ................................................................ 1 .............................. 1
67758 .................................. Toggle Switch .............................................. N/A ............................... 1
52671 .................................. Operator, 3 Pos Key ..................................... N/A .............................. 1

MANUAL 923S0-003
January 1997
SIN X935-970S 1
• FIGURE C-How to Order Parts

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

2. Ifknown, please specify the Condor Div. part number(s) for the part(s) you require, and always
provide a complete description of all parts.

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

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

5. Condor Div. will ship parts as per our customers' request at the time of the order-Le., 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 Div. classifies its orders in the following ways:

Emeraenc.y (unit out of service) - Top priority. Shipping deadline for emergency
orders to ship same day is 2.00 p.m. Central Standard Time. Any
emergency order received after 2.00 p.m. will be shipped the
following day.

Order to be shipped within 1 week.

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

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

MANUAL 923S0-003
January 1997
SIN X93S-970SI
ACCOUNT #
CONDOR DIV. PARTS DEPARTMENT
FAX ORDER FORM FAX NO. 800-443-5803

I PURCHASER SALES ORDER #



I NAME
N NAME
C
U F
S 0 ADDRESS S ADDRESS
T R H T
0 M I 0
M A CITY STATE ZIP P CITY STATE ZIP
E T
R I
0 PHONE FAX PHONE FAX
N ( ) ( ) ( ) ( )
CUST. PURCHASE ORDER NO. I ORDERDATE I REQUEST DATE SPECIAL MARKS & NUMBERS
I J
SHIPPING INSTRUCTIONS

PART NUMBER QTY. DESCRIPTION NOTES

FOR ORDER STATUS PLEASE CHECK


APPROPRIATE BOX BELOW

EMERGENCY

STOCK

MANUAL 92350-003
January 1997
SIN X935-97051
• FIGURE 1: Final Installation

14

5
2

11 4
12 6
13

MANUAL 92350-003
January i997
SIN XlI3S-970S1
FIGURE 1: Final Installation •

ITEM PART NUMBER DESCRIPTION QTY

Ref. 55486 ........................... Final Installation V20331XL ..................................................... Ref.


1 55441 ........................... Arm Stack Installation ................................................................... 1
2 55478 ........................... Platform Assembly ........................................................................ 1
3 55467 ........................... Chassis Assembly ...................................................................... ,... 1
4 55468 ........................... Belly Pan Assembly ....................................................................... 1
5 54918 ........................... 110V Ext. To Platform Installation ................................................ 1
6 55315 ........................... Wiring Installation ......................................................................... 1
7 54783 ........................... Cable Assembly, Emergency Lowering ........................................ 1
-8 ..................................... Oil, Hydraulic Tellus T32 ......................................................... 8GI.
-9 [Not Used] ............................................................................................................................. .
-10 ..................................... Nameplate, Scissor Ident. .............................................................. 1
11 55482 ........................... Cover, LH Side .............................................................................. 1
12 55483 ........................... Cover, RH Side .......... ;................................................................... 1
13 54048 ........................... Latch, Door .................................................................................... 2
14 55317 ........................... Box Assembly, Upper Control ...................................................... 1
15 55489 ........................... Box Assembly, Lower Control ...................................................... 1
-16 55469 ........................... Hose Kit .......................................................................................... 1
-17 55487 ........................... Decal Installation ........................................................................... 1
-18 67837-007 .................... Tie, Nylon 7 1/2 Black .................................................................. 10
-19 34354 ........................... Holder, Safety Manual-Blk Caps ................................................... 1
-20 67793 ........................... Clamp, 2.75 Dia. Cable .................................................................. 2
-21 BOW31401 .................. Washer, Flat .25"ID x .63"OD ....................................................... 2
-22 BOW36780 .................. Nut, Hex .25-20UNC Nylon Lock ................................................. 2
-23 92350-001 .................... Operator'sManual .......................................................................... 1
-24 A630-V2033 ................ Op/MaintIPrtsManual ................................................................... 1
-25 55866 ............................ Elec. Schematic .............................................................................. 1
-26 55309 ........................... Hyd. Schematic .............................................................................. 1
-27 55486 ........................... Dwg. V2033 Final Assembly ......................................................... 1
-28 55469 ........................... Dwg. V2033 Hose Kit ................................................................... 1

- Indicates Items Not Shown

MANUAL 92350-003
January 1997
SIN X93S-970S 1
• FIGURE 2: Decal Installation

PARTIAL SECTION A
APPLIES TO All lAODELS

MANUAL 92350-003
January 1997
SIN X935-97051
FIGURE 2: Decal Installation •

. ITEM PART NUMBER DESCRIPTION QTY

Ref 55982 ............................ DecaIInstallation ...................................................................... Ref.


*1 55890 ............................ Decal V Upper Operator Instructions V2033 ................................ 1
55889 ............................ Decal V XL Upper Operator Intructions V2033 XL ..................... 1
*2 55894 ............................ Decal, V General Caution ............................................................. 1
*3 54652-003 ..................... Decal, Guardrail/Chain Caution .................................................... 1
*4 55944-750 ..................... Decal, 2501750 Rated Load ........................................................... 2
55944-800 ..................... Decal, 250/800 Rated Load ........................................................... 2
*5 55480-002 ..................... Decal, Lower Operating Instructions ............................................. 1
*6 55480-001 ..................... Decal, Lower Controls .................................................................. 1
*7 554652-002 ................... Decal, Arm Stand Caution ............................................................. 1
*8 54984-005 ..................... Decal, Rear Bumper ...................................................................... 1
*9 55882 ............................ Decal, Electrocution Hazard .......................................................... 2
* 10 55871-002 ..................... Decal, V Upper Electrical Box Top .............................................. 1
55856-001 ..................... Decal, V XL Upper Control Box Top ........................................... 1
*11 55871-002 ..................... Decal, V Upper Electrical Box Front ............................................ 1
55856-002 ..................... Decal, V XL Upper Control Box ................................................... 1
12 54984-007 ..................... Decal, Hydraulic Fluid .................................................................. 1
13 55940-023 ..................... Decal, CONDOR 3.45x23 .......................................................... 2
14 55984 ............................ Decal, V2033XL ................................. ~ ......................................... 2
15 55941-017 ..................... Decal, Condor "Bird" .................................................................... 2
16 53259 ............................ Tape, Non-Skid 6" Black .................................................... 1.50LF
17 66921 ............................ Coating, Non-Skid Jet Black ............... ~ ............................... 025GL
18 55982-DWG ................. Dwg. V 20331XL Decal Installation .............................................. 1
19 54984-006 ..................... Decal, 110V Extention To Platform V2033XL ............................ 1

31 51340 ............................ Nameplate Scissors Indentification .......................................... Ref.

* 55982-102 ..................... Decal Kit, V2033XL Essential ................................................. Ref.


* 55982 ............................ Decal Kit, V2033 Essential ..................................................... Ref.

- Indicates Items Not Shown


*Indicates Included In Essential Decals

r 2 1/4 MARGIN
NO NON-SLIP
COATING

PLANVIEW OF P.4.RTIAL REAR VIEW OF


MODEL V20J.3 MODELS '12033

MANUAL 92350.003
January 1997
SIN X93S-970S I
. , FIGURE 3: Carriage Assembly
,-----,
,, ,, 3 2 PL
1-----,
,
I
,
I

L __ -----~
iNOTES:
, 1. BRAKE RELEASE HANDLES (ITEM 31) MUST SWING
, FREELY. DO NOT TIGHTEN ITEMS 35, 36, & 37
__________ ~ ANY MORE THAN SNUG FIT (2 PL).

2. FOR ITEMS IDENTIFIED


FINAL ASSY.
e SEE HOSE KIT IN

2 PL 27
REF
SEE NOTE 1

TOP VIEW OF AXLE

NOTES:
1. LOCTITE ITEM 8 INTO ITEMS 4 & 5.

o o
,-------------------------,
!, SELeY PAN FRONT WALL n o !,

o I,
,
0 I

2 2 PL

2 PL
TOP VIEW OF CHASSIS WELDMENT

TOP VIEW OF STEERING COMPONENTS


MANUAL 92350.003
January 1997
SIN X935-97051
FIGURE 3: Carriage ASSembly •

. ITEM PART NUMBER DESCRIPTION QTY

Ref. 55467 ............................ Assembly, Carriage .................................................................. Ref.


1 55445 ............................ Chassis Weldment ......................................................................... 1
2 34145 ............................. Bushing R#81368 .......................................................................... 2
3 02219 ............................ Elbow, 90° MJ04 FJ04 .................................................................. 2
4 55496-001 .... ~ ................ Knuckle Weldment, LH Str ................................ ;.......................... 1
5 55496-002 ..................... Knuckle Weldment, RH Str ........................................................... 1
6 54776 ............................ ThrustWasher,Kingpin ................................................................ 2
7 55402 ............................ Retainer, Kingpin .......................................................................... 2
8 BOW30106 ................... Bolt, Hex .sO-13UNC x 1.50 ......................................................... 2
9 54775 ............ ~ ............... Connecting Arm, Steering ............................................................. 1
10 81368-01-08 ................. Bearing, .75"ID x 1.00"00 x .50"L ............................................. .4
11 BOW36708 ................... Washer, Flat .75 ............................................................................ 4
12 55111 ............................ Cylinder, 2.00"Oia./6/81" Steer ..................................................... 1
13 54035 ............................ Pin, Steering Cylinder ................................................................... 2
14 BOW36718-HD ............ Washer, Flat 3// SAE .................................................................... 2
15 BOW38230 ......... ;......... Pin, Cotter .125"Dia. x 1.25 .......................................................... 4
16 54644-001 ..................... Motor, 11.9 Hyd. Wheel ................................................................ 2
17 BOW30109 ................... Bolt, Hex .50-13UNC x2.25 ......................................................... 8
18 BOW36605 ................... Nut, 1/2-13 ...................................................................................... 8
19 55302 ............................ Hub Assembly, Drive w/Studs ...................................................... 2
20 ~ot Used] ............................................................................................................................. .
21 BOW38232 .•................. CotterPin, .12x 1.75L .................................................................. 2
22 54885-001 ..................... Adapter, MOR08 FORI 0 1.00 Lg ................................................. 1
23 54885-002 ..................... Adapter, MOR08 FROIO 1.812 Lg............................................... 1
24 54885-003 ..................... Adapter, MOR08 FORI0 2.625 Lg ............................................... 1
25 54885-004 ..................... Adapter, MOROS FORI 0 3.438 Lg ............................................... 1
26 36085 ............................ Fitting, Swivel 90° Elbow 8-8 ...................................................... .4
27 54929 ............................ Tire & Wheel Assembly (Tire & Whell Not Sold Seperately) ..... .4
28 91029 ............................ Nut, .50-20UNF Wheel R#30288 ................................................. 10
29 54714 ........................... :.BrakeCylinder .............................................................................. 2
30 54796 ............................. Pin, Brake ...................................................................................... 2
31 54795 ............................ Handle Weldment, Brake Release ................................................. 2
32 54779 ............................ RearHubAssembly ...................................................................... 2
33 BOW38233 ................... Pin, Cotter . 125"Oia. x 2.00 .......................................................... 2
34 BOW36058 ................... Bolt, Hex .38-16UNC x 2.00 ...................... ~ .................................. 2
35 BOW36062 ................... Bolt, Hex .38-16UNC x 3.00 .......................................................... 2
36 BOW36703 ................... Washer, Flat .38"10 x .81 "00 ..................................................... .4
37 BOW34274 ................... Nut, Hex Lock 3/s-16UNC ............................................................. 4
38 02236 ............................ Elbow, 900 MJ04 M004 ................................................................ 6

- Indicates Items Not Shown

MANUAL 92350-003
1anuary 1997
SIN X93S·970S I
• FIGURE 4: Hose Kit

I BACK
BELLY PAN
WALL

LIFT CYLINDER

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

I TOP ," ,
I
I

I BELLY PAN
: FRONT WALL
I
I
I

I I
I
I

=====J

RIGHT MOTOR LEFT MOTOR

STEER

P2 Pl
VALVE ASSY
HYDRAULIC TANK

ELECTRIC MOTOR

MANUAL 92350-003
January 1997
SIN X93S-97051
FIGURE 4: Hose Kit •

ITEM PART NUMBER DESCRIPTION QTY

Ref. 55469 ............................ Hose Kit V2033 ........................................................................ Ref.


1 66698-119.00 ................ Hose Assembly, #0666645 J37 ST-ST ......................................... 1
2 66044-151.00 ................ Hose Assembly, #04 67685 J37 ST-ST ......................................... 1
3 66702-019.00 ................ Hose Assembly, #1066137 J37 ST-ST ......................................... 1
4 66698-020.00 ................ Hose Assembly, #0666645 J37 ST-ST ......................................... 1
5 66698-017.00 ................ Hose Assembly, #06 66645 J37 ST-ST ......................................... 1
6 66696-012.5 .................. Hose Assembly, #04 66646 J37 ST-ST ......................................... 1
7 66696-012.5 .................. Hose Assembly, #04 66646 J37 ST-ST ......................................... 1
8 66696-012.5 .................. Hose Assembly, #0466646 J37 ST-ST ......................................... 1
9 66696-012.5 .................. Hose Assembly, #04 66646 J37 ST-ST ......................................... 1
10 66700-026.00 ................ Hose Assembly, #0666645 J37 ST-STJ ....................................... 1
11 66700-024.00 ................ Hose Assembly, #06 66645 J37 ST-STJ ....................................... 1
12 66700-026.00 ................ Hose Assembly, #04 66646 J37 ST-STJ .. :.................................... 1
13 66700-025.00 ................ Hose Assembly, #04 66646 J37 ST-STJ ....................................... 1
14 66043-028.00 ................ Hose Assembly, #0367684 J37 STJ-STJ ..................................... 1
15 66043-019.50 ................ Hose Assembly, #0367684 J37 STJ-STJ ..................................... 1

- Indicates Items Not Shown

MANUAL 923S()'()o3
January 1997
SIN X93S-970S 1
• FIGURE 5: Lift Cylinder

00
Ww
1---0
U z
<l:w
0::1---
I---x
~w
1")1"-
<t~
oN
I")~
c.o~

ITEM PART NUMBER DESCRIPTION QTY

Ref. 54705-001 ..................... Cylinder, Lift ............................................................................ Ref.


54705-100 ....•................ Seal Kit .......................................................................................... 1
1 54705-101 ..................... Castle Nut ...................................................................................... 1
2 54705-102 ..................... Cast Iron Ring ............................................................................... 1
3 54705-103 ..................... Piston (Steel) ................................................................................. 1
4 54705-104 ..................... Wear Ring ..................................................................................... 1
5 ...................................... PolyPack (Included in Seal Kit 54705-100) .................................. 1
6 ...................................... O-Ring(Included in Seal Kit 54705-100) ..................................... 1
7 ...................................... Stop Tube (Included in Seal Kit 54705-100) ................................. 1
8 54706-105 ..................... JacketAssembly ................................•........................................... 1
9 54705-106 ..................... Piston Rod ..................................................................................... 1
10 ...................................... Polypack (Included in Seal Kit 54705-100) .................................. 1
11 ...................................... O-Ring (Included in Seal Kit 54705-100) ..................................... 1
12 54705-107 I
..................... Gland Nut ...................................................................................... 1
13 ........................... ;.......... Rod Wiper (Included in Seal Kit 54705-100) ................................ 1
-14 55221 ............................ Flow Control Valve ....................................................................... 1

- Indicates Items Not Shown


MANUAL 92350-003
January 1997
SIN X935-97051
FIGURE 6: Steer Cylinder . ,

o
wO
f-W
uo
«z
o:::w
f-f-
WX
<.0 r------f+---I o:::W
r<)LO
mi'
t.()r---_--.I rrio
~N

ITEM PART NUMBER DESCRIPTION QTY

Ref. 55111 ............................ Cylinder, Steer .......................................................................... Ref.


55111-100 ..................... Seal Kit .·......................................................................................... 1
1 55111-101 ..................... LockNut ........................................................................................ 1
2 ...................................... Polypak (Included in Seal Kit 55111-100) .................................... 2
3 ...................................... O'Ring (Included in Seal Kit 55111-100) ...................................... 1
4 55111-102 ..................... Piston(Alum) ................................................................................ 1
5 55111-103 ..................... JacketAssembly ............................................................................ 1
6 55111-104 ..................... Piston Rod .............. :...................................................................... 1
7 ...................................... Polypak (Type B) (Included in Seal Kit 55111-100) ..................... 1
8 ...................................... O'Ring (Included in Seal Kit 55111-100) ...................................... 1
9 55111-105 ..................... GlandNut ...................................................................................... 1
10 ...................................... Rod Wiper (Included in Seal Kit 55111-100) ................................ 1
11 55220 ............................ Jam Nut 5/s-18 .............................................................................. 1

- Indicates Items Not Shown

MANUAL 92350-003
Jamwy 1997
SIN X93S-970SI
• FIGURE 7: Cylinder, Brake

I
CB
I

7/16- 20 O-RING
PORT TYP

If - . - - - - - - - - - - - - - - f---I.-
10.18 EXTENDED _ _ _ _ _ _ _ _ _ _ _ _ _ _--1
9.31 RETRACTED
3.06 ----1:1

ITEM PART NUMBER DESCRIPTION QTY

Ref. 54714 ............................ Cylinder, 1.7SB x 1.13Rx .88 Stroke ...................................... Ref.
54714-100 ..................... Seal Kit .......................................................................................... 1
1 54714-101 ..................... JacketAssembly ............................................................................ 1
2 54714-102 ..................... Piston Rod ..................................................................................... 1
3 54714~103 ..................... Spring ............................................................................................ 1
4 ...................................... Teflon Backup (Included in Seal Kit 54714-100) ......................... 1
5 ...................................... Polypak (Included in Seal Kit 54714-100) .................................... 1
6 54714-104 ..................... Piston(Alum) ................................................................................ 1
7 ...................................... QIRing (Included in Seal Kit 54714-100) ...................................... 1
8 ........ ,............................. Polypak (Type IBI) (Included in Seal Kit 54714-100) ................... 1
9 ...................................... QIRing (Included in Seal Kit 54714-100) ...................................... 1
10 54714-105 ..................... Gland Nut ...................................................................................... 1
11 ...................................... Rod Wiper (Included in Seal Kit 54714-100) ................................ 1

- Indicates Items Not Shown


MANUAL 92350-003
January 1997
SIN X935·9705 I
FIGURE 8: Hub Motor ASSembly.

10
1
9 1
1

1 1 1

10 11

ITEM PART NUMBER DESCRIPTION QTY

Ref. 54644-001 ..................... Motor, 11.9 Hydraulic Wheel ................................................... Ref.


1 54644-100 ..................... Seal Kit For Wheel Motor ............................................................. 1
2 54644-101 ..................... Housing, Bearing ........................................................................... 1
3 54644-102 ..................... Shaft & Bearing Kit (11/4 in Tapered) .......................................... .4
4 54644-103 ..................... Key(ForTapered Shaft) ................................................................ 1
5 54644-104 .. ~ .................. Nut, Hex (For Tapered Shaft) ....................................................... 1
6 54644-105 ..................... Plate, Wear .................................................................................... 1
7 54644-106 ..................... Drive .............................................................................................. 1
8 54644-107 ..................... Geroler ........................................................................................... 1
9 54644-108 ..................... Drive, Valve .................................................................................. 1
10 54644-109 ..................... Plate Drive ..................................................................................... 1
11 54644-110 ..................... Valve ............................................................................................. 1
12 54644-111 ..................... Balance Ring ................................................................................. 1
13 54644-112 ..................... Pin ................................................................................................. 2
14 54644-113 ..................... Spring ............................................................................................ 2
15 54644-114 ..................... Bolt ................................................................................................ 4
16 r
54644-115 ..................... Housing, Valve 18-14 Staggered Ports) ...................................... 1
17 54644-116 ..................... Plug Assembly 7116-20UNF ............................................................ 1

- Indicates Items Not Shown

MANUAL 92350-003
January 1997
SIN X93S-970S 1
• FIGURE 9: Hub Assembly, Rear

Chassis Weldment
:&f.
9

/J
4
3

12

10
ITEM PART NUMBER DESCRIPTION QTY

Ref. 54779 ............................ Hub Assembly .......................................................................... Ref.


1 54779-109 ..................... Hub ................................................................................................ 1
2 54779-101 ..................... Inner Cup ....................................................................................... 1
3 54779-102 ..................... InnerCone .......... ;.......................................................................... 1
4 54779-106 ..................... Seal ........................................................................................... ~ .... 1
5 54779-103 ..................... Outer Cup ...................................................................................... 1
6 54779-104 ..................... Outer Cone .................................................................................... 1
7 BOW36718-IID ............ Washer ........................................................................................... 1
8 BOW1802 ..................... SlottedNut, 3/.t-16UNF ................................................................ 1
9 BOW38233 ................... CotterPin, .125" x 2.00" ............................................................... 1
10 54779-105 ..................... DustCap ........................................................................................ 1
11 54779-107 ..................... Stud ............................................................................................... 5
12 54779-108 ..................... Stud Nut ......................................................................................... 5

- Indicates Items Not Shown


MANUAL 92350-003
lanuary 1997
SIN X93S-970S I
MANUAL 923SO-OO3
January 1997
SIN X93S·970S 1
o
:::J

~-
NOTES:
1. REFER TO SHEET 2 FOR HYDRAULIC ASSEMBLY
INFORMA TION.
2. FOR ITEMS IDENTIFIED 8SEE HOSE KIT IN 2 PL
PL
FINAL ASSY.
3. FOR ITEMS IDENTIFIED ®SEE TUBE KIT. 4 PL o
4. FOR ITEMS IDENTIFIED E9 SEE CABLE KIT. OJ
5. EST. WT.= 706 Ibs.
+ SOd + SOd
~
"'C
~
CHARGER
BATTERY ©©© ©©© ~
g.~
gl~-l gl~-l

N'vTOcH N'VTOtU ~3N -

-<
CK RED BLK
"4
2i~
~! ~ CK
.... -tl '5
~:s~
:-!":s ti
... GROUND
STUD

TROJAN TROJAN
T-125 T-125

MOTOR ©©© ©©©


c=J POS + POS +

SEE NOTE 4
FIGURE 10: Belly Pan Assembly •

ITEM PART NUMBER DESCRIPTION QTY

Ref. 55468 ............................ Belly Pan Assembly ................................................................. Ref.


1 55481 ............................ Belly Pan Weldment ....................................................................... 1
2 54989 ............................ MotorlPump Assembly .................................................................. 1
3 55379 ............................ Valve Installation .......................................................................... 1
-4 55297 ............................ Tank Weldment, Hyd.................................................................... 1
5 50316 ............................ Breather Filler ................................................................................ 1
6 52049 ....... '" .................. Gauge, Fluid Level ........................................................................ 1
7 BOW13382 ................... Plug, Countersank 1/2" ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1
8 02806 ............................ Straight, MJI0 MP12 .................................................................... 1
9 33430 ............................ Filter .............................................................................................. 1
67408 ............................ -Filter Element .............................................................................. 1
10 00324 ............................ Elbow, 90° MJ08 MP12 .............................................................. ~.1
11 02430 ............................ Straight, MJ04 MB04 .................................................................... 3
12 02431 ............................ Fitting, StraightMJ06MB06 ........................................................ 2
13 02303 ............................ Elbow, 900 MJ06 MB06 ................................................................. 2
14 00345 ............................ Tee, MJ06 MJ06 MB06 .................................................................. 1
15 00334 ............................ Nut, Bulkhead 04 ........................................................................... 5
16 00336 ............................ Nut, Bulkhead 06 ........................................................................... 5
17 02662 ............................ Elbow, 90° MJ06 M006 ............................................................... 2
-18 55398 ............................ Cable Kit (See Note 4) .................................................................. 1
19 04674 ............................ Elbow, 90° MJI0 M008 L ............................................................ 1
20 02407 ............................ Tee, MJ04 MJ04 MP)4 .................................................................. 1
21 55333 ............................ ChargerMod.115V/25A ................................................................ 1
22 52138 ............................ Solenoid24V ................................................................................. 1
23 55334 ............................ Jumper Assembly, 12 LG Wire ..................................................... 1
24 52627 ............................ Battery, 6V Trojan T125-WT ....................................................... .4
25 55505 ............................ Angle, Battery Tie Down 22" ........................................................ 2
26 55506 ............................ J-Bolt, Battery Hold Down ............................................................ 2
27 BOW30054 ................... Bolt, Hex .38-16UNC x 1.00 ......................................................... 1
28 BOW30055 ................... Bolt, Hex .38-16UNC x 1.25 ......................................................... 2
29 BOW30057 ................... Bolt, Hex .38-16UNC x 1.75 ......................................................... 2
30 BOW31433 ................... Washer,.38 x .81"OD Flat SAE Gr 5 ............................................ 5
31 BOW34274 ................... Nut, Hex Lock 3fs"-16UNC ........................................................... 5
32 BOW30037 ................... Bolt, Hex .31-18UNC x 3.00 ......................................................... 3
33 BOW30029 ................... Bolt, Hex .31-18UNC x 1.00 ........................................................ .4
34 BOW31432 ................... Washer, Flat .31 "ID x .68"OD .................................................... 13
35 BOW34273 ................... Nut, Lock Hex 5/ 16"-18UNC .......................................................... 4
36 BOW30003 ................... Bolt, Hex .25-20UNC x .875 ........................................................ .4
37 BOW31401 ................... Washer, Flat .25"ID x .63"OD .................................................... 10
38 BOW36780 ................... Nut, Hex .25-20UNC Nylon Lock ................................................ 6
-39 55397 ............................ Tube Kit (See Note 3) ................................................................... 1
40 04185 ............................ Fitting, Bulkhead Tee .................................................................... 2

- Indicates Items Not Shown

MANUAL 92350-003
January 1997
SIN X93S-970S I
,
~
2:1
~
-
s>
tJ:j

~
~
~

l
LEFT ~
SIDE P2 Pl
~
51

'---+--052
SEE NOTE .l
Gl

~i'~ 2 PL
~~ ~
'f'_~

~~~~5
... 2 PL l IJ
'2/ t~ Q<,7:j
'-!3/

~ I
1)1
P -ei{
n_
?J i*~

BACK~
TANK

BELL Y PAN BELLY PAN FRONT WALL


MOTOR

5 2 PL
2 PL
FIGURE 10: Belly Pan Assembly •

ITEM PART NUMBER DESCRIPTION QTY

Ref. 55468 ............................ Belly Pan Assembly ................................................................. Ref.


1 55481 ............................ BellyPan Weldment ...................................................................... 1
2 54989 ............................ MotorlPump Assembly .................................................................. 1
3 55379 ............................ Valve Installation .......................................................................... 1
-4 55297 ............................ Tank Weldment, Hyd .................................................................... 1
5 50316 ............................ Breather Filler ................................................................................ 1
6 52049 ............................ Gauge, Fluid Level ........................................................................ 1
7 BOW13382 ................... Plug, Countersank 1/2" ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1
8 02806 ............................ Straight, MJIO MP12 .................................................................... 1
9 33430 ............................ Filter .............................................................................................. 1
67408 ............................ -Filter Element .............................................................................. 1
10 00324 ............................ Elbow, 90° MJ08 MP12 ................................................................ 1
11 02430 ............................ Straight, MJ04 MB04 .................................................................... 3
12 02431 ............................ Fitting, StraightMJ06MB06 ........................................................ 2
13 02303 ............................ Elbow, 900 MJ06 MB06 ................................................................. 2
14 00345 ............................ Tee, MJ06 MJ06 MB06 ................................................................. 1
15 00334 ............................ Nut, Bulkhead 04 ........................................................................... 5
16 00336 ............................ Nut, Bulkhead 06 ........................................................................... 5
17 02662 ............................ Elbow, 90° MJ06 M006 ............................................................... 2
-18 55398 ................... ;........ Cable Kit (See Note 4) .................................................................. 1
19 04674 ............................ Elbow, 90° MJI0 M008 L ............................................................ 1
20 02407 ............................ Tee, MJ04 MJ04 MP)4 .................................................................. 1
21 55333 ............................ ChargerMod.115V/25A ................................................................ 1
22 52138 ............................ Solenoid 24V ................................................................................. 1
23 55334 ............................ Jumper Assembly, 12 LG Wire ..................................................... 1
24 52627 ............................ Battery, 6V Trojan T125-WT ....................................................... .4
25 55505 ............................ Angle, Battery Tie Down 22" ........................................................ 2
26 55506 ............................ J-Bolt, Battery Hold Down ............................................................ 2
27 BOW30054 ................... Bolt, Hex .38-16UNC x 1.00 ......................................................... 1
28 BOW30055 ................... Bolt, Hex .38-16UNC x 1.25 ............................................ :............ 2
29 BOW30057 ................... Bolt, Hex .38-16UNC x 1.75 ......................................................... 2
30 BOW31433 ................... Washer,.38 x .81 "OD Flat SAE Gr 5 ............\............................... 5
31 BOW34274 ................... Nut, Hex Lock 3/s"-16UNC ........................................................... 5
32 BOW30037 ................... Bolt, Hex .31-18UNC x 3.00 ......................................................... 3
33 BOW30029 ................... Bolt, Hex .31-18UNC x 1.00 ......................................................... 4
34 BOW31432 ................... Washer, Flat.31 "ID x .68"OD .................................................... 13
35 BOW34273 ................... Nut, Lock Hex sI16"-18UNC .......................................................... 4
36 BOW30003 ................... Bolt, Hex .25-20UNC x .875 ........................................................ .4
37 BOW31401 ................... Washer, Flat .25"ID x .63"OD .................................................... 10
38 BOW36780 ................... Nut, Hex .25-20UNC Nylon Lock ................................................ 6
-39 55397 ............................ Tube Kit (See Note 3) ................................................................... 1
40 04185 ............................ Fitting, Bulkhead Tee .................................................................... 2

- Indicates Items Not Shown

MANUAL 92350-003
Jamwy 1997
SIN X935·9705 I
• FIGURE 11: Motor & Pump Assembly

ITEM PART NUMBER DESCRIPTION QTY

Ref. 54989 ............................ MotorlPump Assembly ............................................................. Ref.


1 54761 ............................ Duplex Pump & Parts (See Page 45) ............................................ 1
54761-101 ..................... Seal Kit (pump) ............................................................................. 1
2 BOW30029 ................... Bolt,Hex.3I"-18UNCx 1.00" .................................................... .4
3 ...................................... Tag Nails ...................................................................................... ..
4 BOW31444 ................... Washer, Flat 5/16" ........................................................................... 4
5 54759 ............................ 24 Volt Motor (See Page 46) ........................................................ 1
6 54989-100 ..................... Gasket ............................................................................................ 1
7 54760 ............................ ReplacementCoupling .................................................................. 1
8 [Not Used] ............................................................................................................................ 1

- Indicates Items Not Shown

MANUAL 92350-003
January 1997
SIN X935·97051
FIGURE 12: Pump Assembly •
SECTION A-A
A 14
9 10 18 17 6 13
15

1
I
I 7
---+

©
© 12

A
HYDRAULIC SCHEMATIC
B 24 23 4 11

OUTLET PORTS
9/16-18 SAE 20

ITEM PART NUMBER DESCRIPTION QTY

Ref. 54761 ............................ DuplexPump&Parts ............................................................... Ref.


54761-100 ..................... Seal Kit .......................................................................................... 1
1 54761-103 ..................... GearHousing ................................................................................. 1
2 ................................................................................................................................................
3 ............................................................................................................................................... .
4 54761-108 ..................... Drive Pin ....................................................................................... 1
5 ............................................................................................................................................... .
6 ...................................... Oil Seal (in seal kit) ....................................................................... 1
7 54761-112 ..................... Drive Shaft .................................................................................... 1
8 ...................................... Lee Plug ........................................................................................ 1
9 54761-107 ..................... 375 Gear Face ................................................................................ 1
10 ...................................... Gasket (in seal kit) ......................................................................... 1
11 54761-102 ..................... Needle Bearing .............................................................................. 1
12 54761-101 ..................... IdlerShaft ...................................................................................... 1
13 54761-105 ..................... Stator ............................................................................................. 1
14 54761-106 ..................... Screw ............................................................................................. 8
15 54761-109 ..................... Shear Pin ....................................................................................... 1
16 ...................................... Plastic Plug .................................................................................... 1
17 ...................................... Gasket (in seal kit) ......................................................................... '1
18 54761-111 ..................... Woodruff Key ............................................................................... 1
19 ............................................................................................................................................... .
20 ...................................... Plastic Plug .................................................................................... 1
21 ............................................................................................................................................... .
22 ................................................................................................................................................
23 54761-110 ..................... CreascentRing .............................................................................. 1
24 54761-104 ..................... GearHousing ................................................................................. 1
- Indicates Items Not Shown MANUAL 92350-003
JIIIUlU}' 1997
SIN X93S-970S 1
• FIGURE 13: Motor 24VDC Assembly

-l----l-
NAMEPLATE

15

MANUAL 92350-003
January 1997
SIN X935-9705 I
FIGURE 13: Motor 24VDC Assembly •

ITEM PART NUMBER DESCRIPTION QTY

Ref. 54759 ............................ Motor, 24VDC Assembly ......................................................... Ref.


1 ...................................... Complete Stator Assembly ............................................................ 1
2 NSS ............................... Complete Terminal Assembly .............: ......................................... 2
3 ...................................... Screw Hex lID Cap 3/8 "-16 ........................................................... 2
4 ...................................... Jam Nut, Hex 3/8 "-16 ...................................................................... 2
5 ...................................... Jam Nut, Hex 3/8"-16 ...................................................................... 2
6 ...................................... Insulator ......................................................................................... 4
7 ...................................... Insulator ......................................................................................... 2
8 ...................................... Lock Washer, Split 3/8 " •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••.••••• 2
9 ...................................... Lock, Washer, Ext. TTH 3/8" •••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4
10 ...................................... Field Coil Assembly ...................................................................... 1
11 ...................................... Field Pole ....................................................................................... 4
12 ...................................... Screw, BTIN lID Socket, 3/8"-16 x 5/8 " ••••••••••••••••••••••••••••••••••••••••• 8
13 ...................................... Field Coil Terminal ..................... ,................................................. 1
14 ...................................... Loctite,222 ................................. :................................................... ..
15 ...................................... Pulley Cover .................................................................................. 1
16 ...................................... Screw, Socket lID #10-32 xl.00" ................................................. 4
17 54759-117 ..................... Complete Armature Assembly ...................................................... 1
18 54759-118 ..................... Fan ................................................................................................. 1
19 54759-119 ..................... Bearing, Pulley .............................................................................. 1
20 54759-120 ..................... Bearing, Comm ............................................................................. 1
21 ...................................... Complete Comm Cover Assembly ................................................ 1
22 54759-122 ..................... Complete Brush Ring Assembly ................................................... 1
23 54759-123 ..................... Brush Spring .................................................................................. 8
24 54759-124 ..................... BrushAssembly ............................................................................ 2
25 ...................................... Screw, RH Slotted #10-32 x 3/4" .................................................... 4
26 ...................................... Nut, Hex #10-32 ............................................................................ 4
27 ...................................... Washer Bearing Spring ................................................................. 1
28 ...................................... Screw, Hex fID #10-32 x 2.00" ...................................................... 4
29 54759-129 ..................... Brush Inspection Cover ................................................................. 1
30 ...................................... Screw, PH fID #10-32 x 1-3/ 4" ....................................................... 1
31 ...................................... Nut, Square #10-32 ....................................................................... 1
32 ...................................... Insulator ......................................................................................... 1
33 ...................................... Screw, RH Slotted 1/4"-20 x 3/S" ..................................................... 2
34 ...................................... Lock Washer, Ext. TTH 1/4" .......................................................... 2
35 54760 ............................ Coupling Assembly ................................................................... Ref

NSS - Not Sold Separately


- Indicates Items Not Shown

MANUAL 923S().OQ3
Jonuary 1997
SIN X9JS·97051
• FIGURE 14: Valve Assembly

.3
P2 L Pl

~~ ~

~
M2

REAR VIEW

LEFT END VIEW


MANUAL 92350-003
January 1997
SIN X935-97051
FIGURE 14: Valve Assembly •

CREEP

o
o

RIGHT END VIEW

ITEM PART NUMBER DESCRIPTION QTY

Ref. 55379 ............................ Valve Installation ..................................................................... Ref.


1 55296 ............................ ValveAssembly ............................................................................ 1
2 54892 ............................ Valve, Load Control ...................................................................... 2
3 02525 ............................ Straight, MJ04 M004 .................................................................... 3
4 02448 ............................ Straight, MJ06 M006 .................................................................... 5
5 00458 ............................ Straight, MJ08 M008 .................................................................... 1
6 04579 ............................ Elbow, 90° MJ06 M006 LL .......................................................... 1
7 04682 ............................ Tee, MJ04 MO~4 MJ04 ................................................................ 1
8 04003 ............................ Nut, Cap #04 ................................................................................. 2

- Indicates Items Not Shown

MANUAL 9235()"()()3
January 1997
SIN X93S·97051
• FIGURE 15: Charger 115V/60HZ-25A124VDC

( ® )
~~K
:00 'WillY IPUJJI!.I!.V ~'if1l© 1ID&.~1f\i\1 ©1HJ.i?IU!i~~
#!........ .1 aATTBIIYCAPACITY
~v-Electrlcal-- .. c<"
....nc.. NECTE.
825 W••• A St. Lincoln. NE 88522 USA LEAD.:=r:~=T::' u.
ACYOlTl
IJI!J
[Ij
HERTZ

ru
[ill
MODEL
1171701
aERIAL NO.
DCYDlTS

00
[EJ
U.•• PAT.NO.I.l.....S
.........T.NO.I........
::~='~S=:.
""::::=====:::'-

RING
I
:0
I
I
I #12 AWG,
I 2 PL

~o
III
.281 X .625 SLOT
I
MOUNTING HOLES
4 PLCS.
(IN BASE LEG)
AMMETER, 0-30 AMP

r- -,
®
~~ ~ ~ ~
®I
I
~ ~ ~

\~
1/ ~ ~ ~
~ ~ ~ ~
~ ~ ~
/
~ ~ ~ VENTILATION LOUVERS
/ ~ ~ ~ I ON BACK SIDE
/ ~ ~ ~ I
~ ~ ~
/
~ ~ ~
I ~
~
~ ~
~ ~
\OS
® ®

MANUAL 923SO-OO3
January 1997
SIN X93S-970S 1
FIGURE IS: Charger llSV/60HZ-2SAl24VDC •

ELECTRIC TIMER
BLACK

RED
GREEN

TRANSFORMER FAN
RED or WHITE
+
TO BATTERIES

• BLACK
2

BLACK

WHITE

120 Voe
INPUT
-GREEN WIRE NOT USED
ON SOME MODELS.

ITEM PARTNUMBER DESCRIPTION QTY

Ref. 54908 ............................ Charger, 115V160HZ-25A124VDC .......................................... Ref.


54908-101 ..................... Transformer Assembly ................................................................... .
54908-102 ..................... Heatsink Assembly, with Diodes .................................................. ..
54098-103 ..................... Ammeter ......................................................................................... .
54908-104 ..................... Electronic Timer Assembly ............................................................ .
54908-105 ..................... Capacitor, 6.0 MFD,660VAC ........................................................ .
54908-106 ..................... Fuse Assembly ............................................................................... .

- Indicates Items Not Shown

MANUAL 92350-003
January 1997
SIN X93S-970S I
This Page Intentionally Left Blank

MANUAL 92350-003
January 1997
SIN X935-97051
FIGURE 17: Box Assembly - Lower Control •

. ITEM PART NUMBER DESCRIPTION QTY

Ref. 55489 ............................ BoxAssembly- Lower Control ............................................... Ref.


1 55488 ............................ Box, Mach. Lower Control ............................................................ 1
2 55029 ............................ Decal, Box Elec. Tags ................................................................... 1
3 51913 ............................ Operator, RedP-Pull ..................................................................... 1
4 51914 ............................ Base + 1 NC Contact .......... :.......................................................... 1
5 52670 ............................ Operator, 3 Pos. Rot ...................................................................... 1
6 52029 ............................ Base + 2 NO Contacts ................................................................... 1
7 50075 ............................ Switch, (Ref PIN 67760) ............................................................... 1
8 54438 ............................ Relay, 24V SPDT Bosch ............................................................... 1
9 206-00001-00 ............... Diode ............................................................................................. 9
10 67114-013 ..................... Strain Relief 1 NPT .62/.75 ........................................................... 1
11 67114-008 ..................... Connector, Strain Relief ................................................................ 1
12 67114-009 ..................... Strain Relief, 3/4 NPT .62/.75 ......................................................... 2
13 67124-003 ..................... Locknut, 1" NPT ........................................................................... 1
14 67124-002 ..................... Locknut, 3/4" NPT Conduit ............................................................ 3
15 67123-003 ..................... Seal, Connector Elect 1" ................................................................ 1
16 67123-002 ..................... Seal, Connector Elect. 3/4" .•...........•....•.•.••...............................•...•. 3
17 34542 ............................ Jumper ........................................................................................... 4
18 67837-006 ..................... Tie, Nylon 6" Black ........................ ,.............................................. 8
19 BOW31430 ................... Washer, Flat #10 ID ...................................................................... 1
20 BOW31129 ................... Screw, Slot Round Hd 8-32UNC x 3fs" ......................................... 1
21 BOW31232 ................... Nut, Hex Keps #8-32UNC ............................................................ 1
22 BOW31124 ................... Screw, Round Hd #6-32 x 1/2"Lg .................................................. .4
23 BOW31231 ................... Nut, Hex Keps #6-32 ..................................................................... 4
24 BOW31428 ................... Washer, Flat #6 ............................................................................. 4
25 67295-024 ..................... Cable, 8 Condo 16AWG Type SO ...................................... 9 .50LF.
26 67295-004 ..................... Cable, 12 Conductor 16Ga ...................................................... SLF.
27 34552-016 ..................... Terminal Strip ................................................................................ 2
28 67295-022 ..................... Cable, 3 Conductor 12 AWG ............................................. 5.S0LF.
29 67940 ............................ Holder, Fuse .................................................................................. 1
30 67939-015 ...................... Fuse, 15Ga 1/4" x 1-1/4" •••••••••..••............•.••.••.•.•.....•....•...........••.••••. 1
31 58282 ............................ Wire, 12 Ga Black ................................................................... 4LF.
32 58300 ............................ Wire, 16 Ga Black ................................................................... lLF.
33 66720-001 ..................... Disconnect, STA-KONFemale ..................................................... 6
34 BOW23087 ................... Terminal, Female Push-On .250W ................................................ 3
35 67960-006 ..................... Terminal, Ring 10 16-14AWG ...................................................... 2
36 BOW23024 ................... Ring, Tongue 16-14 Ga 1/4" Stud ................................................... 1
37 BOW23025 ................... Terminal, Ring Tongue 16-14 Ga ................................................. 1
38 BOW18578 ................... Terminal, Piggyback R 67963 ....................................................... 1
39 BOW23087-2 ............... Terminal, Female Push-On .250W ................................................ 2
40 55489 ............................ Dwg. Box Assembly, Lower Control ....................................... Ref.

51 A626-2633 .................... Low Volt AlarmlInterrupt ........................................................ Ref.


52 A309-2633 .................... Motion Alarm ............... ~ ........................................................... Ref.
53 A310-2633 ................. :.. StrobeLight .............................................................................. Ref.

- Indicates Items Not Shown

MANUAL 92350-003
January 1997
SIN X93S·970S 1
• FIGURE 17: Box Assembly - Lower Control

,------------------------- ------,---------------5 -----l


I I 12 GA
I I

I
I .
I 50
A

"DOWN"
MOTION ALARM
OPTION SG
"UP"

12 GA

9 9 PL
SE

12 GA

'--------
1 72 PL
22 4 PL
234 PL
244 PL
I
-------------~----------l--------
i 58.° J:
I

~./MOTOR l=m : ~~ ~g~~~~~~


I

~YQ_-­ ~________
I S" SLOPE OPTION
VALVES CONTACTOR

SEE SHEET 113 SEE SHEET ,3 SEE SHEET 13

,---- ---------------------------1

NOTIES:
1. THIS SHEET SHOWS ALL OPTIONS. SEE SHEET :2 FOR "STANDARO:!".
2. CONNECT "RED/BLK" TO SPARE. AS SHOWN, IF NO ALARM aPllON.
CONNECT "RED/8LK" TO CIRCUIT aeFOR MonON ALARM OPTION.
CONNECT "RED!BLK" TO CIRCUIT 9 FOR DESCEND ALARM OPTION.
CONNECT "RED/BLK" TO ClRCUIT 80 FOR TRAVEL ALARM OPTION.
3. ALL WIRING TO BE 16 GA, EXCEPT CIRCUITS 3.5. &: 50 AS MARlII'iED.
4. IF lOW VOLT OPTION IS USED. THEN DO NOT USE JUMPER BE""
8A AND aE.
5. SEE WIRING DRAWING FOR COLOR TO CIRCUIT NUM8ER TABLE.
51 lOW VOLTAGE
EAnERY
PROTECnoN
OPTION

L _____________ : -=: ________________ -.J

MANUAL 92350-003
January 1997
SIN X935"970S1
FIGURE 17: Box Assembly - Lower Control.

ITEM PART NUMBER DESCRIPTION QTY

Ref. 55489 ............................ Box Assembly - Lower Control ............................................... Ref.


1 55488 ............................ Box, Mach. Lower Control ............................................................ 1
2 55029 ............................ Decal, Box Elec. Tags ................................................................... 1
3 51913 ............................ Operator, Red P-Pull ..................................................................... 1
4 51914 ............................ Base + 1 NC Contact ..................................................................... 1
5 52670 ............................ Operator, 3 Pos. Rot ...................................................................... 1
6 52029 ............................ Base + 2 NO Contacts ................................................................... 1
7 50075 ............................ Switch, (Ref PM 67760) ............................................................... 1
8 54438 ................: ........... Relay, 24V SPDT Bosch ............................................................... 1
9 206-00001-00 ............... Diode ............................................................................................. 9
10 67114-013 ..................... Strain Relief 1 NPT .62/.75 ........................................................... 1
11 67114-008 ..................... Connector, Strain Relief ................................................................ 1
12 67114-009 ..................... Strain Relief, 3// NPT .62/.75 ....................................................... 2
13 67124-003 ..................... Locknut, 1" NPT ........................................................................... 1
14 67124-002 ..................... Locknut, %"NPTConduit ............................................................ 3
15 67123-003 ..................... Seal, Connector Elect 1" ................................................................ 1
16 67123-002 ..................... Seal, Connector Elect. 3// ............................................................. 3
17 34542 ............................ Jumper ........................................................................................... 4
18 67837-006 ..................... Tie, Nylon 6" Black ....................................................................... 8
19 BOW31430 ................... Washer, Flat #10 ID ...................................................................... 1
20 BOW31129 ................... Screw, Slot Round Hd 8-32UNC x 3/s" ......................................... 1
21 BOW31232 ................... Nut, Hex Keps #8-32UNC ............................................................ 1
22 BOW31124 ................... Screw, Round Hd #6-32 x 1/2"Lg .................................................. .4
23 BOW31231 ................... Nut, Hex Keps #6-32 ..................................................................... 4
24 BOW31428 ................... Washer, Flat #6 ............................................................................. 4
25 67295-024 ..................... Cable, 8 Condo 16AWG Type SO ...................................... 9.50LF.
26 67295-004 ..................... Cable, 12 Conductor 16Ga ...................................................... 5LF.
27 34552-016 ..................... Terminal Strip ................................................................................ 2
28 67295-022 ..................... Cable, 3 Conductor 12 AWG ............................................. 5.50LF.
29 67940 ............................ Holder, Fuse .................................................................................. 1
30 67939-015 ..................... Fuse, 15Ga 1/4" x 1-1/4" .................................................................. 1
31 58282 ............................ Wire, 12 Ga Black ................................................................... 4LF.
32 58300 ............................ Wire, 16GaBlack ................................................................... 1LF.
33 66720-001 ..................... Disconnect, STA-KONFemale ..................................................... 6
34 BOW23087 ................... Terminal, Female Push-On .250W ................................................ 3
35 67960-006 ..................... Terminal, Ring 10 16-14AWG ...............'....................................... 2
36 BOW23024 ................... Ring,Tongue 16-14 Ga 1// Stud ................................................... 1
37 BOW23025 ................... Terminal, Ring Tongue 16-14 Ga ................................................. 1
38 BOW18578 ................... Terminal, Piggyback R 67963 ....................................................... 1
39 BOW23087-2 ............... Terminal, Female Push-On .250W ................................................ 2
40 55489 ............................ Dwg. Box Assembly, Lower Control ....................................... Ref.

51 A626-2633 .................... LowVoltAlarmlInterrupt .................................................... ~ ... Ref.


52 A309-2633 .................... Motion Alarm ............................................................................ Ref.
53 A310-2633 .................... Strobe Light .............................................................................. Ref.

- Indicates Items Not Shown

MANUAL 923S()"()()3
Il111U81}' 1997
SIN X93S·970S 1
• FIGURE 18: Armstack Assembly

SEENOTE2~3 _ _ ___ ~ ~ ~ SEE NOr;: 2'


-----~~
:-~_~----- -~3
n
- - - - ----_____ SEE NOTE 2 \ 3 _ - - - - - - - - - - - - - - - - - - -___

-----
14 15 -- -----
-----___ - _____c---""--- --------
'F\'I. --------..:::..-_---- ------
~_
-- ----- ----- ----- -----
13 14 15

-------- ---
_---------------- ~-.I't ----
---~-:.
- -----., .....
--
---- --:.----
--------- ,,~
~"'"'~f!/~~ ~--~--~- --~--- -:~--j~
_---- _---- 14 15 ---- --

5');-----<::___ _____ _ _____ ------- --..:::!J\


----- --- - ---- ----- -- - - - ------ ~
14 15 - - ___
-- - - --- - -
- -::- -
_

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

SEE NOTE 2 ~3
r:::--- - _
---- - -
--- ___ ------ - - ----
7
2
- -
--
--- --------- ----- ----- ----
____
~
~
~ _ - - _ _ : - ___ _ _

-~--::---... ------,
~3 SEE NOTE 2

-- >-:::--- - -~;::,/
---.:::::::--- _ _ 14 15

~
f-:::::-< n
-- - -...:::::::- --
26
---- -- ---.:: :: ~
I
14 15
--

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


~...~
18 19

-::-------------- -------- ----


\~\ -: ''0-- --<~-----
__ ==:~"':~::~~--- ~9
2 PL
\'=
~;:=~::=~- -----
[j
---
------_
--
30 2 PL

~
4 15 __ ___ - - ____- _------ ------ __ 0 ----- -- __ ~3 SEE NOTE 2

~
~ -----
13
_------------

SEE NOTE 2
----------__

---- --

- -
~4
~
,-
15

NOTES:
1. TOTAL EST. WT. = 1090 LBS.

2. ITEM 13 TO BE ON UPHILL SIDE OF


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

3. THIS DWG SUPERCEDES 55282.

MANUAL 92350-003
Janwuy 1997
SIN X935-970S1
FIGURE 18: Armstack Assembly . ,

ITEM PART NUMBER DESCRIPTION QTY

Ref. 55441 ............................ ArmstackAssembly ................................................................. Ref.


55418 ..~ ......................... Armstack Weldment+ Brg/Pin ..................................................... 1
1 55418-001 ..................... Arm Weldment, Lower Outer ........................................................ 1
2 55418-002 ..................... Arm Weldment, Lower Inner ........................................................ 1
3 55418-003 ..................... Arm Weldment, Left Middle Outer .............................................. 1
4 55418-004 ..................... Arm Weldment, Right Middle Outer ............................................. 1
5 55418-005 ..................... Arm Weldment, Middle Inner ....................................................... 1
6 55418-006 ..................... Arm Weldment, Upper Outer ........................................................ 1
7 55418-007 ..................... Arm Weldment, Upper Inner ......................................................... 1
8 81368-007 ..................... Bearing, 1.50"ID x 2.50"L x 118 W ............................................. 14
9 54616-002 ..................... Shaft, Arm Pivot 6 314"Lg ............................................................. .4
10 54616-001 ..................... Shaft, Arm Pivot 18" Lg ................................................................ 5
11 67281-005 ..................... Wrapping, %" Black/Spiral ................................................ 2.83LF.
12 66388-001 ..................... Collar, 1 1/ 2" Shaft ........................................................................ 14
13 BOW30037 ................... Bolt, Hex .31-18UNC x 3.00 ....................................................... 11
14 BOW31432 ................... Washer, Flat.31 "ID x .68"OD .................................................... 21
15 BOW34273 ................... Nut, Lock Hex s/l/-18UNC ........................................................ 15
16 55327 ............................ Harness, Main Control .................................................................. 1
17 67295-017 ..................... Cable, 3 Conductor 12 Ga ..................................................... 39LF.
18 67998-001 ..................... Screw, Thread Frmng . .38-16 x 1.0 Lg ......................................... 2
19 BOW32606 ................... Clamp, Wire Loom 1"Dia ............................................................. 9
20 BOW9977 ..................... O-Ring, .375"ID x .50"OD ............................................................ 1
21 BOW30000 ................... Bolt, Hex .25-20UNC x .50 ........................................................... 2
22 BOW31401 ................... Washer, Flat .25"ID x .63"OD ...................................................... 2
23 BOW30035 ................... Bolt, Hex .31-18UNC x 2.50 ......................................................... 2
24 BOW30036 ................... Bolt, Hex .31-18UNC x 2. 75 ......................................................... 4
25 55083 ............................ Manifold Assembly, Lift Cylinder ................................................ 1
26 54569 ............................ Cable Bracket, Holding Valve ....................................................... 1
27 54798 ............................ Nut, 10-32UNF Coupling .............................................................. 1
28 54705 ............................ Cylinder, Armstack Lift ................................................................. 1
29 34145 ............................. Bushing, (R#81368) ...................................................................... 4
30 BOW36780 ................... Nut, Hex .25-20UNC Nylon Lock ................................................ 8
31 54616-004 ..................... Shaft, Arm Pivot 6.50"Lg.............................................................. 1
32 55027 ............................ Pin Weldment, Lift Cylinder .......................................•................. 1
33 55279 ............................ Block, HOPE Slide ........................................................................ 2
34 54616-009 ..................... Shaft, Aim Pivot 20.38"Lg ............................................................ 2
35 54701 ............................ Block,ArmstackNylatron ............................................................. 2
36 54616-008 ..................... Shaft, Arm Pivot 26.62"Lg............................................................ 2
37 54582 ............................ Block, UHMWPE Bearing ............................................................ 2
38 02236 ............................ Elbow, 900 MJ04 M004 ............................................................... 1
39 02662 ............................ Elbow, 900 MJ06 M006 ............................................................... 1

- Indicates Items Not Shown

MANUAL 92350-003
1anuary 1997
SIN X935-970S I
o
:::l

~
. ~4PL

st
, J
'0
~-
00

7
~ ~""~~ .1 ~
l~
~-----~--
6

C
5 PL !
-<
B

~!~ 5 I
I ----

~! :
._t;l
~~U\
~~~
....

RIGHT SIDE VIEW


FIGURE 18: Armstack Assembly •

ITEM PART NUMBER DESCRIPTION QTY

Ref. 55441 ............................ ArmstackAssembly ................................................................. Ref.


55418 ............................ Armstack Weldment + BrgIPin ..................................................... 1
1 55418-001 ..................... Arm Weldment, Lower Outer ........................................................ 1
2 55418-002 ..................... Arm Weldment, Lower Inner ........................................................ 1
3 55418-003 ..................... Arm Weldment, Left Middle Outer .............................................. 1
4 55418-004 ..................... Arm Weldment, Right Middle Outer ............................................. 1
5 55418-005 ..................... Arm Weldment, Middle Inner ....................................................... 1
6 55418-006 ..................... Arm Weldment, Upper Outer ........................................................ 1
7 55418-007 ..................... Arm Weldment, Upper Inner ......................................................... 1
8 81368-007 ..................... Bearing, 1.50"ID x 2.50"L x 118 W ............................................. 14
9 54616-002 ..................... Shaft, Arm Pivot 6 31/Lg ............................................................. .4
10 54616-001 ..................... Shaft, Arm Pivot 18" Lg ................................................................ 5
11 67281-005 ..................... Wrapping, 3// Black/Spiral ................................................ 2.83LF.
12 66388-001 ..................... CoUar, 1 1/ 2 " Shaft ........................................................................ 14
13 BOW30037 ................... Bolt, Hex .31-18UNC x 3.00 ....................................................... 11
14 BOW31432 ................... Washer,Flat.31"IDx.68"OD .................................................... 21
15 BOW34273 ................... Nut, Lock Hex s/16"-18UNC ........................................................ 15
16 55327 ............................ Harness, Main Control .................................................................. 1
17 67295-017 ..................... Cable, 3 Conductor 12 Ga ..................................................... 39LF.
18 67998-001 ..................... Screw, Thread Frmng . .38-16 x 1.0 Lg ......................................... 2
19 BOW32606 ................... Clamp, Wire Loom 1"Dia ............................................................. 9
20 BOW9977 ..................... O-Ring, .375"IDx .50"OD ............................................................ 1
21 BOW30000 ................... Bolt, Hex .25-20UNC x .50 ........................................................... 2
22 BOW31401 ..... :............. Washer, Flat .25"ID x .63"OD ...................................................... 2
23 BOW30035 ................... Bolt, Hex .31-18UNC x 2.50 ......................................................... 2
24 BOW30036 ................... Bolt, Hex .31-18UNC x 2.75 ......................................................... 4
25 55083 ............................ Manifold Assembly, Lift Cylinder ................................................ 1
26 54569 ............................ Cable Bracket, Holding Valve ....................................................... 1
27 54798 ............................ Nut, 10-32UNF Coupling .............................................................. 1
28 54705 ............................ Cylinder, Armstack Lift ..................................................................1
29 34145 ......... ,.................. Bushing, (R#81368) ...................................................................... 4
30 BOW36780 ................... Nut, Hex .25-20UNC Nylon Lock ................................................ 8
31 54616-004 ..................... Shaft, Arm Pivot 6.50"Lg .............................................................. 1
32 55027 ............................ Pin Weldment,LiftCylinder ......................................................... 1
33 55279 ............................ Block, HDPE Slide ........................................ :............................... 2
34 54616-009 ..................... Shaft, Afm Pivot 20.38"Lg ............................................................ 2
35 54701 ............................ Block,ArmstackNylatron ............................................................. 2
36 54616-008 ..................... Shaft, Arm Pivot 26.62"Lg............................................................ 2
37 54582 ............................ Block, UHMWPEBearing ............................................................ 2
38 02236 ............................ Elbow, 90° MJ04 M004 ............................................................... 1
39 02662 ............................ Elbow, 90° MJ06 M006 ............................................................... 1

- Indicates Items Not Shown

MANUAL 92350-003
lanulJ)' 1997
SIN X935-970S1
• FIGURE 18: Armstack Assembly

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

10 PL 12

SEE NOTE #1
SECTION C-C
Scoie= 1: 3

2 PL 12

SEE NOTE #1

SECTION 8-8
Scoie= 1: 3

2 PL 12

SEE NOTE #1

SECTION A-A
Scoie= 1: 3

MANUAL 92350-003
January 1997
SIN X93S-970S I
FIGURE 18: ArmstackAssembly •

. ITEM PART NUMBER· DESCRIPTION QTY

Ref. 55441 ............................ ArmstackAssembly ................................................................. Ref.


55418 ............................ Armstack Weldment + Brg/Pin ..................................................... 1
1 55418-001 ..................... Arm Weldment, Lower Outer ........................................................ 1
2 55418-002 ..................... Arm Weldment,LowerInner ........................................................ 1
3 55418-003 ..................... Arm Weldment, Left Middle Outer ......... :.................................... 1
4 55418-004 ..................... Arm Weldment, Right Middle Outer ............................................. 1
5 55418-005 ..................... Arm Weldment, Middle Inner ....................................................... 1
6 5S418-006 ..................... Arm Weldment. Upper Outer ........................................................ 1
7 55418-007 ..................... Arm Weldment. Upper Inner ......................................................... 1
8 81368-007 ..................... Bearing. 1.50"ID x 2.50"L x 118 W ............................................. 14
9 54616-002 ..................... Shaft. Arm Pivot 6 3/4"Lg .............................................................. 4
10 54616-001 ..................... Shaft. Arm Pivot 18" Lg ................................................................ 5
11 67281-005 ..................... Wrapping. 3// Black/Spiral ................................................ 2.83LF.
12 66388-001 ..................... Collar. 1 1/ 2" Shaft ........................................................................ 14
13 BOW30037 ................... Bolt. Hex .31-18UNC x 3.00 ....................................................... 11
14 BOW31432 ................... Washer. Flat .31 "ID x .68"OD .................................................... 21
15 BOW34273 ................... Nut, Lock Hex s/16-18UNC .......................................................... 15
16 55327 ............................ Harness. Main Control .................................................................. 1
17 67295-017 ..................... Cable. 3 Conductor 12 Ga ..................................................... 39LF.
18 67998-001 ..................... Screw. Thread Frmng..38-16 x 1.0 Lg ......................................... 2
19 BOW32606 ................... Clamp. Wire Loom I"Dia ............................................................. 9
20 BOW9977 ..................... O-Ring•. 375"ID x .50"OD ............................................................ 1
21 BOW30000 ................... Bolt, Hex .25-20UNC x .50 ........................................................... 2
22 BOW31401 ................... Washer, Flat .25"IDx .63"OD ...................................................... 2
23 BOW30035 ................... Bolt, Hex .31-18UNC x 2.50 ......................................................... 2
24 BOW30036 ................... Bolt, Hex .31-18UNC x2.75 ......................................................... 4
25 55083 ............................ Manifold Assembly, Lift Cylinder ................................................ 1
26 54569 ............................ Cable Bracket, Holding Valve ....................................................... 1
27 54798 ............................ Nut, 10-32UNF Coupling .............................................................. 1
28 54705 ............................ Cylinder, Armstack Lift ................................................................. 1
29 34145 ............................ Bushing, (R#81368) ...................................................................... 4
30 BOW36780 ................... Nut, Hex .25-20UNC Nylon Lock ................................................ 8
31 54616-004 ..................... Shaft, Arm Pivot 6.50"Lg.............................................................. 1
32 55027 ............................ Pin Weldment, Lift Cylinder ......................................................... 1
33 55279 ............................ Block, HDPE Slide ........................................................................ 2
34 54616-009 ..................... Shaft, Aim Pivot 20.38"Lg ............................................................ 2
35 54701 ............................ Block, Armstack Nylatron ............................................................. 2
36 54616-008 ..................... Shaft, Arm Pivot 26.62"Lg ............................................................ 2
37 54582 ............................ Block, UHMWPE Bearing ............................................................ 2
38 02236 ............................ Elbow, 90° MJ04 M004 ............................ " ................................. 1
39 02662 ............................ Elbow, 90° MJ06 M006 ............................................................... 1

- Indicates Items Not Shown

MANUAL 92350-003
January 1997
SIN X935·97051
• FIGURE 19: ArmstackLiftCylinder Assembly

MANUAL 92350-003
January 1997
SIN X93S-970SI
FIGURE 19: Armstack Lift Cylinder Assembly •

. ITEM PART NUMBER DESCRIPTION QTY

Ref. 54705 ............................ Armstack Lift Cylinder Assembly ............................................ Ref.


54705-100 ..................... Seal Kit ........................................................................................... .
54705-101 ..................... Castle Nut ....................................................................................... .
54705-102 ..................... Cast Iron Ring ................................................................................ .
54705-103 ..................... Piston (Steel) .................................................................................. .
54705-104 ..................... Wear ring ........................................................................................ .
54705-105 ..................... JacketAssembly ............................................................................. .
54705-106 ..................... Piston Rod ...................................................................................... .
54705-107 ..................... Gland Nut ....................................................................................... .
55221 ............................ Flow Control Valve, Lift Cylinder ................................................. .

- Indicates Items Not Shown

MANUAL 923S()'()()3
January 1997
SIN X93S-97051
This page intentionally left blank

MANUAL 92350-003
Janwuy 1997
SIN X93S-970SI
FIGURE 20: Manifold Assembly •

. ITEM PART NUMBER DESCRIPTION QTY

Ref. 55083 ............................ Manifold Assembly ................................................................. Ref.


-1 54596-001 ..................... Manifold, Lift Cylinder ................................................................. 1
-2 54635-001 ..................... Valve, 2W NC SPCL Cartridge ..................................................... 1

No Drawing At This Time


- Indicates Items Not Shown

MANUAL 92350-003
Jamwy 1997
SIN X93S-97051
• ·FIGURE 21: Platform Installation

2 3
o o

o
2 PL

, 0

10

o o

MANUAL 92350-003
Januuy 1997
SIN X935-97051
FIGURE 21: Platfonn Installation •

ITEM PART NUMBER DESCRIPTION QTY

Ref. 55478 ............................ Platformlnstallation ................................................................. Ref.


1 54598 ............................ Platform Weldment ....................................................................... 1
2 55474-001 ..................... Toeboard WeldmentLH ................................................................ 1
3 55474-002 ..................... Toeboard Weldment RH ............................................................... 1
4 54682 ............................ Mount Weldment, Ext. Deck Roller .............................................. 4
5 54689 ............................ Roller, Ext. Deck ........................................................................... 4
6 55476 ............................ Deck Weldment, Ext..................................................................... 1
7 55267 ............................ Handrail Weldment, Ext. Deck ..................................................... 1
8 55241 ............................ Latch Assembly, .62-11 UNC Mount.. ........................................... l
9 55473 ............................ Handrail Weldment, Side .............................................................. 2
10 55470 ............................ Gate, Lift Up ................................................................................. 1
11 55471 ............................ Plunger,Latch ............................................................................... 2
12 55243 ............................ Spring, Deck Latch ........................................................................ 2
13 55244 ............................ Finger Ring, Deck Latch ............................................................... 2
14 BOW36702-HD ............ Washer, .313, .813 "OD x .344"IDx.l0 ....................................... 8
15 BOW2548 ..................... S-Hook .......................................................................................... 1
16 164-00013-00 ............... Chain 2/0 ............................................................................ 2.50LF.
17 50286 ............................ Chain Snap .................................................................................... 1
18 BOW34273 ................... Nut, Lock Hex s/16"-18UNC ........................................................ 34
19 BOW36718-HD ............ Washer, Flat 3// SAB .................................................................... 4
20 BOW30002 ................... Bolt, Hex .25-20UNC x .750 ....................................................... 12
21 BOW30008 ................... Bolt, Hex .25-20UNC x 2.00 ......................................................... 6
22 BOW31444 ................... Washer, Flat .25"IDx .63"OD .................................................... 16
23 BOW36780 ................... Nut, Hex .25-20UNC Nylon Lock .............................................. 18
24 BOW30027 ................... Bolt, Hex .31-18UNC x .75 ......................................................... 18
25 BOW34602 ................... Bolt, Carr .31-18UNC x 1.25 ...................................................... 16
26 BOW31432 ................... Washer, Flat .31"IDx .68"OD .................................................... 52
27 55207 ............................ Plug, Dome .................................................................................... 2
28 55563 ............................ Bracket Weldment, Lock Mount ................................................... 1

- Indicates Items Not Shown

~
~
~'" 0

0
0

0
0

0
0

0
0

0
0

0
0

0
0

0
0

0
0

0
0

0
0

0
0

0
0

0
0

0
0

0
0

0 •
0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0
0 0 0 0 0
0 0 0 0 0
o Tr oj{ ;:( 0

05
MANUAL 923so.oo3
January 1997
SIN X93S-970SI
This page intentionally left blank

MANUAL 92350-003
January 1997
SIN X935-97051
FIGURE 22: 110 Volt Extension To Platform •

GREEN

WHITE

BLACK

:3 PL-LOCATED
UNDER
PLATFORM

RE~ CABLt IS INCLUDED


IN ARMSTACK

AT CHASSIS

12

REF. LEFT
GOLD SCREW

FRONT OF CHASSIS

GREEN SCREW

11

Sil VER SCREW

ITEM PARTNUMBER DESCRIPTION QTY

Ref. 54918 ............................ 110 Volt Extension To Platform (Option) ................................ Ref.
1 .................................................................................................................................................
. .

2 66357 ............................ Receptacle, Ground Fault .............................................................. 1


3 55019 ............................ OutletBox, Platform ..................................................................... 1
4 66358 ............................ Cover, Weatherproof ..................................................................... 1
5 67114-003 ..................... Strain Reliefl/2"NPT .37/.5 ........................................................... 1
6 67124-001 ..................... Locknut, 1/2"NPT Strain Relief ...................................................... 1
7 67123-001 ..................... Seal, Connector Elect. 1/2" ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1
8 BOW31105 ................... 10-32 x .75 Slotted Pan Head, Machine Screw ............................. 2
9 BOW31233 ................... Nut, Hex Keps #10-32 ................................................................... 2
10 BOW32603 ................... Clamp, Wire Loom .50 .................................................................. 4
11 52710 ............................ Plug, 110 Volt ............................................................................... 1
12 55036-001 ..................... Grommet, 1/2" ID 114 x 13/ 16" Dia. Grv ........................................... 1
13 BOW34272 ................... Nut, Hex Lock .25"-20UNC .......................................................... 4

- Indicates Items Not Shown


MANUAL 92350-003
January 1997
SIN X93S·97051
• FIGURE 23: Upper Control Box Assembly

33 REF

17

REF 31

35 REF ~
I

37 REF

FORWARD 19

LOW L@}
REVERSE
DRIVE SPEED

17

(-----------------------------1
(I, ,\
, \

I I
8 9 1/

POWER RAISE

I
I
I
I
I
I
I
LOWER :
I
I [I I I t

\___________________________ liJJ __
I II II
~
t

MANUAL 92350-003
lanwuy 1997
SIN X935-97051
FIGURE 23: Upper Control Box Assembly •

ITEM PART NUMBER DESCRIPTION QTY


Ref. 55317 ............................ Upper Control Box Assembly .................................................. Ref.
1 54587 ............................ Box, Upper Control ....................................................................... 1
2 54589 ............................ Contr. BMS4RM9071 WIRG5 + Lever ........................................ 1
S4589-100 ..................... -Boot .............................................................................................. 1
3 51913 ............................ Operator-PushPull ........................................................................ 1
4 51914 ............................ ContactBlockNC ......................................................................... 1
5 52670 ............................ Operator Selector ........................................................................... 1
6 34464 ........... ! ................ Contact Block NO-NC .................................................................. 1
7 52669 ............................ Operator Black Pushbutton ........................................................... 1
8 52672 ............................ Contact Block 1 NO ...................................................................... 2
9 69146 ............................ Operator, Green Pushbutton ................................. 1
>0 • • • • • • • • • • • • • • • • • • • • • • •

10 54913 ............................ Operator - BlackIBlack Dual Switch ............................................. 1


11 52029 ............................ Block Contact 2 NO wlBase ......................................................... 1
12 54910-104 ..................... Mounting Base - AG Panel ........................................................... 1
13 54910-102 ..................... Recep. Screw Term. #1-16 ............................................................ 1
14 67837-006 ..................... Tie, Nylon 6.00" Black .................................................................. 5
15 BOW31125 ................... Screw, Slotted Pan #06-32VNF x .62" .......................................... 4
16 BOW31231 ................... Nut, Hex Keps #6-32 ..................................................................... 4
17 55012 ............................ Insert, Control Box Plastic ............................................................ 2
18 58300 ............................ Wire, 16GaBIack .................................................................... 8LF.
19 54976-001 ..................... Decal, Upper Control Box ............................................................. 1
20 54976-002 ..................... Decal, Upper Control Box ............................................................. 1

31 A620-2633 .................... Battery Condition Indicator (Option) ....................................... Ref.


32
33 A353-2633 .................... Slope Alarm (Option) ............................................................... Ref.
34
35 A626-2633 .................... Low Volt AlarmlInterrupt (Option) .......................................... Ref.
36
37 A304-2633 .................... Signal Hom (Option) ................................................................ Ref.

- Indicates Items Not Shown

MANUAL 923S0-003
January 1997
SIN X93S·970S I
1-----------------, e~

~
OPTIONAL
SLOPE.
ALARM
~

SEE 13
i!i
eo
NOTE 1
tv
w

~
1

r-- -- -- -~ _~LI~ ~LlPPED .:''':.EN) -l-~ -- ----=':F! ~'~ - - -~ - -I-~


1

---- ---~ ---~ ---~ - - ------1 "t:l


1 ~
(j
o
ij
g.
OPTIONAL
BATTERY
INDICATOR
to
OPTIONAL
LOW VOLTAGE
~
OVERRIDE SWITCH )-
1:lIII til

g.~
3A
~

~ -<
2~~
III 1

d~
'"
'"'-t;l
~:g?
~o"J8
...
~ISEE
NOTE 1 t NOTE 1
~ 16

OPTIONAL
SIGNAL HORN

1
SWITCH
____' 1

3B
r----------I----~------- ~;--~
6

DRIVE SPEED J
~I
"'I
L ____________________ -.J
1
VIEW OF INSIDE OF BOX
L _________________ ~

~fAR"INflIIN"1IOM ~_

~~~~~ ~ WACO, TEXAS


NOTES:
1. CONNECT CIRCUIT :5 AS REQUIRED BY OPTIONS. - .....'.l.:.. ••":o.n BOX ASSY, MDD2633
2. CIRCUITS 1, 5, 13, 14, 15, & 16 ARE FOR OPTIONS. ~'-~:r;:.iii. "'="1 UPPER CNTRL
...
-I ~I
s. SEFC't- cI........ 55317 C
RAJ(1ova11Mf~1:1.5 2.1'2
FIGURE 23: Upper Control Box Assembly •

ITEM PART NUMBER DESCRIPTION QTY

Ref. 55317 ............................ Upper Control Box Assembly .................................................. Ref.


1 54587 ............................ Box, Upper Control ....................................................................... 1
2 54589 ............................ Contr. BMS4RM9071 WIRG5 + Lever ........................................ 1
54589-100 ..................... -Boot .............................................................................................. 1
3 51913 ............................ Operator-PushPull ........................................................................ 1
4 51914 ............................ ContactBlockNC ......................................................................... 1
5 52670 ............................ Operator Selector ........................................................................... 1
6 34464 ............................ Contact Block NO-NC .................................................................. 1
7 52669 ............................ Operator Black Pushbutton ........................................................... 1
8 52672 ............................ Contact Block 1 NO ....................................................................... 2
9 69146 ............................ Operator, Green Pushbutton .......................................................... 1
10 54913 ............................ Operator - BlackIBlack Dual Switch ............................................. 1
11 52029 ............................ Block Contact 2 NO wlBase ............................ ;............................ 1
12 54910-104 ..................... Mounting Base - AG Panel ........................................................... 1
13 54910-102 ..................... Recep. Screw Term. #1-16 ............................... ~ ............................ 1
14 67837-006 ..................... Tie, Nylon 6.00" Black .................................................................. 5
15 BOW31125 ................... Screw, Slotted Pan #06-32UNF x .62" ......................................... .4
16 BOW31231 ................... Nut, Hex Keps #6-32 ..........~ ........................................................... 4
17 55012 ............................ Insert, Control Box Plastic ............................................................ 2
18 58300 ............................ Wire, 16Ga Black .................................................................... 8LF.
19 54976-001 ..................... Decal, Upper Control Box ............................................................. 1
20 54976-002 ..................... Decal, Upper Control Box ............................................................. 1

31 A620-2633 .................... Battery Condition Indicator (Option) ....................................... Ref.


32
33 A353-2633 .................... Slope Alarm (Option) ............................................................... Ref.
34
35 A626:"2633 .................... Low Volt AlarmlInterrupt (Option) .......................................... Ref.
36
37 A304-2633 .................... Signal Hom (Option) ................................................................ Ref.

- Indicates Items Not Shown

MANUAL 92350-003
J8IlU8IY 1997
SIN X93S-97051
• FIGURE 24: Travel Alarm (Option)

ITEM PART NUMBER DESCRIPTION QTY

Ref. A301-2633 .................... Travel Alann ............................................................................ Ref.


-1 80188-024 ..................... Wobbulator and Speaker ............................................................... 1
-2 67295-035 ..................... Cable, 16Ga'/2 Conductor SJO ............................................... 2LF
-3 BOW23027 ................... Terminal 6 Stud 16114Ga. Spade .................................................. 4
-4 55036-001 ..................... Grommet, 1/2"ID 1/4" x 13/16"Dia. Grv ............................................ 1

- Indicates Items Not Shown

MANUAL 923S()'()()3
January 1997
SIN X93S·970S I
FIGURE 25: Motion Alarm (Option) •

. ITEM PART NUMBER DESCRIPTION QTY


Ref. A309-2633 .................... MotionAlann ........................................................................... Ref.
-1 80188-024 ..................... Wobbulator and Speaker ............................................................... 1
-2 67295-035 ..................... Cable, 16Ga.l2 Conductor SJO ............................................... 2LF
-3 BOW23027 ................... Terminal 6 Stud 16/14Ga. Spade ................................................. .4
-4 55036-001 ..................... Grommet, 1/2"ID 1// x 13/16"Dia. Grv ............................................ 1
-5 206-00001-00 ............... Diode ............................................................................................. 2

- Indicates Items Not Shown

MANUAL 92350-003
January 1997
SIN X93S-970S 1
. , FIGURE 26: Strobe Light (Option)

REF. RIGHT SIDE VIEW


OF PLATFORM.

ITEM PART NUMBER DESCRIPTION QTY

Ref. A310-2633 '" ................. Strobe Light ............................................................................... Ref.


1 58395 ............................ LightAmberStrobe 12-72 VDC .................................................. 1
2 BOW31400 ................... Washer,Flat #10 ......................................................................... :3
3 BOW31144 ................... Screw, SlotRnd. #10-32VNFx.50 .............................................. 3
4 55400 ............................ Mount - Strobe Light 14" ............................................................. 1
5 BOW34001 ................... Bolt, Hex .25-20UNC x 1.00 ........................................................ 2
6 BOW31432 ................... Washer, Flat .31 IDx .68 OD ....................................................... 2
7 BOW36780 ................... Nut, Hex .25-20UNC Nylon Lock ............................................... 2
8 67295-035 ..................... Cable, 16Ga.l2 Conductor SJO ............................................ 50LF
9 52672 ............................ Base + 1 NO Contact ZB2BZI0l ................................................. 2
10 58259 ............................ Wire, 18Ga. Black-Bulk .......................................................... ILF

- Indicates Items Not Shown

MANUAL 923S0-003
January 1997
SIN X93S-970S 1
FIGURE 27: Descend Alarm (Option) •

. ITEM PART NUMBER DESCRIPTION QTY

Ref. A312-2633 .................... DescendAlarm ......................................................................... Ref.


-1 80188-024 ..................... Wobbulator and Speaker 24V ...................................................... 1
-2 67295-035 ..................... Cable, 16Ga.l2 Conductor SJO .............................................. 2LF
-3 BOW23 027 ................... Terminal 6 Stud 16/14Ga. Spade ................................................. .4
-4 55036-001 ..................... Grommet, 1/2"ID 1/4" x 13fI/Dia ..................................................... 1
-5 34542 ............................ Jumper ........................................................................................... 1

- Indicates Items Not Shown

MANUAL 92350-003
Janwuy 1997
SIN X93S·970S1
• FIGURE 28: Slope Alarm (Option)

ITEM PART NUMBER DESCRIPTION QTY

Ref. A353-2633 .................... Slope Alann .............................................................................. Ref.


-I 32002 ............................ Slope Sensor 2-Axis ..................................................................... 1
-2 BOW30002 ................... Bolt, Hex .25-20UNC x .750 ........................................................ 2
-3 BOW31432 ................... Washer,Flat .3IIDx.680D ....................................................... 2
-4 67295-024 ..................... Cable, 8 Conductor 16AWG Type SO ................................... 7LF
-5 BOW23003 ................... Terminal Ring #6796022-18 #10 Stud ........................................ 2
-6 ~4644 ............................ Alann ............................................................................................. 1
-7 58259 ............................ Wire, 18Ga. Black-Bulk .......................................................... 2LF

- Indicates Items Not Shown

MANUAL 923S0-003
January 1997
SIN X93S-970SI
FIGURE 29: Hour Meter (XL-Option) •

8 2 PL
1 j

8B=WHT
#1 =BLK

©J #1=BLK 8B=WHT

REFERENCE PL
MOTOR CONTACTOR

ITEM PART NUMBER DESCRIPTION QTY

Ref. A619-2633 .................... Hour Meter ............................................................................... Ref.


-1 80027 ............................ Meter, Hour 4/40V DC ................................................................. 1
-2 67840-001 ..................... Bracket, -Gage Mounting ............................................................... 1
-3 BOW30003 ................... Bolt, Hex .25-20UNC x .875 ........................................................ 2
-4 . BOW31401 ................... Washer,Flat .25IDx.630D ....................................................... 4
-5 BOW36780 ................... Nut, Hex .25-20UNC Nylon Lock ............................................... 2
-6 67295-035 ..................... Cable, 16Ga.l2 Conductor SJO .............................................. 6LF
-7 BOW23087 ................... Coupler- R#67963 16-14 Female ................................................. 2
-8 67960-006 ..................... Terminal Ring - 16-14 # 10 Stud ................................................... 2
-9 67837-004 ..................... Tie, Nylon-4" Black ...................................................................... 4

- Indicates Items Not Shown

MANUAL 923S()'()()J
January 1997
SIN X9JS-970S I
. , FIGURE 30: Battery Condition Indicator (XL-Option)

ITEM PART NUMBER DESCRIPTION QTY

Ref. A620-2633 .................... Battery Conditon Indicator ....................................................... Ref.


-1 37716 ............................ Meter, 24V Battery ....................................................................... 1
-2 37993 ............................ MeterGuard .................................................................................. 1
-3 58300 ............................ Wire, 16Ga.-Black ................................................................... 2LF
-4 67963-001 ..................... Coupler - 22-18 Male .................................................................... 2

- Indicates Items Not Shown

MANUAL 923S0-003
Jomwy 1997
SIN X93S·970S 1
FIGURE 31: Low-Voltage Warning Interrupt (XL-Option) •

ITEM PART NUMBER DESCRIPTION QTY

Ref. A626-2633 .................... Low-Voltage Warning Interrupt ............................................... Ref.


-I 54169 ............................ LowVoltage Interrupt 24V .......................................................... 1
-2 54967-104 ..................... 0perator, Blue Illum Pushbutton ................................................... 1
-3 55902 ............................ Base + NO/NC Contact w124V Bulb ............................................. 1
-4 58259 ............................ Wire, 18Ga. Black-Bulk .......................................................... 6LF
-5 54935 ............................ Decal- Low Volt Warning/Override ............................................. 1
-6 BOW31141 ................... Screw,SlottedRnd. #10-24 x 2.00 ............................................... 2
-7 BOW31288 ................... Nut, Hex #10-32 ........................................................................... 2
-8 BOW31430 ................... Washer, Flat #IOID ..................................................................... 4

- Indicates Items Not Shown

MANUAL 92350-003
January 1997
SIN X935-97051
This page intentionally left blank

MANUAL 92350-003
January 1997
SIN X93S-970S 1
FIGURE 32: Larger Batteries IPOS (XL-Option) •

ITEM PART NUMBER DESCRIPTION QTY

Ref. A629-2633 .................... Larger Batteries IPOS ............................................................. Ref.


-1 50046 ............................ Battery - 6 Volt .............................................................................. 4
-2 52627 ............................ Battery - 6V Trojan T125-WT .................................................... -4
-3 54836 ............................ Angle - Option Battery Tie-Down ................................................. 2
-4 55505 ............................ Angle, E2633 Battery Tie-Down 22" ........................................ -2

- Indicates Items Not Shown

MANUAL 92350-003
January 1997
SIN X93S·970S I
A div. of TIME Manufacturing Company

SELF-PROPELLED
ELEVATING WORK PLATFORM

MODEL V2033XL, V2033


Serial Number X935-970S1

SHIPPING ADDRESS MAILING ADDRESS

CONDOR® CONDOR®
A DIY. OF TIME MFG. CO. A DIY. OF TIME MFG. CO.
8300 IMPERIAL DRIVE P.O. Box 21447
WAco,TEXAS76712 WAco,TEXAS 76702-1447
(817) 420-5200 (817) 420-5200

MANUAL 92350-003
January 1997
SIN X93S-970S I
CONDOR® MODEL V2033XL, V2033
VENDOR SECTION

TABLE OF CONTENTS

CONTROLLER .................................................................................................. OEM CONTROLS

CHARGER ................................................................................................ LESTER ELECTRICAL

OPEN CIRCUIT TRANSFORMER TEST ....................................................................................... .

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


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OWNERS MANUAL

24 Volt
Fully Automatic
Battery
Charger
Model 17970
Specifications:

ACSuPOly DC Output Battery Specifications


120 Volts 24 Volts Use only on 24 volt. 12 cell.
8 Amps 25 Amps Tapering series connected wet lead
60 Hertz t08 amps acid systems. 180-305
Single-Phase ampere-hour (20 hr. rate)

eL'kte:v-4y-Electr;cal •
625 West A St.
Lincoln, NE 68522
USA

F01532 A
SAVE THESE IMPORTANT INSTRUCTIONS

READ AND FAMILIARIZE YOURSELF WITH THIS ENTIBE MANUAL BEFORE INSTALUNG OR OPERATING THE
'::HARGER. FOLLOW ALL INSTRUCTIONS ON THE BATTERY CHARGER. AND BATTERY POWERED EQUIP·
.lItENT. THIS MANUAL CONTAINS IMPORTANT SAFETY AND OPERATING INSTRUCTIONS FOR THIS BATTERY
CHARGER.

A LOOK FOR THIS SYMBOL TO POINT OUT SAFETY PRECAUTIONS. IT MEANS BECOME ALERT· YOUR
SAFETY IS INVOLVED. IF YOU DO NOT FOLLOW THESE SAFETY INSTRUCTION, PERSONAL INJURY OR
PROPERTY DAMAGE CAN OCCUR. SAVE THESE IMPORTANT INSTRUCTIONS.

IMPORTANT SAFETY INSTRUCTIONS to ensure superior battery performance and life. A patented
electronic circuit turns the charger on and off automatically.
1. SAVE THESE INSTRUCTIONS· This manual contains When the battery has reached its maximum state of charge.
imponant safety and operating instructions for battery charger the cirCUitry will turn the charger off.
Model 17970.
2. Before using battery charger. read all instructions and RECEIVING AND INSTALLATION
cautionary markings on (1) battery charger. (2) battery. and
(3) product using battery. . When the charger is received. check for possible in tranSit
A CAUTION: TO REDUCE RISK OF INJURY, CHARGE ONLY damage. If any damage is found. it should be reponed as a claim
to the carrier.
LIQUID ELECTROLYTE (WET) LEAD ACID RECHARGE·
ABLE BATTERIES. OTHER TYPES OF BATTERIES MAY Proper installation of the charger is important in order to
BURST CAUSING PERSONAL INJURY AND DAMAGE. achieve good charger performance and to prevent damage
3. Do not expose charger to rain or snow. to the charger and batteries. The charger should be located
4. Use of an attachment not recommended or sold by the in a clean. cool. dry. and well ventilated area. To permit free
battery charger manufacturer may result in a risk of fire. air flow for convection cooling. allow three inches minimum
electric shock. or injury to persons. between the charger and any wall and six inches between
the charger and other equipment. Position the charger on a
5. To reduce risk of damage to electric plug and cord. pull by
foundation of stone. brick, concrete or grounded metal.
plug rather than cord when disconnecting charger.
'\. Make sure cord is located so that it will not be stepped on. A DANGER: TO REDUCE THE RISK OF FIRE, 00 NOT USE
tripped over. or otherwise subjected to damage or stress. THE CHARGER NEAR FLAMMABLE MATERIALS OR
VAPORS.
7. An e«tension cord should not be used unless absolutely
necessary. Use of improper extension cord could result in a
risk of fire and electric shock. If extension cord must be AC INPUT AND GROUNDING INSTRUCTIONS
used. make sure:
8. Pins on plug of extension cord are the same number. A CAUTION: TO REDUCE RISK OF ELECTRIC SHOCK
size. and shape as those of plug on charger OR FIRE, DISCONNECT POWER TO RECEPTACLE
b. Extension cord is properly wired and in good electrical BEFORE INSTALUNG OR REMOVING UNIT.
condition. This battery charger must be connected to a 120 Vac. 60
c. Wire size is large enough for ac ampere rating of charger. hertz. 1 phase AC power source which is properly
8. Do not operate charger with damaged cord or plug - replace installed and grounded in accordance with the National
it immediately. Electrical Code (U.S.) and all local codes and ordinances.
9. 00 not operate charger if it has received a sharp blow. been GROUNDING INSTRUCTIONS • Charger should be
dropped. or otherwise damaged in any way; take it to a grounded to reduce risk of electric shock. Charger is
qualified service center. _ equipped with an electric cord having an
10. 00 not disassemble charger; take it to a qualified service equipment-grounding conductor. The installed plug must be
center when service or repair is required. Incorrect plugged into an outlet that is properly installed and grounded
reassembly may result in a risk cif electric shock or fire. in accordance with all local codes and ordinances.
11. To reduce risk of electric shock, unplug charger from a live A DANGER: NEVER ALTER AC CORD OR PWG IF IT
outlet or disconnect AC power to the outlet before WILL NOT FIT OUTLET. HAVE A PROPER OUTLET
attempting any maintenance or cleaning. Turning off INSTALLED BY A QUAUFIED ELECTRICIAN. IM-
controls will not reduce this risk. PROPER CONNECTION CAN RESULT IN A RISK OF
AN ELECTRIC SHOCK.
-A- -8-
INTRODUCTION
This battery charger is a self-regulating charger with a minimum
=:'~ADAPTER~
I 6:"!
0U1I.ET BOX I I I .

~~l.~~
of moving parts. designed for long. trouble free service. Built-in
'ine voltage compensation produces a consistent output when
the AC supply voltage varies by as much a 10% from nominal.
Convection cooling maximizes the reliability and minimizes any . . - GIIOUNDED
0U1I.ET
maintenance costs. ONLY LIQUID ELECTROLYTE (WET) NOTE: Use of an adapter shown in figures B and C is not
LEAD ACID BATTERIES should be recharged with this charger permitted in Canada.

-2-
This battery charger is for use on a nominal 120 volt circuit ana 4. Monitor the ammeter for correct charge current. The
has a grounding plug. which looks like the adapter Illustrated in initial charge current should range between
figure A. A temporary adacter. which looks like the adapter approximately 25 amps. If the batteries have not been
illustrated in figures Band C. may be used to connect this plug discharged. or the AC supply voltage is lower than 120
.0 a two-pole receptacle as shown in figure B if a properly volts. the initial charge rate may be less. If the batteries
grounded outlet is not available. The temporary adapter should have been excessively discharged. or AC supply
be used only until a properly grounded outlet can be installed by voltage is higher than 120 volts. the initial charge rate
a Qualified electrician. may be more than 25 amps.
A DANGER: BEFORE USING ADAPTER AS ILLUSTRATED, 5. Charge current will gradually taper to approximately 8
BE CERTAIN THE CENTER SCREW OF OUTLET PANEL amps depending on the age and condition of the
PLATE IS GROUNDED. batteries. Charger turns off automatically and the
The green-colored rigid ear or lug extending from adapter must "CHARGE COMPLETE~ light will glow when banery is
be connected to a properly grounded outlet. If necessary. replace fully charged. Charge time varies with battery size and
original outlet cover plate screw with a longer screw that will depth of discharge. Allow 12-14 hours for normal
secure adapter ear or lug to outlet cover plate and make ground charging. Severely discharged batteries may require
connection to grounded outlet. more time to be properly charged and equalized.
6. After the charger has turned off. discoMect the DC
output plug from the battery (if required) and the AC
EXTENSION CORD REQUIREMENTS supply cord from outlet.
Always use a three conductor No. 14 AWG (1.5mm) heavy duty
cord with ground. properly wired. in good electrical condition and MAINTENANCE INSTRUCTIONS
keep it as short as possible. Make sure the pins on the plug of
the extension cord are the same number. size and shape as the The battery charger requires minimal maintenance. It should
AC plug of the battery charger. The use of an improper extension be kept clean and all connections are to be tightly secured.
cord could result in a risk of fire or electric shock. Locate all cords In the event of intermittent operation. examine and tighten. if
so they will not be stepped on. tripped over or otherwise necessary. all connections. BE SURE THE CHASSIS IS
subjected to damage or stress. SECURELY GROUNDED. If any problems cannot be
resolved consult a Qualified service center.
DC OUTPUT Observe the following battery maintenance procedures to
obtain good performance and maximum cycle life.
This battery charger is designed to produce a 24 volt de output 1. Always observe the following personal safety
Nith an initial charge current of 25 amps. ONLY 24 VOLT. 12 precautions when working with lead acid baneries:
CELL. SERIES CONNECTED. 180 TO 305 AMP-HOUR. 8. Someone should be within range of your voice or
LIQUID-ELECTROLYTE (WET) LEAD-ACID BATTERIES close enough to come to your aid when you work
SHOULD BE USED. The charge current will decrease gradually near a battery.
to about 8 amps as the battery reaches full charge and will remain b. Have plenty of fresh water and soap nearby in case
there until the charger turns off. As the battery ages the charge battery acid contacts skin. clothing or eyes.
current may no longer decrease to the 8 amp finish current. liquid c. Wear complete eye protection and clothing
electrolyte batteries will normally be charged to 2.5 volts per cell. protection. Avoid touching eyes while working near
battery.
OPERATING INSTRUCTIONS d. If battery acid contacts skin or clothing. wash
immediately with soap and water. If acid enters eye.
1. Connect AC supply cord to a properly grounded 120 Volt. 60 immediately flood eye with running cold water for at
hertz. single phase outlet. least ten minutes and get medical attention.
2. Connect the DC output plug to batteries (if required). The e. NEVER smoke or allow a spark or flame in the
black wire must be connected to battery negative (-). and vicinity of batteries.
the red or white wire to battery positive (+). Make sure all f. Be extra cautious to reduce risk of dropping a metal
connections are clean and tight. tool onto battery. It might spark or short-circuit battery
or other electrical part that may cause explosion.
3. The charger will start after a short delay as indicated by the g. Remove personal metal items such as rings,
"CHARGING" light. transformer hum and the ammeter bracelets. necklaces. and watches when working with
movement. a lead acid battery. A lead acid battery can produce a
A WARNING: LEAD ACID BATTERIES GENERATE GASES short-circuit current high enough to weld a ring or the
WHICH CAN BE EXPLOSIVE. CHARGE ONLY IN WELL VEN- like to metal, causing a severe burn.
TILATED AREAS. DO NOT DISCONNECT CHARGER DC OUT- h. NEVER charge a frozen battery.
PUT TERMINALS FROM BATTERY WHEN CHARGER IS ON.
THE RESULTING ARCING AND BURNING COULD CAUSE
A DANGER: TO REDUCE RISK OF ELECTRIC SHOCK.
ALWAYS DISCONNECT THE AC SUPPLY CORD FROM
THE BATTERY TO EXPLODE. KEEP SPARKS, FLAME, AND
ITS OUTLET AND THE DC OUTPUT CORD FROM THE
SMOKING MATERIALS AWAY FROM BATTERY. BATTERY BEFORE ATTEMPTING ANY MAINTENANCE
If the charger must be stopped. always disconnect the AC (CHANGING FUSES, ETC.) OR CLEANING OF THE BAT-
suppfy cord from its outlet before disconnecting the DC output TERY OR BATTERY CHARGER.
terminals from the battery. 2. New batteries should be given a full charge before their
first use because it is difficult to know how long baneries
have been stored.

-3-
3. Limit use at new batteries for first five cycles. New batteries c. AC circuit is not live (power outage or circuit breaKer
are not capable of their rated output until they have been blowni.
discharged a number of times. 4. CHARGER DOES NOT TURN OFF
00 not excessively discharge batteries. Excessive 8. The charger is connected to a battery with an
discharge can cause polarity reversal of individual cells amp-hour capacity greater than specified.
resulting in complete failure shortly thereafter. Limited use b. The charger is connected to a battery pack with a
of new batteries will minimize the chance ot cell reversal. system voltage higher or lower than specified.
5. CHECK THE LEVEL OF THE ELECTROLYTE IN c. New batteries (5 cycles or less). cold batteries or over
CONVENTIONAL LIQUID ELECTROLYTE LEAD ACID discharged batteries may require an extended charge
BATTERIES MONTHLY. MAINTAIN THE PROPER time to achieve full charge.
ELECTROLYTE LEVEL BY ADDING DISTILLED OR 5. CHARGER FUSE BLOWS (OR CIRCUIT BREAKER)
PURIFIED WATER WHEN NECESSARY. Electrolyte levels 8. AC fuse blows when wrong AC power supply is used.
lower during discharge and rise during charge. Therefore. it 6. BUILDING AC LINE CIRCUIT BREAKER OR FUSE
is mandatory that water be added to cells ONLY when they BLOWS
are fully charged - do not overfill. Old batteries require more a. A "weak" fuse or circuit breaker is protecting the
frequent additions of water than new batteries. circuit. Connect the charger to another outlet on a
6. Keep tops of batteries clean and dry to prevent excessive different circuit. If the charger operates properly, have
self discharge. Keep battery terminals reasonably tight. a qualified electrician inspect and test the original
circuit.
TROUBLE SHOOTING b. The circuit is overloaded. Connect the charger to
another outlet on a different circuit.
FOR SAFE AND EFFICIENT TROUBLE SHOOTING. READ 7. EQUIPMENT RANGE DeCREASING
THIS TROUBLE SHOOTING GUIDE COMPLETELY BEFORE a. The electrolyte level in conventional liquid electrolyte
BEGINNING ANY TESTS. lead-acid batteries was allowed to drop below the too
A CAUTION: DO NOT OPERATE THE CHARGER IF IT IS of the battery plates. Add distilled water to JUST
COVER THE TOPS OF THE PLATES immediately
DAMAGED OR >APPEARS· TO BE MALFUNCTIONING.
PERSONAL INJURY OR DAMAGE TO THE CHARGER OR upon discovery and fill to the proper level with
BATTERIES MAY RESULT. DO NOT DISASSEMBLE THE distilled water at the completion of the very next
CHARGER. TAKE IT TO A QUAUFIED SERVICE AGENT charge cycle. Battery capacity lost in this manner is
WHEN SERVICE OR REPAIR IS REQUIRED. INCOR· permanent and is not recovered with additional
RECT REASSEMBLY MAY RESULT IN A RISK OF ELEC- charge cycles.
TRIC SHOCK OR FIRE. b. Use of the equipment before the batteries have been
fully charged and the charger turns off. This shortens
10 determine if a charger malfunction exists, eliminate the battery life and hastens the onset of reduced daily
problems not associated with the charger in the sections below. range. Battery capacity lost in this manner is
If the problem can not be resolved, contact a qualified service permanent and is not recovered with additional
center. charge cycles.
1. CHARGER DOES NOT TURN ON c. This is the normal wear out process for all types of
8. Battery is not connected to charger. deep-cycle motive power batteries.
b. Charger is not plugged into a live AC outlet.
A WARNING: IF THE AC OR DC PLUG OR RECEPTACLE IS
BROKEN, TWISTED, BENT OR LOOSE AND DOES NOT
MAKE GOOD ELECTRICAL CONTACT, HAVE IT RE·
PLACED BY QUAUFIED SERVICE PERSONNELIMMEDI·
ATELY. DO NOT USE THIS CHARGER IN THIS
CONDITION AS FIRE OR PERSONAL INJURY CAN RE-
SULT.
c. DC fuses blown.
2. CHARGER REMAINS AT HIGH RATE
a. The charger is connected to a battery pack with a system
voltage lower than specified.
b. Battery amp-hour capacity is greater than speCified for
charger.
c. One or more of the batteries in the battery pack has
reversed polarity.
3. CHARGER TURNS OFF EARLY
a. The DC cord was accidentally disconnected from the
battery during charge. .
b. The battery has been allowed to sulfate. Charge the
battery at least once every three days when the
equipment is lightly utilized. Once sulfation is allowed to
take place it may be partially reduced by returning,
temporarily, to daily charging.

-4-
WIRING DIAGRAM

ELECTRONIC TIMER block

red
green-

TRANSFORMER
red or
white
~----------~-----~~-----~~
I
147
TO
BATTERIES

block

2
AMMETER

DIODE
4
ton
white

CAPACITOR
*Green wire not used
on some models.

PARTS UST FOR LESTRONIC II CHARGER


MODEL 17970 TYPE 24LC25-8ET
120 VAC 60 Hz
PART NO DESCRIPTION

23278S CASE ASSEMBLY


16105S TRANSFORMER ASSEMBLY
16354S HEATSINK ASSEMBLY, WITH DIODES
16369S AMMETER
18320S ELECTRONIC TIMER ASSEMBLY
02390S CAPACITOR, 6.0 MFD, 660 VAC
02028S BUSHING, 7W-2, INSULATOR FOR CORDSET
23282S CORDSET, DC, 75", NO PLUG
Oan6S FUSE ASEMBLY
04328S AC RECEPTACLE

-5-
Limited Warranty•
Lester Electrical warrants each new Lester Battery Charger tor defects in material and workmanship for a period
of two years from the date of manufacture of the complete unit. Repairs can be made at the Lester factory. To
do so send the defective unit with transportation charges prepaid to:

Lester Electrical
625 West "A" Street
Lincoln, NE 68522 U.S.A.
Attention: Repair Department

For repairs made at other than the Lester factory, Lester will provide only the replacement parts. Defective parts
should be sent with transportation charges prepaid to the Lester factory at the previously mentioned address.

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

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

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

Some states do not allow the exclusion or limitation of incidental or consequential damages; or limitations on
how long an implied warranty lasts, so the above limitations may not apply to you. This warranty gives you
specific legal rights, and you may also have other rights which vary from state to state.
Lester's obligation under this warranty is strictly and exclusively limited to the repair or replacement of defective
items. Lester issues this warranty in good faith and with full confidence in the workmanship and quality of Lester
products.

-6-
OPEN CIRCUIT TRANSFORMER TEST

Failure of the transformer can be the result of natural aging,


premature shorting of adjacent coil turns or overheating damage. The most
common cause of transformer overheating and premature burn-out is the
result of misuse, connecting the charger to a battery system of lower
voltage than specified on the charger. Darkening of all the transformer
secondary coil windings is an indication of possible overheating damage.

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

To test transformers used in chargers of different output voltages


than 36 Volt as covered in manual, Form 00910, the transformer coil AC
voltages are:

Charger Number of No Load Open Circuit


Nameplate Lead-Acid Transformer Secondary Coil
Voltage Battery Cells 6~_I~§!_YQli~g~§ ______________________ _
VDC in Series Resonant Resonant
VN Capacitor Capacitor
Connected Disconnected

12 6 27 to 33 17 to 23

24 12 54 to 66 36 to 44

36 18 83 to 97 55 to 65

48 24 110 to 130 73 to 97

Use the equations to calculate approximate test voltages for other


systems.

The readings are approximate and transformer failure is indicated


when measured voltages are significantly lower than those calculated in
the table. DC voltages measured at the charging leads are about 1/2 the
transformer test voltage amounts.

Transformer secondary voltage measurements made with the resonant


capacitor connected can occasionally result in noticeably higher readings
than expected. No-load transformer instabilities and peculiar wave shapes
can increase these voltage readings. This is particularly true when using
digital meters, as several models get confused with other than pure sine
wave AC or pure ripple-free DC.
PROPER CARE OF MOTIVE POWER BATTERIES alloweo to Sit unmalOtalOed in storage self discharge.
Motive power battenes are subjecteo to severe deeD sulfate to vanous degrees ana lose cacaclty.
crcle duty on a dally basIs. Althougn these oattenes are Repeateo charg,"; 'Hlil generally result in the recov·
designed to withstand sucn duty the following precau. ery of most ot the oattery's capaCity. though some
tions must be observed to cetalO 0000 cerformance ana - permanent loss can be exeected.
maximum cyc!e life. - 5. 00 NOT EXCESS1VE!..Y DISCHARGE THE BATTE:;-
IES. Excessive disc~arge can cause polarity reversal
A CAUTION: Always wear protective eye shields and of individual cells resulting in complete failure shortly
clothing when working with batteries. thereafter. Heavily discharging (Over 60%) new batter-
Batteries contain acids which can cause ies before they have ceen broken in (approximately 20
bodily harm. Do not put wrenches or cycles) can cause permanent cell damage. resulting in
other metal objects across the battery reduced energy capacity and shortened life.
terminal or battery top. Arcing or explo· 6. Maintain the proper electrolyte level by adding water
sion of the battery can result. when necessary. Never allow the electrolyte level to
tall below the top at the battery plates. Electrolyte lev-
,. When installing new batteries be sure the polarity of
els tall during discnarge and rise during charge.
each battery and overall battery pack is correct. Due Therefore. to prevent the overflow at electrOlyte when
to the electrical charac:enstics ot this charger it is charging. it is mancatory that water be added to ceUs
possible to improperiy hook up the battenes and not AFTER they have been fully charged. DO NOT OVER-
blOW the fuse when charglOg. Battery anal or charger FILL Old batteries reauire more frequent additions at
damage can result.
water than do new catteries.
2. New batteries should be given a full charge before 7. When the temperature falls below 65 degrees F. the
their first use because it is difficult to know how long batteries should be placed on charge as soon after
the batteries have been stereo. use as possible. Cold batteries require more time to
3. Umit the use at new batteries for the first 20 cycles. fully recnarge.
New batteries and older battenes that have been in 8. The tops of the battenes and battery hold-downs must
storage are not caeable at their rated outeut until they be keet c!ean anc or" at all times to orevent excessive
have been discharged ana cnarged a number of times. self diSCharge and ;Iow at current Oetween the battery
4. Sulfation results when batteries in storage are not posts ana frame.
maintained in a charged ac:ive state. Internal self dis· 9. Follow all operatinc instructions. cautions. and warn-
charge can bring about the Start ot thiS condition in as ings as specified in :his manual. on the charger. and
little as three days in warm temperatures. Batteries in your vehicle owner's manual.

TROUBLE SHOOTING GUIDE


TO BE ABLE TO USE THE TROUBLE SHOOTlNG GUIDE SAFE1.Y AND EFFECTIVE1.Y IT IS IMPORTANT TO READ THIS
GUIDE COMPLETELY BEFORE BEGINNING ANY TESTS.
A CAUTION: REPAIRS BY QUALIFIED PERSONNEL ... DANG~R: HIGH VOLTAGE - With the charger on.
ONLY. NOTe: Modifying this charger for the Internal charger capaCitor voltage is
use other than that for which it was approximately 650 volts.
intended. repairs by persons not quali-
fied. or not using original equipment .At. CAUTION: ALWAYS UNPLUG THE ELECTRICAL
replacement parts will void the warranty CORDS FROM THE AC OUTLET AND
and Lester liability. THE BATTERIES BEFORE ATTEMPTING
A CAUTION: DO NOT DISASSEMBLE THE CHARGER. ANY REPAIRS TO THE CHARGER.
TAKE ITTO A QUAUFIED SERVICEMAN
WHEN SERVICE OR REPAIR IS .At.WARNING: Do not operate the charger If it Is mal-
REQUIRED. Incorrect assembly may functioning. Personal injury or property
result in a risk of electric shock or fire. damage could resulL
The Lestronic II battery Charger is a reliable. automatic charger designed for long, trouble-free service. If a malfunction
should develop. identify the symptom and follow the associated test procedures.

MALFUNCTlON SYMPTOM
SECTION SECTION
CHARGER DOES NOT TURN ON 3 AMMETER i=\EADS 30 AMPS FOR MORE
A. Relay does not Close. No Tra:'lsformer THAN 30 MINUTES
Hum and Ammeter Does Not Register. 4 CHARGER OUTPUT IS LOW
B. Relay Closes But No Transformer Hum
and Ammeter Does Not Register. 5 CHARGER TURN OFF MALFUNCTIONS
C. Relay Closes and Transformer Hums A. Charger Turns Off Too Soon.
But Ammeter Does Not Register. B. Charger Does Not Turn Off.
D. E!ectronic Timer Kit Replacement C. Charger Runs Too Long But Does Turn
Instructions. Off.
2 CHARGER FUSE BLOWS 6 ACUNE FUSE OR CIRCUIT BREAKER
BLOWS
A. Single Fuse Link Blows
B. 80th Fuse Links Blow 7 TRANSFORMER SHORT OR BURN-OUT
SECTION 1 - CHARGER DOES NOT TURN ON The Ejectromc Timer Kit may be bypassed in order to
in normal -::cer:;wcn :~e c:;arcer CC outout connector verify that a malfunction eXists. First eisconnect the
must be :::crnec:e-:: to :ne oattenes !n orcer to turn the cnarger cower sucoly core from its outlet ana the DC
charger on. ,l. :Ime -::e!av oi 2 :0 5 secones IS orovlded to output connector from :ne battery connector. Place a
ailow ace':!.:ate !Ime :0 maKe a sec:.:re connectIon beior-e jumper wire oetween terminals iFl and #3 to bypass the
the c:;ar;er :t.;r:;s on . .At:er thiS time ae!ay the power Eiectronrc Timer Kit as snown in Figure 2 and Figures 6
relay C:Cses ar::: an at.;c:o:e "c::c!<" should be heare. and 7.
When troe re!aV c:cses. AC :::O'Ner IS 5uociied to the trans- Tne power sucpiy cord is now connected directly to the
former or:mar:! ce::. !f o:::eratlng oroceriy the transformer primary transformer coil ana the transformer should hum
snoutc ~L;m arc :~e ammeter snot.;ic InClcate the charge when the power sUDpiy cord is connected to a live outlet.
rate. if ::;e :::-ar:er :ces ~ct ::.;rr. on orocenv reier to Part The cnarger oceration may be checked by first connect-
A. S or C fer seee::lc :est ~rocecures. . ing the DC outout connec:orto the battery connector. anc
then connecting the power supply cord to an outlet. If
PART A - RELAY DOES NOT CLOSE. NO TRANS- normal cnarging current is indicated on the ammeter the
FORMER HUM AND AMMETER DOES NOT ElectroniC Timer Kit :s detective and must be replaced.
REGISTER.
Checl< :0 be sure tne power suociy cord is securely con- A CAUTION: DO NOT charge batteries with the EJec-
nec:ea to a iive outlet CheCK the DC outout connector tronic Timer Kit bypassed. The charger
ana the banerl connector for damage. dirt or corrosion will remain on as long as the power
that would prevent a gooa electrical connection. supply cord is connected to an outlet.
Severe overcharging and eventual dam-
A WARNING: If the plug or receptacle is broken. age to batteries will result.
twisted. bent or loose and does not If the transformer does not hum and the ammeter still
make good electrical contact. have it does not register witn the Electronic Timer Kit bypass ea.
replar.ed by a qualified serviceman a continuity cneck of the charger AC circuit is necessary.
immediately. DO NOT USE THIS Disconnect tne Dower sUDeiy cord from ItS outlet and the
CHARGER IN THIS CONDITION AS DC output connector from the banery connector and.
FiRE OR PERSONAL INJURY CAN with a suitable continuity tester. cnecl< tne circuit across
RESULT. the power supeiy cord prongs as snown in Figure 2.
Then cisconnee: ·!l'le cower suociv cord from its outlet With the Electronic Timer Kit bypassed. the CIRCUIT
With tt:e DC outout connec:or stl'lI connec:ed to the bat- SHOULD BE COMPLETE. If the circuit is not comelete.
tery connee:cr. measure the voltage at the battery con- Indiviaually check the continuity of the power SUPPlY
nec!or uSing a suitacle DC voitmeter as snown in Figure 1. cord. ptlmary transformer coil and all connections.
:. ... - PART B - RELAY CLOSES BUT NO TRANSFORMER
HUM AND AMMETER DOES NOT REGISTER
Check to be sure the.power supply cord is securely con-
nected to a live AC outlet. When three-prong to two-
prong adapter$ are used. they tend to work loose result-
ing in a poor connection. Check the AC line fuse or
circuit breaker and. if possible. measure the AC line vol-
tage at the outlet to be sure AC power is present. If
necessary connect a functioning charger. utility light or
other electrical appliance to the outlet to verify the pres-
ence of AC power.
If AC power is present. disconnect the power sUDply
cord tram its outlet and the DC output connector trom
the banery connector. Bypass the Electronic Timer Kit as
described in Section 1. Part A. and with a suitable conti-
FIGURE 1 nuity tester check the circuit across the power supply
Battery DC Voltage Test cord prongs as shown in Figure 2. With the ElectrOnic
The voltage reading should be the same as the battery
terminal voltage and must be between 24 and 50 volts DC
in order to close the relay. If the DC voltage is withir:J the
above limits. remove the charger cover and verifythatthe
charger is properly wired and you read the same voltage
(24 to 50 Vdc: inSide the charger where the white and
black wires of the DC cord attaCh. (Fig. 4 and wiring
diagram Fig. 8.) If th e battery DC voltage measured inside
the charger is now below the above limits or not present,
the DC plug or corcset has an internal breal< and must be
replaced. If the cnarger is wired correctly and a satisfac-
tory battery DC voltage is measured inside the charger. a
malfunction in the Electronic Timer Kit has probably
occurred. Due to its complexity. do not attempt to make
field repairs to any part of the E!ectronic Timer Kit If a
maifunction-exists. simpiy remove-the entire Electronic
Timer Kit and reoiace it with a new one. Refer to Part FIGURE 2
D-"E!ectronic Timer Kit Replacement"-for correct Charger AC Circuit Continuity Test
procedure. (Transformer removed for clarity)
Timer Kit byoassea. the CIRCUIT SHOUl!:) BE CC~"l­ connec:or. and c:1eck the charger fuse. If a fuse link is
?LSTc. if the Circuit IS comele!e. refer to me winne ::::Ia- ;:)Iown. rerer to Section 2 - "Charger Fuse Slows" for
gram In F:gure a.
ana C:1eCK :r.e relay wifing ana all ~urtner tests. if the fuse cnecks gooa. use a low voltage
connections. If the Circuit IS nct comolete. cneCK me wlr- continuity :ester to penorm the following tests:
mg at :he cower sucolY core. trans:ormer pnmarf cOli
leaas ana the EiectrOnlC Timer r<it. if the cnarger IS wlreo ,. Connec::ne tester leads to the charger DC output
c::meC:ly. IndlVlcually cneek :r:e ccr.lInUlty ot the po'."er connec:or as snown In Figure 3. ana note the reac-
sueply cord. transicrmer pnmary C::II ana relay. Ing. Reverse the tester leads and cneck the output
connec:or again. The circuit should be complete In
PART C - RELAY C1.0SES AND TRANSFORMER HUMS only one oirectlon. If the Circuit does not conduct in
BUT AMMETER DCES NOT REGISTER either OlrectlOn ana the fuse is gooa. individually
If the relay c!oses ana the transformer nums. the cnarge! c:-:eCK the continuity of the DC output cora. ammeter.
AC c:rcUit ana E:ee:ronlc Timer Kit are functioning prco- dlooes. ana all connections. If the Circuit conducts in
erly. It the ammeter ooes ne: reels.er. a fault in the both dlrec:lons. a "short" exists in the Charger DC
charger DC circuit eXists ane a continUIty Check mus, be CIrcuit. First Check the DC output cord for a "short"
performea. Disconnect the power sue ply core trom ItS between the two wires. It is more likely that one or
outlet ana the DC output cor.nee::::r from the battery both dIodes have "Shorted." Refer to Section 2 -
"Charger Fuse SlOWS" for continuity test of diodes.

2. If the Charger DC circuit test is good. a check of the


capacaor is necessary. Disconnect the power suo ply
cord from ItS outlet ana the DC output connector from
the battery connector. Then disconnect both trans-
former COil leads from the capacitor terminals. Use
care when disconnecting the capacItor leads so the
wires do not break. USing an ohmmeter. set the scale
to R X 10K ohms ana test the capacitor as follows:

GOOD CAPACITOR-When the ohmmeter leaes


are connected to the capa-
citor terminals. the me!er
needle jumps to mid-scaie
FIGURE 3 and rapidly moves to hign
Charger DC C~ntinuity Test resistance (x).

CAPAcrrOR COIl.
(SecONOARY COIl.
UNDERNEATHI

alJ<Cl< WIRE - - . . I .
OFOCCORO

:;;;;'-GREEN WIRE
ELECTRICAl.
KIT

FIGURE 4
Electronic: TImer Kit Wiring
OPEN CAPAClTOR-When the ohmmeter leads either transiormer primary lead to terminal #2. ar.e
are connec:ea to the capa- the remaining primary lead to terminal ~3.
citor terminals. the meter Connect the OlaCK leaa of the power supply cord :e
needle does not move and terminal *1 on the E:ectronic TImer Kit and the white
stays at nlgn resistance (::C). ieaa of the power suCPly cord to terminal #2.
A butge in the top of the Connec: the red wire of the Electronic TImer Kit alone
capaciter mav be viSible if With the wmte leae of the DC cora to the Heat SinK
the capacitor has failed Assemolv. Connect the black wire of the Eiectronlc
"Open."' Timer Kii along WIth the black leaa of the DC cord :0
SHORTED CAPACITOR-When the ohmmeter leads the ammeter post. Do not allow the ammeter post to
are connected to the capa- turn when tigntenlng the nut Reconnect the green
citor terminals. the meter wire of the E!ectronic Timer Kit along with the trans-
neeale jumps immediately former secondary lead to the diode lead terminal.
to zero ohms and remains A CAUTION: Be sure all connections are clean and
there. tight. Also check to be sure all wires and
If the capacitor is "Open" or "Shorted" it must be terminals are positioned so they do not
reelaced. short together or to the charger case.
A CAUTION: Use only a 6 Mfd. 660 volt AC rated 4. Reelace the charger cover and check the Electronic
capacitor for replacement (Part No. Timer Kit for proper operation as follows:
02390S). The use of a different value a. With the DC outout connector disconnected from
capacitor may result in improper charg- the battery connector. insert the power SUPCIY
ing, capacitor failure. transformer burn- cord intO an outlet. The relav on the ElectrOniC
out. and/or battery damage. Timer Kit should not close. A DC voltmeter c::n-
3. If ~he charger DC circuit and capacitor check good. a nected across the DC output connector Should
test of the transformer is necessary. Refer to Section indicate zero '1OitS.
i - "Transformer Short or Burn-Out" for test proce- b. Disconnect the power supply cord from its outlet
cwres. and connect the DC output connector to the bat-
PART D - ELECTRONIC TIMER KIT REPLACeMENT tery connector. The relay on the Electronic Timer
The E:ectronlc Timer Kit should always be replaced as a Kit should close with an audible "click" after a two
complete assemcly. The tOOlS reauired are a Phillips to five second delay.
head screwdriver. 3/8" and 11/32" wrenches. and pli- c. If the Electronic Timer Kit does not ooerate as (al
ers. No soldering is required. To replace the kit follow the and (b) above. reter to the wiring diagram in Figure
step-by-step procedures listed below. ' 8 and check to be sure the charger is wired cor-
, . Disconnect the charger power supply cord from its ' rectly.lf the Electronic TImer Kit operates properlY.
the charger is ready for use. Always monitor the
outlet and the DC output connector from the battery
connector. and remove the charger cover. first charge cycle to verify that the charger is turn-
ing off properly.
2. Disconnect the green. black. and red wires of the
Electronic TImer Kit as shown in Figure 4. Then SECTION 2 - CHARGER FUSE BLOWS
remove the black and white leads of the power The charger fuse assemoly consists of a dual element fusa
supply cord and both primary transformer coil leads link under a transparent cover mounted on the charger front
from the Eiec:ronic Timer Kit terminal tabs. The Kit panel. Each fuse element is electrically connected in series
can be removed by removing the three mounting with a rectifier diode to provide protection for the transformer
screws on the Charger front panel. Save all hardware in the event of a diode failure. Visually inpsect and electncaily
for reassembly. test the fuse to determine if one or both fuse links are blown
3. Install the replacement Electronic TImer Kit by revers- and refer to Part A or Part 8 for test procedures. LOCATE
ing the disassembly procedures described in Step 2. AND CORRECT CAUSE OF TROUBLE BEFORE REPLAC·
When reconnecting the wires to the 8ectronic TImer ING BLOWN FUSE. DO NOT attempt to repair the fuse linK
Kit terminal tabs support the terminal board to pre- as inadeQuate protection wiil resull
vent damage to the electronic circuit board. Connect PART A - SINGLE FUSE UNK BLOWS
This condition is normally caused by a short circuit fail-
ure of one diode. The fuse link will blow when the
charger DC output connector is connected to the battery
connector. regardless of whether the power supply cord
is connected to an outlet. To check the diodes. discon-
nect the power supply cord from its outlet and the DC
output connector from the battery connector. and then
disconnect one transformer secondary coil lead from the
diode terminal. USing a low voltage continuity tester.
connect one tester lead to the diode mounting plate and
the other tester lead to a diode terminal as shown in
Figure 5.
Note the reading and then reverse the tester leads and
check each diode again. If a diode conducts current in
both directions. it is "shorted" and the complete Heat
FtGURE 5 Sink Assembly with Diodes (Part No. 096535) must be
Diode Continuity Test replaced.
On rare occasions a slngie fuse linK may melt due to Wlilrise. tne tower Ine rimsh cnarge rate wiil be berore
excessive neat. ihls can oe causea by a loose Internal the Elec:ronlc Timer terminates cnarglng.
fuse connection. Check all :hree iuse connections Inside. The following timer malfunctions are occasionally due
the cnarger to be sure they are Clean ana tight. The to factors other than the charger's perlormance. To heip
proper torque on the fuse connec:or nuts is 20 lnch- isolate the problem it is otten necessary to use the
Pounas (23 Cm-Kg). charger on a different set of batteries and the original
PART B - BOTH FUSE LINKS BLOW set of batteries on another charger.
ihis is normally caused by a reverse oolanty connection PART A - CHARGER TURNS OFF TOO SOON
between tne crtarger DC cutout connector ana the bat- Check to oe sure the ::lower suopty cord is securely cen-
tery connector. ChecK the oattery pack anc battery con- nec:ed to a live outlet. if the power suoply outlet is live
nec:or to be sure they are wired In the correct polanty. If proceea with the next step.
possible checK the voltage and polanty at the battery
connector with a DC voltmeter. Also. check the cnarger To determine if the charger did shut off too soon. discon-
DC output connec:cr for the correc: pOlarity. The white nect and reconnect tne cnarger D.C. cuteut connector.
wire Should be connected to the positive (+) contact. ana This Will restart the charger. Observe cnarger output on
the black wire to the negative H contact. If a reverse the ammeter.
pOlarity connection is mace between the charger ana 1. The ammeter needle jumps smartly to between 20
battenes. botn fuse links Will blow regardless of whether and 25 amps and then tapers beiow 14 amps within
the power suo ply cora is connec:ed to an outlet 15 minutes. This inaicates that the battenes were truly
Anetner cause for both fuse links blowing is the short charged. The apoarent short c~arging time is in
CIrC:.llt failure of both diodes. Although this is rare. it may response to the batteries' ability to accept charge and
occ~r as the result of a lightning strike at the charging the electronic timer is performing properly.
location. Excessive heat aue to a loose connection may 2. The ammeter needle jumps smartty to between 20 and
aiso cause both fuse links to melt Refer to Part A - 25 amps. but does not taper below 14 amps within 15
"Single Fuse Link 810ws" for trouole-snootlng proce- minutes. If the battenes have been properly main-
dures. talnea ana chargee regularly, this generaily indicates
SECTION 3 - AMMETe.q READS 30 AMPS FOR MORE that the batteries were not tully cnarged. If possibie.
THAN 30 MINUTES use a hydrometer to check the specific gravity of sev-
This high outout condition is caused by misuse. connecting eral battery cells. If ~he specific gravity readings are
the charger to an incorrect battery system which is lower than more than 30 pointS (.030) lower than normal full
36 vOits. A common error is to instail one or more of the 6 voit charge readings. the electronic timer has malfunc-
batteries in a 36 volt battery pack reverse polarity. Using a tioned and the complete Eiectronic Timer Kit must be
suitaole DC voltmeter test to be sure all batteries in a battery replaCed. Reter to Section 1. Part D-"Sectronic
pack are correctly wired. and also test the battery pack volt- Timer Kit Replacement" for correct procedure.
age at the charging connector. After charging for 30 minutes If the batteries have not been used or charged regu-
at this excessive rate the measured on charge voltage should larly, they may be sulfated and will not produce their
rise to 34 to 38 volts DC for a 36 volt system. Voltage meas- full capacity. Repeated cycles (at least 5) of a light
urements. while charging, lower than this indicate an incorrect discharge followed by a tull charge will generally
or failed battery pack that must be corrected betore using the result in the recovery of most of the battery's capacity.
charger. 00 not interpret this reduced battery capacity as being
A CAUTION: DO NOT connect the charger to battery caused by the charger turning off too soon. The
packs which are not 36 volt systems. This charger is working properly if, after several charge
misuse will cause overheating and trans- cycles. the battery cacacity increases to nea~ normal.
former bum-out will resulL Sultation occurs most often when the battenes have
SECTION 4 - CHARGER OUTPUT IS LOW been stored without weekly charging. New batteries
The most probable cause at low output is a single fuse may also be sulfated due to extended shipment or
link blowing as the result of a short circuit failure ot one storage time prior to sale.
dioee. Refer to Section 2 - "Charger Fuse 810ws" for As batteries age, individual cells may weaken causing
trouble-shooting procedures. On rare occasions a short a reduction in battery capacity. This condition nor-
circuit failure at the transformer coils may cause the out- mally results in a finish charge rate higher than 10
put to be low. Refer to Section 7 - "Transformer Short or amps and less time is required to tully ch~ge .the
8urn-Out" tor test procedures. batteries. Do not interpret this shorter chargIng time
A CAUTION: Do not use the charger if the output is and reduced battery capacity as being caused by the
low. Batteries will not reach full charge. charger turning off too soon. The battery is aging
thereby increasing the possibility of a naturally and the charger is working properly. When
harmful deep discharge during their next the batteries will no longer perform as required they
use. should be replaced.
PART 8 - CHARGER DOES NOT TURN OFF
SECTlON 5 - CHARGER TURN OFF MAlFUNCTlONS
New batteries with all good cells should rise to at least
The Electronic Timer Kit turns the charger off as well as 2.5 volts per cell. This will allow the finish charge rate to
on. Proper charge time is determined by many factors. taper below 8 amperes. As batteries age individuai cells
but the main elements are: (1) 8attery size. (2) Depth of may weaken and these cells may not reach 2.5 volts.
battery discharge, and (3) Finish charge rate. large This will result in finish Charge rates greater tha~ 8
severely discharged batteries require more time to reach amperes. and less time will be required for the batteries
full charge than do smaller lightly discharged batteries. to reach full charge. At a finish charge rate of 8 amperes
The charge rate. as indicated by current flow in amperes or less the charge time should not exceed 18 hours. At a
on the panel meter. is controlled by the baueries' rising .finish charge rate greater than a amperes the charge
voltage during charge. The higher the on charge voltage time should .not exceed 14 hours.
If the cnarger remains on longer than the sceclfied max- allow [0 charge normally. Atter the charge rate has
imum time. cneck to see it the charger turns on imme- tapereo to its lowest pOint. measure the battery terminal
diately when the D.C. output cord is connected without voltage using a D.C. voltmeter capaDle of reading in
the normal two to five second delay. If the charger turns incremeins ot .001 volts. Continue charging and check
on instantly without the two to five second delay the' the battery vOltage reading every hour. If the battery volt-
Electronic TImer Kit has probably failed. This type of mal- age increases less than .012 volts. or if the battery volt-
function generally results in the charger not turning off age decreases cetween successive hourly readings. the
and the complete Electronic Timer Kit must be replaced. charger should turn off. If the charger does not turn off.
Refer to Section 1. Part D - "Electronic TImer Kit the Eiectronic TImer has malfunctioned and the com-
Replacement." for correct procedures. plete Electronic TImer Kit must be rePlaced.
If the charger remains on longer than the maximum time
specified and the two to five second delay is present. PART C - CHARGEii RUNS TOO LONG BUT DOES
verify that the green wire from the Electronic TImer Kit TURN OFF
and the secondary transformer coil lead are securely In the event of A.C. power interruption when the charger
connected to the diode lead as snown in Figure 4. The is on. the charger will automatically restart when A.C.
charger will NOT turn off if the green wire is loose or power is restored. This power outage can make the
disconnected. If the green wire is secureiy connected. apparent charge time seem longer than the actual
the E:ectronic Timer has malfunctioned and the com- charge time. To check for A.C. power interructions plug
plete Electronic Timer Kit must be replaced. an electric clock into the same outlet to which the A.C.
If a precision digital type D.C. voltmeter is available. a cord is connected. Charge normally and note any time
test to verify that the ElectroniC TImer has malfunctioned difference between the test clock time and the actual
can be made. Connect the charger to the batteries and time.

SECCNIWIY~COIL
SECClNDAII'f'

t\_
C)
.AH

• 2
I

r.""
)
"YM:
115Y11c
N'UI'
rT
&rw./

FIGURE 6 FIGURE 7
Transformer Coil Voltage Test Transiormer Coil Voltage Test
(without capacitor) (with capacitor)

BJ!iCTIIONC'
KIT

TOOCPWI
AID IlAlTEfIlES

~-'----

FIGURE 8
CluIrget Wiring Diagram.
SECTION 6 - AC LINE FUSE OR CIRCUIT caution wnen working near the capacitor
BREAKER BLOWS terminals.
If this occ:.:rs when the charger power sueply core is
connec:ea to an outlet. without the DC output connector In oraer to acoiy AC oower directly to the transformer
connectea to the battery connecter. the c:1arger power' prtmary COli ~I'le Eiec:ronJc Timer Kit must oe bypassea.
sUPcly cera may be shorted. Disconnect the power Refer to Sec:lon 1. Part A lor bypass procedures. With
sUOOly cora from Its outlet ana the DC outout connector the E:ectronlC Timer Kit bypassed and taking care for
from the battery connector. then check to oe sure the personal safety. connect the power sue ply cord to an
::ec:ronlc Timer Kit is NOT bypassed. With a suitable outlet. If the AC line fuse or CIrCUit breaker blows. the
continUity tester check the circuit across the power transformer IS snortea Internally ana must be replaced. If
supely core orangs as shown in Figure 2. THE CiRCUIT tt'liS does not occur. C!'leCI< the transformer seconaary
SHOULD NOT 8E COMPLElE. If the CirCUit IS complete. and capacitor COil voltages as shown in Figure 6. using a
check the relay contacts to "e sure they are open ane SUitable AC voltmeter, If the measured voltages are sub-
have not weided closed. If the relay contacts are open. Stantially lower than those shown. the transformer IS
the power supply cord is shorted and must oe replacee. snonea internally ana must be replaced.
If the power suoply cord checks good the transformer
COils may be snorted. Refer to Section 7 - "Transformer If the transformer secondary coil voltage and capacitor
Short or Burn-Out" for test proceaures. coil voltage cneck good. disconnect the power supply
cord from itS outlet. Check the capac:lor to be sure its
SECTION 7 - TRANSFORMER SHORT OR BURN OUT rating is 6 Mfd. 660 VOlts AC. and then carefully reconnect
Failure of the transformer can be the resuit of natural aging, the capacitor colileaas to the capacitor terminals. Then.
premature shoning at adjacent coil turns or overneating dam- taking care for personal safety. reconnect the power
age. The most common cause of transformer overheating and supply cord to an outlet and measure the transformer
premature burn-out is the result of misuse. connecnng the secondary voltage again. The correct voltage reading is
charger to a battery system of lower voltage than specitied on shown in Figure 7. If the transformer secondary voltage
thecnarger. (See Section 3) Darkening of all the transformer reading is the same as measured with the capaCitor dis-
seconaary coli Windings is an indication of posslole overneat- connected. from Figure o. the capacitor may be open. the
ing Clamage. A low or complete lac:< of outout would be caoac:tor coil may be ooen or the capac:tor coil terminals
ooserved on the ammeter. however the transformer may hum may not be making proper electrical contact Refer to
or the AC line fuse or circuit breaker may biow when the Section 1. Part C. Item 2 for capacitor test proceaures. If
charger is turned on. To test the transformer. aisconnect the the voltage readings are correct both the transformer ana
power suoply cord from its outlet and the DC outout connector capacitor are good. reter to Section 1. Part C. Item 1 for
from the battery connector. Then disconnect the transformer further tests of the DC circuit
secondary coil leads #1 and #4 from the diode terminals and If it should become necessary to replace a terminal on
disconnect the transformer capacitor coil leadS from the one of the transformer leads. the new terminal must be
capacitor terminals. Use care when disconnecting the capaci- crimped AND soldered. NOTe: Some transformer leads
tor lead so the wires do not break. may be aluminum wire and a solder must be used on
OANGE.q-HIGH VOLTAGE: With the charger oper- these wires that is intended for use on aluminum. such
ating, the charger capacitor voltage is as Alcoa #807 solder with Alcoa #69 flux. If these mate-
approximately 650 volts AC. Use extreme rials are not available locally. contact the Lester fac:ory.
NO. 7-124

Eaton
Hydraulics
Division

2000 Series Char-Lynn~ Motors OOB


2 Valve
Balancing
Ring Pin I
Housing

Valve
Shaft Plate
Face Geroler
Seal
Splined Seal
Drive
Wear
Back-up Plate
Washer
Bearing Inner
Housing Shaft Face
Seal Seal

Spring
Exclusion Valve
Seal Drive Case
Drain
Plug
Seal

Tools required for disassembly and reassembly.


Torque wrench 500 Ib-in[57Nm1 capacity
12-16(300-4501* breaker bar
9/16 socket
Small screwdriver 6-Sx1/4[150-200x6,5] blade
3/16 allen wrench .
Press
*Unless indicated otherwise, measurements
are given in inches(mm] .
"Shaft seal installation tool
**Bullet for 1 diameter shafts
The following tools are not necessary for disassembly and
reassembly, but Bre extremely helpful.
Alignment studs (2)

-1 1[25;1--
.,- S{200]
'I rAPprox.1/2{131

o Q Ii iii ii iiiii
5/16[SIJ L ~ 3/S{9,5] Dia. Steel Rod
3/S-24 UNF~
Grind Flat Spots on Each Side
** Available--by special order

C Copyright 1985 Eaton Corporation


3 Disassembly
CleanHness is extremely important when rapairing "a 2 Remove 4 bolts from motor.
hydraulic motor. Work in a clean area. Before dis·
connecting the lines, clean the port area of the mo-
tor thoroughly. Use a wire brush to remove foreign
material and debris from around the exterior joints
of the motor. Check the shaft and keyslot. remove
all nicks, burrs or sharp edges that might damage the
bearing housing seals when installing the shaft and
bearing assembly. Before starting the disassembly
procedures, drain the oil from inside the motor.

Figure 3

3 Lift valve housing straight up. I f done care-


fully the pins, springs, balance ring assembly, and
valve will remain on the valve plate.

Figure 1

1 Place the motor in a vise with the output shaft


down. Clamp across the mounting flange of the mo-
tor not the housing. Excessive clamping pressure
will cause distortion. When clamping, use some pro-
tective device on the vise, such as special soft jaws,
pieces of hard rubber or board.
'--__0.,- Case
~ ___ Drain
Although not all drawings show the motor in a Seal ......-: 'j, Plug
vise, we recommend that you keep the motor in
the vise during disassembly and reassembly. Figure 4
Follow the clamping procedures explained
throughout the manual.

4 Carefully remove 3[76] diameter seal from


valve housing.

5 Remove case drain plug-with seal, from valve


housing.

6 Remove 2 pins and 2 springs from balance


ring assembly, see Fig. 5.

Tie Bolts
Figure 2
Disassembly 4
Outer Face Seal ~,.
15 Remove me 3 [76] diameter seal from wear

~'IIj~' ~ ,V
"
l" plate, see Fig. 7.

Bearing Wear

~~ /- - yQ'~ '\ Spring


Housing

~
/ Plate

\)
~ . i / -"'- ~
_ Inner
Face Seal
__c:::;...-c;..;.- Valve Balance Ring

Figure 5 Shaft Face Seal


7 Remove balance ring assembly. Figure 8
8 Remove inner and outer face seals from 16 Remove the wear plate.
balance ring..
17 Remove the shaft face seal from the wear plate.
9 Remove the valve.
18 Remove the 3[76J diameter seal from bearing
housing.
Bearing
Housing

\
Shaft &
Bearing
Figure 6 Assembly
10 Remove the valve plate. Figure 9

11 Remove the 3[76] diameter seal from valve 19 You may need a press to remove shaft and
plate. bearing assembly from bearing housing. (Key must
be removed before removing shaft.)
12 Remove the valve drive.

Bearing
Housing ___

Back·up Washer
Figure 10

20 Use a small screwdriver to remove shaft seal,


Figure 7 back-up washer and exclusion seal from bearing
housing, see Fig. 10. Do not damage bore of
13 Remove me Geroler. Be sure to retain the rol- housing.
lers in the outer ring if they are loose.
Note: Individual parts of shaft and bearing assembly
14 Remove the drive. are not sold separately. Replace as a unit.
Check all mating surfaces. Replace any parts that 5 Reassembly
have scratches or burrs that couid cause leakage.
Clean all metal parts in clean solvent. Blow dry with 26 Alignment studs can be very helpful in reassem-
air. Do not wipe dry with cloth or paper towel be- blV of the motor. See special tool listing page 2. If
cause lint or other matter can get in the hydraulic you use studs. install 2 studs diagonally opposed in
system and cause damage. Do not use a coarse grit the bearing housing.
or try to file or grind these parts. Check around
the keyway and chamfered area of the shaft for
burrs, nicks or sharp edges that can damage the 27 Install the shaft face seal in the wear plate as
shown in Fig. 11. Do not distort seal.
seals when reassembling. the bearing housing.
Note: Lubricate all seals (prior to installation) with 28 Install the wear plate, see Fig. 11.
petroleum jelly such as Vaseline. Use new seals when
reassembling this motor. Refer to parts list (6-129) 29 Apply a light film of petroleum jelly to the
for proper seal kit number. 3[76] diameter seal and install seal in the wear
plate.
21 Use a press to install exclusion seal in outer bore
of bearing housing. Lip of seal must face outward. See 30 Install the drive into the output shaft.
Fig. 11. If a press is not available use a plastic or rub-
ber hammer, being careful not to damage or cock 31 Align the notch on the outside of the Geroler
seal in the bore. with the notch on the wear plate. Install the
Shaft Face Geroler against the wear plate. Be sure to retain
the rollers in the outer ring if they are loose.
Shaft
Shaft Seal
~~====~~~r-------Face
;:.. Seal 32 Install the valve drive in the Geroler.

Note: Installation at this time involves 3 steps in the


timing of the motor. Timing determines the direction
of rotation of the output shaft. Timing parts include:

I~~~II[___-seal
1. Geroler
2. Valve Drive
3. Valve Plate
Shaft & 4. Valve
Exclusion
Seal Searing Ass'y
Geroler Valve
valve Plate
' \ Drive
Figure 11 ~
Drive~Q ./ ~
22 Place back-up washer into seal bore. Place.
" 0 .......
shaft seal onto installation tool
seal into seal bore of the housing.

23 Clamp housing in vise, see Fig. 1.


and press

LargeSt;7<
;..II
o
Q ~
I
Open Alignment
24 Place protective bullet (see note below) over Pocket Ref. Only
shaft. Apply petroleum jelly to inside diameter of
dust and shaft seal. You may need a press to install Figure 12 Timing Alignment
shaft and bearing assembly. Do not distort shaft
seal. Damage to this seal will cause leakage.
Timing Step H= 1-Locate the largest open pocket in
Note: Bullet for 1" shafts, available-- the Geroler and mark it on the outside edge of the
by special order. Use tape over other shafts to Geroler.
prevent cutting the seals.
33 Apply a light film of petroleum jelly to the
25 Apply petroleum jelly to the 3[76] diameter 3[76] diameter seal. Install seal in groove of valve
seal. Install seal into the bearing housing. plate.
Reassembly 6
34 Align the notch on the outside of the valve Imeortant: Install face seals in the positions shown
plate with the notch on the Geroier as shown in in Fig. 15. or the motor will not operate properly.
Fig. 12. Do not force or bend the face seals. Any damage to
these seals will affect the operation of the motor.
Timing Step t=I= 2- Locate the slot opening in the
valve plate which is in line with the largest open Pin Notch Inner Seal
pocket of the Geroler.
Timing Step t=I= 3- Locate anyone of the side open- I
ings of the valve and align this opening with the
open slot of the valve plate that is in line with the
largest open pocket of the Geroler. Install the valve Balance Ring
by rotating it clockwise until the spline teeth
engage (1/2 spline tooth max.). This will provide Figure 15
the proper rotation when pressurized as shown in
Fig. 13.
38 Align pin notches in balance ring with pins in
bore of valve housing. Install balance ring assembly
in valve housing.

Clockwise
Rotation

Balance
Ring -

Counter
Clockwise - - - - -
Rotation Housing

Figure 13
Figure 16

Valve
Housing
./

Alignment
Studs _______

Figure 14

Figure 17

35 Install 2 springs and 2 pins in the holes located 39 Insert your finger through port of valve
in the bore of the valve housing, ..s shown in fig. 14. housing. Apply pressure to side of balance ring as
shown in Fig. 16. Hold ring in position until
36 Apply a light film of petroleum jelly to the valve housing is in place against valve plate. See
3[76] diameter seal. Install seal in the valve Fig. 17.
housing.
37 Apply petroleum jelly to inner and outer face Note: After installing the valve housing on the valve
seals. I nstall seals on balance ring as shown in Fig. plate check for proper placement. Push down on the
15. valve housing. You should get a slight spring action.

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

41 Install seal on case drain plug then install in


. valve housing. Torque to 50 Ib·in[6Nml.

Figure 18

Wheel Motor Bearing


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

Exclusion Seal Seal


Figure 19

Flange Seal
Bearingless Motor
This motor is the same as the standard motor with·
out the shaft/bearing assembly, and bearing housing.
The mounting flange replaces the bearina housing,
see Fig. 20. Follow same disassembly and reassembly
procedures as rear section of standard motor.

Figure 20

- t
-- .. _. ---.---- -- --- . .:- ~,:~