Condor Lift Model 68

() A div. of TIME Manufacturing Company

OPERATOR'S MANUAL

MODEL 58/68/76 BOOM-SUPPORTED ELEVATING WORK PLATFORM

PLATFORM-MOUNTED

SHIPPING ADDRESS

CONDOR® A DIV. OF TIME MFG. CO.

8300 IMPERIAL DRIVE

WACO, TEXAS 76712 (817) 666-4545

MANUAL 92344-001 OCTOBER 1996

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MAILING ADDRESS


P.O. Box 21447 WACO, TEXAS 76702-1447

(817) 666-4545

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INTRODUCTION

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

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

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

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

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

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 UNIT WITHOUT PRIOR WRITTEN APPROVAL FROM THE MANAGEMENT OF CONDOR DIVISION

SERVICE & MAINTENANCE

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


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TABLE OF CONTENTS

IN"TRODUCTION ....•...........•...................................................................................................................... i

TABLE OF CONTENTS ..........•..................................•......................................•........•......•.•..........•......... 1

I. PREPARATION, INSPECTION, AND MAINTENANCE .............................................................. 3

A.. Overall Machine Condition .................................................................................................... 3 B. Lower Control Station ............................................................................................................ 3 C. Platform and Upper Control Station .................................•................................................... 4 D. Hydraulic System .................................•.................................................................................. 4 E. Multi-Axis Slope Sensor ..............................................................................•........................... 4 F . Battery .............•.................................................................•...................................................... 4

II. MACHIN"E OPERATION ................................................................................................................... 4

A. Rated Work Load .................................................................................................................... 4 B. Upper Con trois ........................................................................................................................ 5 C. Lower Controls ........................................................................................................................ 7 D. Travel ....................................................................................................................................•.. 8

III. OPTIONAL EQUIPMENT ................................................................................................................. 8

IV. AUXILIARY LOWERING ................................................................................................................. 8

v. MOVING FROM JOB SITE TO JOB SITE ..................................................................................... 8

A. TOWING ................................................................................................................................. 8 B. TRANSPORTING ................................................................................................................... 8

VI. EMERGENCY STOPPING ....................•........................................................................................... 8

APPENDIX: DECALS ILLUSTRATION .............................................................................................. 10

ANSIISIA 92.5-1992 MANUAL OF RESPONSIBILITIES

INSPECTION REPORT


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IMPORTANT: A COpy OF THE ANSIISIA 92.5 - 1992 MANUAL OF RESPONSIBILITIES IS • ATTACHED TO THIS OPERATOR'S MANUAL. IT CONTAINS IMPORTANT OPERATING INFORMATION FOR TIDS MACHINE. READ BEFORE OPERATING THIS MACHINE.

I. PREPARATION, INSPECTION, AND MAINTENANCE

The condition of the unit is very important, as it directly affects the operator's safety as well as the safety of others. The operator must perform a thorough walk-around inspection each day prior to operating the machine. Any damage or faulty operation should be reported immediately. A DO NOT OPERATE tag outlining the problem should be attached to the lower control station and any discrepancies should be corrected before operating the CONDOR®.

KNOW THE UNIT AND ITS CAP ABILITIES. REPORT ANY UNUSUAL OPERATION, SUCH AS ERRATIC SWAY OR MOTION OF THE BOOM, ARM, OR PLATFORM.

Some major areas to check daily are:

A. OVERALL MACHINE CONDITION.

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TIRES AND WHEELS:

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

MISSING, BROKEN, OR DAMAGED PARTS:

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

STRUCTURAL:

Check for damaged or cracked welds on structural components-boom, platform, skirt, chassis, and turret.

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STEERING:

Check tie rod ends and steering cylinder for proper and secure mounting.

SWING BEARING:

Check that all mounting bolts are securely in place.

DECALS:

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

CAUTION: Defective components, structural damage, missing parts, and equipment malfunctionjeopardize the safety of the operator and other personnel and may cause excessive damage to the unit. A poorly maintained machine could become the greatest operational hazard you may encounter.

B. LOWERCONTROLSTATION

D Check electrical installations for loose, broken, or frayed wires and cables.

D Check that all functions operate properly, and that all controls return freely to center (neutral) position.


• C. PLATFORM AND UPPER CONTROL STATION

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Check for hydraulic oil leaks at all fittings, valves, and controls.

Check to see that slide bar is in place and moves freely at access opening.

Check to see that footswitch operates properly, and that guard is secured and in its proper place on the platform floor.

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

Check the red EMERGENCY STOP button: this button disconnects power to the controls and stops all powered functions.

Check the operation of the auxiliary lowering pump.

D. HYDRAULIC SYSTEM

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Check the hydraulic tank fluid level with the arm lowered and the boom lowered and retracted. Maintain fluid level at the full mark on the sight glass. Add only Shell Tellus T-32 Hydraulic Oil to the system. Ensure that the breather cap is clean and in place on the tank.

Check for hydraulic oil leaks at all fittings, valves, and controls.

D Check hydraulic hoses and tubes for damage and kinks. Also check to see that hydraulic lines are routed properly to avoid pinch points.

E. MUL TI-AXIS SLOPE SENSOR

The CONDOR® is equipped with a slope sensor to warn the operator of an out-of-Ievel operating condition. The slope sensor is located inside the lower control station compartment, near the lower control box mounting posts (see LOWER CONTROLS illustration). The slope alarm system sounds an audible alarm and illuminates the warning light on the upper control console when the unit is out of level

D Check the general condition of the slope sensor, inspect for loose or damaged wires, and ensure that mounting is secure and housing is not cracked or broken.

F. BATTERY

D Check the battery electrolyte level and ensure that all caps are present and tight on the battery. All battery cable connections should be tight and clean.

II. MACHINE OPERATION

A. RATEDWORKLOAD

The CONDOR® Model 68 equipped with optional Platform-Mounted Full-Pressure Hydraulic Controls has an unrestricted work load of 800 lbs. (362.9 kg.), or two occupants. This means that the platform will support an 800-lb. combined weight (including personnel and their tools and equipment) throughout the working envelope of the machine.


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B. UPPER CONTROLS

The upper controls allow for complete operation of the machine. The unit is equipped with an EMERGENCY STOP BUTTON- push to tum off the engine and stop all functions.

The DRIVE/STEER controller is located on the right side of the control box. For information on driving and steering the CONDOR®, see item "D" of this section.

Located to the left of the DRIVE/STEER controller is the control console, containing the following controls:

• ENGINE START/STOP-this red pushbutton switch is used to start the engine from the upper controls, and is also used as an emergency stop switch.

UPPER CONTROLS •

• CHOKE/GLOWPLUG8-provided as a starting aid on units equipped with a Wisconsin gasoline or Isuzu diesel engine as the primary power source (Ford gasoline engine has auto-choke). Hold the momentary switch ON while starting the engine and release the switch after the engine starts.

• SPEED CONTROL-allows operator to select either HIGH or LOW drive speed.

• LIFT AND DRIVEILIFT OR DRIVE SELECTOR--determines parameters in which the unit operates. LIFT AND DRIVE allows the lift functions to operate while driving, but at reduced speed; LIFT OR DRIVE allow the lift functions OR the drive functions to operate at full speed, but not both functions simultaneously.


• • AUXILIARY LOWERING CONTROLthis white pushbutton switch is used to supply fluid power to the lift controls in the event of primary power source failure. No drive functions are available on auxiliary power.

• SLOPE ALARM LIGHT-slope sensor mounted on the turret sounds an audible alarm and illuminates an alarm light on the upper control console when the unit encounters a tilt condition of 5° or more. At this point, drive the unit back onto firm, level ground.

• PROPANE/GAS (OPTION)-switch used to select fuel source (for units equipped with Dual Fuel option only).

Located just below the control console are six (6) handles that control the following functions:

• BOOM LIFT (UP/DOWN)

• PLATFORM TILT (up/DOWN)

• TURRETROTATE(LEFTIRIGHT)

• PLATFORM ROTATE (LEFTIRIGHT)

• BOOM SCOPE (IN/OUT)

• AUXILIARY CONTROL VALVE-this sixth valve is used only on units equipped with special optional functions, and standard units will not be equipped with a sixth control handle.

The lift functions operate in the directions indicated on the upper control console.

NOTE: The LEFT and RIGHT directions on the turret rotation and platform rotation controls are the OPERATOR'S LEFT and OPERATOR'S RIGHT. When the TURRET ROTATE control is actuated in the «) LEFT direction, the turret will rotate in a clockwise direction, causing the aerial structure to move to the operator's left. When the PLATFORM ROTATE control is actuated in the «) LEFT direction, the platform will rotate to the operator's left.

FOOTSWITCH

As a safety precaution, the footswitch must be depressed and held during all functions-with the exception of starting the engine, which may only be accomplished with the foot off of the footswitch. The function of this switch is similar to that of the THROTTLE control switch at the lower control station. The footswitch is located on the floor of the platform below the upper control console.


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LOWER CONTROLS •

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C. LOWER CONTROLS

The lower control station is located on the turret of the machine. From this control station, all machine functions may be performed, with the exception of DRIVE/STEER. The main key switch is located on the lower control box front panel. With the key in the OFF position, the unit is off and all power is disconnected. With the key in the ON position and the emergency stops off, the engine is started by pushing upward on the start switch.

Also located on the lower controls are the NORMAL OPERATION switch and the AUXILIARY LOWERING switch. The NORMAL OPERATION switch is a pushbutton switch that must be depressed continuously while operating any of the functions from the lower control station-the

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function of this switch is similar to that of the platform-mounted footswitch. When switched upward, the AUXILIARY LOWERING switch will energize the auxiliary pump. This switch is only to be used in the case of primary power failure.

Below the control console are five (5) handles that control the following functions:

• CONTROL STATION SELECTOR (UPPERILOWER)--controllever located only at the lower control station; allows operator to select either the UPPER (platform) or LOWER (ground) controls for operation.


•• BOOM LIFT (up/DOWN)

• TURRETROTATE(LEFTIRIGHT)

• PLATFORM ROTATE (LEFTIRIGHT)

• BOOM SCOPE (IN/OUT)

• AUXILIARY CONTROL VALVE-this sixth valve is used only on units equipped with special optional functions, and standard units will not be equipped with a fifth control handle.

The lift functions operate in the directions indicated on the decal at the lower control station.

NOTE: the LEFT and RIGHT directions on the turret rotation control are the OPERA TOR'S LEFT and OPERATOR'S RIGHT. EXAMPLE: when the control is actuated in the «) LEFT direction, the turret will rotate to the operator's left.

D. TRAVEL

Driving the machine may only be accomplished from the platform, with the boom either in the raised position or in the stowed position.

Although the gradeability of the unit is 14° (25%), such a grade is only negotiable with the boom in the fully lowered (stowed) position, and only at a slow rate of speed. The CONDOR® is designed to travel with the platform elevated only on firm, level ground.

The CONDOR® is designed to be driven-under normal conditions-with the counterweight positioned over the steer wheels. In this configuration, the direction of travel corresponds directly to the direction of movement of the drive controller; moving the controller away from the operator propels the unit forward, and motion toward the operator moves the unit in reverse.

The steering control is a spring-loaded, return-tocenter rocker switch located on top of the drive control handle. With the counterweight over the steer wheels, the steering control moves the unit in the direction in which the rocker switch is actuated. Pushing the rocker switch to the left turns the unit to the left, and pushing the switch to the

right turns the unit to the right. When the switch is released and returns to the center (neutral) position, the steering wheels remain in the directed line of travel and do not return to a straight line of travel. Steering is not self-centering.

Whenever the machine is driven with the counterweight in a position other than described above, the drive and steer relationship to the controller will change. The operator should move the unit slowly until familiar with the change in movement.

Always look in the direction of travel, and maintain a good field of vision, paying close attention to overhead objects. Avoid jerky movement of the drive controller by moving slowly into and out of travel. Come to a complete stop before changing directions. The brakes on the unit are springapplied and hydraulically released. They are automatically released when the drive controller is activated, and are applied when the drive controller is returned to the center position.

The upper control box is equipped with a maintained two-position toggle switch to select either FAST or SLOW travel speed. However, when the boom or arm is raised sufficiently to open the boom limit switch (approximately horizontal), both drive speeds are automatically reduced by one half.

III. OPTIONAL EQUIPMENT

The following options are available on the CONDOR® Model 58/68/76.

• ISUZU DIESEL ENGINE • FORD GASOLINE ENGINE • MOTION WARNING HORN • HEAD & TAIL LIGHTS • STROBE LIGHT

LARGER PLATFORM AIR LINE TO PLATFORM FOUR-WHEEL DRIVE

• PLATFORM WORK LIGHTS • DUAL FUEL


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IV. AUXILIARY LOWERING

To assist the operator in the event of primary power loss, the auxiliary pump may be activated from both the upper and lower control stations. To activate the pump from the upper station: with the selector switch on UPPER (at lower control box), depress and hold the footswitch and the yellow auxiliary switch. To activate the pump from the lower station: with the selector switch on LOWER, push up on the auxiliary switch and hold.

With the auxiliary pump activated, all aerial functions are operable-DRIVE/STEER functions are NOT operable.

V. MOVING FROM JOB SITE TO JOB SITE

A. TOWING

The brakes on the CONDOR® are automatically applied when the drive controller is returned to neutral. For towing purposes, the drive hubs may be disengaged by removing the two bolts (.25" -20UNC x .75" long) which secure the disconnect cap. Remove the disconnect cap and reinstall with the nipple facing inward. Secure the cap using the same .25" mounting bolts.

CAUTION: WHEN THE DRIVE HUBS ARE DISENGAGED, THE BRAKES ARE ALSO DISENGAGED.

B. TRANSPORTING

The means of loading/unloading the CONDOR® must be of sufficient strength to withstand the unit's weight. Loading ramps should be set at an angle no greater than 14° (or a grade of25%).

Before driving the unit on the ramp, test all of the • controls and the braking system. Make sure that the controls return smoothly to the center position. Move the unit slowly back and forth and check that the brakes apply each time the drive controller is returned to the center position. It may be necessary to elevate the boom or arm to clear the ground or ramp while loading. The slope sensor will sound and alarm if the arm or boom is raised off of the limit switch and a condition of 5° out of level is encountered.

Move the unit slowly, allowing time to make necessary steering corrections. Keep the unit in alignment with the ramp and carrier during loading or unloading operations. The unit may be transported easily and safely by observing the following procedures: Block all wheels to prevent forward and reverse movement during transportation. Tie down the unit using chains, straps, or cables of sufficient strength. See diagram at right (also located on decals on both sides of the carriage). Support the platform on wooden pallets and tie down the boom near the skirt. Tum the power off at the key switch; remove the key.

VI. EMERGENCY STOPPING

The red pushbuttons located at the upper and lower control stations may be used in an emergency to stop movement. The operator may also stop any function, including drive, by releasing the footswitch.

FACTORY RECOMMENDED TRANSPORTATION DIAGRAM


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PARTIAL VIEW 0

/ 6R/76 STANDARD ("58 1\

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3 19 5

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PARTIAL VIEW A-A

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PARTIAL VIEYV 8 CNTRWT W/LH DOOR

SHOWN OPEN

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PARTIAL VIEVV C 58/68/76 STANDARD

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INSIDE VIEW OF OPEN LH DOOR

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Decal Kit Assembly 0 24 30

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ITEM PART NUMBER DESCRIPTION QTY

Ref. 69626-001 ...................... Decal Kit 58 .................... '" ................................................................. Ref. Ref. 69626-002 ...................... Decal Kit 68 ........................................................................................ Ref. Ref. 69626-003 ...................... Decal Kit 76 ........................................................................................ Ref.

*1 21971-002 ...................... Decal, Do Not Lift Wheels ....................................................................... 3 *2 58419 ............................. Tape OrnlR.ed 5" ............................................................................... 12LF *3 21850 ............................. Decal, Hydrdaulic Fluid ............................................................................ 1 *4 81417 ............................. Decal, Rated Work Load .......................................................................... 1 *5 21882-001 ...................... Decal, Keep Clear ..................................................................................... 2 *6 35042 ............................. Decal, Forward (ARROW) ...................................................................... 2 *7 21882-003 ...................... Decal, Danger "MUST NOT OP" ............................................................. 1 *8 35043 ............................. Decal, Forward ......................................................................................... 1 *9 21658 ............................. Decal, 58/68/76 Transportation ................................................................ 2

*10 21854 ............................. Decal, Caution Welding ............................................................................ 1 *11 34947 ............................. Decal, Drive .............................................................................................. 1 *12 54984-006 ...................... Decal, 110 Volt Ext. To Platform ............................................................. 1 *13 37419 ............................. Decal, Ramping Control Panic Stop ......................................................... 1

14 BOW34105 .................... Rivet, Pop .093 ........................................................................................ 4 *15 54416 ........................ , .... Decal, Caution Tie Down Ring ., ............................... '" ............................ 2 *16 69573 ............................. Decal, Boom Upper Caution ..................................................................... 1 *17 38533 ............................. Decal Boom Lower Caution ..................................................................... 1 *18 21882-004 ...................... Decal, "DANGER" ................................................................................... 2 *19 21079 ............................. Decal. Lube Fitting ................................................................................... 1 *20 21849 ............................. Decal, Gas ................................................................................................. 1

21 69437-003 ...................... Decal, Condor -CO- ................................................................................. 2 22 69437-004 ...................... Decal, Condor -ND- ................................................................................. 2 23 69473-005 ...................... Decal, Condor -OR- ................................................................................. 2 24 69473-001 ...................... Decal, Die-Cut Condor .... , ........................................................................ 1

*25 68859 ............................. Decal, Oil Dipstick ................................................................................... 1 *26 37958-125 ...................... Decal, 1250 LB Rated Work Load (Model 58) ....................................... 2

37958-800 ...................... Decal, 800 LB Rated Work Load (Model 68) ......................................... 2 37958-500 ...................... Decal, 500 LB Rated Work Load (Model 76) ......................................... 2

*27 40791-005 ...................... Decal, 58 ................................................................................................... 2 40791-006 ...................... Decal, 68 ................................................................................................... 2

C. -Indicates Items Not Shown * Indicates Items In Essential Decal Kit


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PARTIAL VIEW D

55/65/76 STANDARD

24 (FOR 69515 ONLY)

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PARTIAL VIEW A-A

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ITEM PARTNUMBER

PARTIAL VIEW C 58/68/76 STANDARD

DESCRIPTION

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Decal Kit Assembly CD 24 30

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QTY

*28 21971-006 ....................... Decal, Tire Pressure 70 PSI (Model 58) .................................................. 2 21971-005 ...................... Decal, Tire Pressure 75 PSI (Model 68) .................................. , ............... 2 58398 ............................. Deqll, Tire Re;lacement Foam (Model) .................................................. 2

29 36894 ............................. Decal, 1250 LBS (Model 58) ................................................................... 1 36888 ............................. Decal, 800 LBS (Model 68) ..................................................................... 1 36885 ............................. Decal, 500 LBS (Model 76) ..................................................................... 1

30 58420 ............................. Tape OrnlRed 7" ............................................................................ 4.80LF

50 Ref. ................................ Nameplate, Boom Identification .......................................................... Ref.

- Indicates Items Not Shown * Indicates Items In Essential Decal Kit


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ATTENTION

MANUAL OF RESPONSIBILITIES

for

Dealers, Owners, Users, Operators, Lessors and Lessees

of

ANSIISIA A92.5-1992 Boom-Supported Elevating Work Platforms

WARNING C J FAILURE TO COMPLY with your REQUIRED

RESPONSIBILITIES in the use and operation of the Aerial Platform could result in DEATH OR SERIOUS INJURY.

IMPORTANT

You are required by ANSI/SIA A92.5-1992 to read and understand YOUR RESPONSmILITIES before you use or operate this Aerial Platform.

This Manual and the manufacturer's operation and safety manual 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, T~INED in the INTENDED USE, SAFE OPERATION, MAINTENANCE AND SERVICE of this type of equipment.

The USER AND OPERATOR MUST MAKE DECISIONS on the maintenance, use and operation of the Aerial Platform with due consideration for the fact that the SAFETY OF THE OPERATOR AND OTHER PERSONNEL is dependent on those decisions. FAILURE TO COMPLY with your REQUIRED RESPONSmILITIES in the use and operation of the Aerial Platform could result in DEATH OR SERIOUS INJURY. Remember that all personnel in the platform must wear a body belt with a lanyard attached to the boom or platform.

Refer to the manufacturer's operation and safety manual for the INTENDED USE of the aerial platform and for further INFORMATION ON SAFE USE AND OPERATION.

The ANSIISIA A92.5-1992 standard for Boom-Supported Elevating Work Platforms has an

effective date of January 2, 1994. This Manual incorporates sections from that standard as follows:

Definitions Section 3 Page 1 Responsibilities of Dealers Section 5 Page 2 Responsibilities of Owners Section 6 Page 2 Responsibilities of Users Section 7 Page 4 Responsibilities of Operators Section 8 Page 6 Responsibilities of Lessors Section 9 Page 8 Responsibilities of Lessees Section 10 Page 8 Examples of A92.5 Aerial Platfonns Figure 1 Page 9 Minimum Safe Approach Distance Figure 3 Page 10

Published by Single copy list price .................. $ 4.95 Scaffold Industry Association, Inc. 14039 Sherman Way, Van Nuys, California 91405-2599

Copyright © 1993 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 mitten permission of the publisher.

Printed in the United States of America

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Reprint from ANSI/SIA A92.5-1992

3. Definitions

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

alternative configuration(s): Arrangements of the aerial platform or its components which differ from each other. Alternative configurations mayor may not have the same rated work load.

authorized personnel (authorized person): Personnel approved or assigned to perform a specific type of duty or duties at a specific location or locations at a job site.

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

boom: A cantilever beam which supports the platform. chassis: The integral part of the aerial platform which

provides mobility and support for the elevating assembly. configurations: All positions in which an aerial

platform or any part thereof can be placed within its intended operating limits.

dealer: A person or entity who buys from a manufacturer or distributor and who generally sells, rents, and services aerial platforms.

delivery: Transfer of care, control, and custody of the aerial platform from one person or entity to another person or entity.

directional controls: Controls that initiate functions that affect movement of the platform or the aerial platform.

elevating assembly: The mechanisms used to position the platform relative to the aerial platform chassis.

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

hazardous location: Any location that contains, or has the potential to contain, an explosive or flammable atmosphere as defmed in ANSIINFP A 505 powered industrial trucks.

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

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

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

manufacturer: A person or entity who makes, builds, or produces an aerial platform.

maximum travel configuration(s): The most adverse configuration( s) with respect to stability in which travel is permitted by the manufacturer, without outriggers, stabilizers, or extendible axles properly set.

modification, modifies: To make a change(s) to an aerial platform which affects the operation, stability, safety

RESPONSmILITIES MANUAL

factors, rated load, or safety of the aerial platform in any way.

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

operator: A qualified person who controls the movement of an aerial platform.

outriggers: Devices that increase the stability of the aerial platform and that are capable of lifting and leveling the aerial platform.

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

owner: A person or entity who has possession of an aerial platform by virtue of proof of purchase.

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

platform: The portion of an aerial platform intended for occupation by personnel with their necessary tools and materials.

platform height: The vertical distance measured from the floor of the platform to the surface upon which the aerial platform is being supported.

platform reach: The horizontal distance measured from the center line of rotation to the outer most edge of the platform.

powered functions: Those which control motion of the platform or the aerial platform and are caused by electromechanical, hydraulic, or pneumatic forces.

qualified person: A person who by reason of knowledge, experience or training, is familiar with the operation to be performed and the hazards involved.

rated work load: The designed carrying capacity of the aerial platform as specified by the manufacturer.

shall: The word "shall" is to be understood as mandatory.

stability, stable: A condition of an aerial platform in which the sum of the moments which tend to overturn the unit is less than the sum of the moments tending to resist overturning.

stabilizers: Devices that increase the stability of the aerial platform but are not capable of lifting or leveling the aerial platform.

unintended motion: Motion of the aerial platform or platform without activation of any control.

unrestricted rated work load: The maximum designed carrying capacity of the aerial platform allowed by the manufacturer in all operating configurations.

user: Person(s) or entity(s) that has care, control, and custody of the aerial platform. This person or entity may also be a dealer, owner, lessor, lessee, or operator.

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RESPONSrnaITIES MANUAL

NOTE: Operating and maintenance manuals covered in Section 4 of ANSIJSIA A92.5, and referred to in this document, should be obtained from the manufacturer of the boom-supported elevating word platform.

5. Responsibilities of Dealers

5.1 Basic principles: Sound principles of safety, training, inspection, maintenance, application, and operation consistent with all data available regarding the parameters of intended use and expected environment shall be applied in the training of operators, in maintenance, application, safety provisions and operation of the aerial platform with due consideration of the knowledge that the unit will be carrying personnel.

5.2 Manuals: Dealers shall keep and maintain copy(ies) of the operating and maintenance manual(s) required in section 4.19 of this standard. Operating manual(s) shall be provided with each rental, lease, or sale delivery. These manual(s) shall be stored in the location required by section 4.20 of this standard. These manual(s) are considered an integral part of the aerial platform and are vital to communicate necessary safety information to users and operators. In addition, parts and maintenance manual(s) shall be provided with each sale delivery.

5.3 Pre-delivery preparation. Aerial platforms shall be inspected, serviced and adjusted to manufacturer's requirements prior to each delivery by sale, lease, or rental.

5.4 Maintenance safety precautions. Before adjustments and repairs are started on an aerial platform, the following precautions shall be taken as applicable:

a) Powerplant stopped and starting means rendered inoperati ve.

b )A11 controls in the "off' position and all operating systems secured from inadvertent motion by brakes, blocks, or other means. . c) Boom and platform lowered to the full down position, If possible, or otherwise secured by blocking or cribbing to prevent dropping.

d)Hydraulic oil pressure relieved from all hydraulic circuits before loosening or removing hydraulic components.

e) Safety props or latches installed where applicable as prescribed by the manufacturer.

5.5 Replacement parts. When parts or components are replaced, they shall be identical or equivalent to original aerial platform parts or components.

5.6 Training. Whenever a dealer directs or authorizes an individual to operate an aerial platform he shall ensure that the individual has been trained under the direction of a qualified person in accordance with the manufacturer's operating manual and requirements listed

Reprint from ANSIJSIA A92.5-1992I

in section 8, of this standard, before operating the aerial platform.

5.6.1 Training on delivery. Manufacturer's operating instruction and required training on the proper use and operation of the aerial platform shall be provided upon each delivery by sale, lease, or rental.

5.7 Operation. When a dealer operates an aerial platform in sales demonstrations or otherwise for his beneficial use, he and his operating personnel shall assume the responsibilities of users as specified in section 7 and responsibilities of operators as specified in section 8 of this standard.

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

5.9 Record retention. Dealer(s) shall retain the following records for at least three years:

a)Name and address of the purchaser of each aerial platform by serial number and date of delivery.

b)Records of the person(s) trained upon each delivery of an aerial platform.

c)Records of the pre-delivery preparation performed prior to each delivery.

5.10 Modifications. Modification or alteration of an aerial platform shall be made only with prior written permission of the manufacturer.

5.11 Manufacturers safety bulletins. The dealer shall comply with safety related bulletins as received from the manufacturer.

5.12 Ownership records. When a change in ownership of an aerial device occurs, it shall be the responsibility of the seller to notify the manufacturer, or successor, of the unit, model and serial number and the name and address of the new owner within si 60 da s.

6. Responsibilities of Owners

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

6.2 Manuals. Owners shall keep and maintain copy(ies) of the operating and maintenance manual(s) required in section 4.19 of this standard. Operating manual( s) shall be provided with each rental, lease, or sale delivery. The operating manual(s) shall be stored in the location required in section 4.20 of this standard. These manual( s) are considered an integral part of the aerial platform and are vital to communicate the necessary safety information to users and operators. In addition, parts and maintenance manual(s) shall be provided with each sale delivery.

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6.3 Pre-delivery preparation. Aerial platfonns shall be inspected, serviced and adjusted to manufacturer's requir~ments prior to each delivery by sale, lease, or rental.

6.4 Maintenance. The owner of an aerial platfonn shall arrange that the maintenance specified in this standard is properly perfonned on a timely basis. The owner shall establish a preventive maintenance program in accordance with the manufacturer's recommendations and based on the environment and severity of use of the aerial platfonn. The owner shall arrange that frequent and annual inspections are perfonned. All malfunctions and problems identified shall be corrected before the aerial platfonn is returned to service.

6.S Frequent inspection. The owner of an aerial platfonn shall cause a frequent inspection to be perfonned on the aerial platfonn:

a) That has been in service for three (3) months or 150 hours, whichever comes first.

b ) Before putting into service a machine which has been out of service for a period longer than three months of time.

The inspection shall be made by a person qualified as a mechanic on the specific make and model of the aerial platfonn. The inspection shall include all items specified by the manufacturer for a frequent inspection and shall include but not be limited to the following:

a) All functions and their controls for speed(s), smoothness, and limits of motion.

b ) Lower controls including the provisions of overriding of upper controls.

c)AlI chain and cable mechanisms for adjustment and worn or damaged parts.

d)AlI emergency and safety devices. e) Lubrication of all moving parts, inspection of filter

element(s), hydraulic oil, engine oil, and coolant as specified by the manufacturer.

f) Visual inspection of structural components and other critical components such as fasteners, pins, shafts, turntable attachment bolts, and locking devices.

g) Placard, warnings and control markings. h) Additional items specified by the manufacturer. i) Correction of all malfunctions and problems

identified and further inspection if necessary. j) After correction or replacement of any component, the

unit shall be inspected and tested in accordance with above paragraph 6.5.

6.6 Annual inspection. The owner of an aerial platfonn shall cause an annual inspection to be perfonned on the aerial platfonn no later than thirteen (13) months from the date of the prior annual inspection. The inspection shall be perfonned by a person(s) qualified as a mechanic on the specific make and model of the aerial platfonn. The inspection shall include all items specified by the manufacturer for an annual inspection.

6.7 Maintenance safety precautions. Before adjustments and repairs are started on an aerial platfonn, the following precautions shall be taken as applicable:


a) Powerplant stopped and starting means rendered inoperative.

b ) All controls in the "otT' position and all operating systems secured from inadvertent motion by brakes, blocks, or other means.

c) Elevating assembly and platfonn lowered to the full down position, if possible, or otherwise secured by blocking or cribbing to prevent dropping.

d) Hydraulic oil pressure relieved from all hydraulic circuits before loosening or removing hydraulic components.


6.8 Replacement parts. When parts or components are replaced, they shall be identical or equivalent to original aerial platfonn parts or components.

6.9 Maintenance training. The owner shall train his maintenance personnel in inspection and maintenance of the aerial platfonn in accordance with sections 6.4, 6.5, 6.6, 6.7, 6.8, and 7.3.3 of this standard and with the manufacturer's recommendations.

6.10 Operator training. Whenever an owner directs or authorizes an individual to operate an aerial platfonn, he shall ensure that the individual has been trained in accordance with the manufacturer's operating manual, and requirements listed in section 8 of this standard before operating the aerial platfonn.

6.10.1 Training on delivery. Manufacturer's operating instructions and required training on the proper use and operation of the aerial platfonn shall be provided upon each delivery by sale, lease, or rental.

6.11 Operation. When an owner operates an aerial platfonn, he shall have the responsibilities of users as specified in section 7 of this standard and his operating personnel shall have responsibilities of operators as specified in section 8 of this standard.

6.12 Assistance to users and operators. If an owner is unable to answer a user's or operator's questions relating to rated capacity, intended use, maintenance, repair, inspection, or operation of the aerial platfonn, the owner shall obtain the proper infonnation from the dealer or manufacturer and provide that infonnation to the user or operator.

6.13 Record retention. The owner shall retain the following records for at least three years:

a)Name and address of the purchaser of each aerial platfonn by serial number and date of delivery.

b)Records of the person(s) trained upon each delivery of an aerial platfonn.

c) Written records of the frequent and annual inspections shall be kept by the owner when he perfonns the inspection. The record shall include deficiencies found, corrective action and identification of the person(s) performing the inspection and repairs.

d) Records of the pre-delivery preparation perfonned prior to each delivery.

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6.14 Modifications. Modification or alteration of an aerial platform shall be made only with prior written permission of the manufacturer.

6.15 Manufacturers safety bulletins. The owner shall comply with safety related bulletins as received from the manufacturer or dealer.

6.16 Ownership records. When a change in ownership of an aerial device occurs, it shall be the responsibility of the seller to notify the manufacturer, or successor, of the unit, model and serial number and the name and address of the new owner within 60 da s.

7. Responsibilities of Users

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

7.2 Manuals. Users shall keep and maintain copy(ies) of the operating and maintenance manual(s) required in section 4.19 of this standard. The operating manual(s) shall be stored in the location required in section 4.20 of this standard. These manuals are considered an integral part of the aerial platform and are vital to communicate the necessary safety information to users and operators.

7.3 Inspection and maintenance. Users shall inspect and maintain the aerial platform as required to ensure proper operation. The frequency of inspection and maintenance shall be determined by the manufacturer's recommendations and be compatible with operating conditions and the severity of the operating environment. Aerial platforms that are not in proper operating condition shall be immediately removed from service until repaired. Repairs shall be made by a qualified person and the repairs shall be in conformance with the manufacturer's recommendations.

7.31 Frequent inspection. An inspection as outlined in section 6.5 of this standard shall be conducted.

7.3.2 Annual inspection. An inspection as outlined in section 6.6 of this standard shall be conducted.

7.3.3 Pre-start inspection. Before use each day or at the beginning of each shift, the aerial platform shall be given a visual inspection and functional test including but not limited to the following:

a) Operating and emergency controls. b) Safety devices. c) Personal protective devices, including fall protection.


d)Air, hydraulic and fuel system leaks. e) Cables and wiring harness. f) Loose or missing parts. g) Tires and wheels. h)Placards, warnings, control markings, and operating

and safety manual(s). i) Outriggers, stabilizers, extendible axles and other

structures. j) Guardrail system. k)Items specified by the manufacturer. 7.3.4 Maintenance safety precautions. Before

adjustments and repairs are started on an aerial platform, the following precautions shall be taken as applicable:

a) Powerplant stopped and starting means rendered inoperative.

b )All controls in the "off" position and all operating systems secured from inadvertent motion by brakes, blocks, or other means.

c) Boom and platform lowered to the full down position, if possible, or otherwise secured by blocking or cribbing to prevent dropping.

d) Hydraulic oil pressure relieved from all hydraulic circuits before loosening or removing hydraulic components.


f) Precautions specified by the manufacturer. 7.4 Replacement parts. When parts or components

are replaced, they shall be identical or equivalent to original aerial platform parts or components.

7.5 Maintenance training. The user shall train his maintenance personnel in inspection and maintenance of the aerial platform in accordance with sections 7.3, 7.3.1, 7.3.2, 7.3.3, and 7.3.4 of this standard and with the manufacturer's recommendations.

7.6 Operator training. Whenever a user directs or authorizes an individual to operate an aerial platform, he shall ensure that the individual has been trained in accordance with the manufacturer's operating and maintenance manual, the user's work instructions and requirements listed in section 8 of this standard before operating the aerial platform.

7.6.1 Model training. The user shall be responsible for the operator being trained on the model of the aerial platform that he will be operating. Such training shall be in an area free of obstructions, under the direction of a qualified person for a time sufficient to determine that the trainee display proficiency in knowledge and actual operation of the aerial platform. Only properly trained and authorized personnel shall be permitted to operate the aerial platform.

7.6.2 Trainee records. A record of the trainee's aerial platform instructions shall be maintained by the user for at least three years.

7.7 Before operation. Before authorizing an operator to operate an aerial platform, the user shall ensure that the operator has:

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a) Been instructed by a qualified person in the intended purpose and function of each control.

b)Read and understood the manufacturer's operating instruction(s) and user's safety rules, or been trained by a qualified person on the contents of the manufacturer's operating instruction(s) and user's safety rules.

c) Understood by reading or by having a qualified person explain all decals, warnings, and instructions displayed on the aerial platform.

d) Determined that the purpose for which the aerial platform is to be used is within the scope of the intended applications defmed by the manufacturer.

e)Been provided with approved fall protection devices and other safety gear for all personnel in the platform.

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

a) Drop-offs or holes. b )Bumps and floor obstructions. c) Debris. d) Overhead obstructions and high voltage conductors. e) Hazardous locations. 1) Inadequate surface and support to withstand all load

forces imposed by the aerial platform in all operating configurations.

g) Wind and weather conditions. h) Presence of unauthorized persons. i) Other possible unsafe conditions. 7.9 During operation. The aerial platform shall be

used in accordance with this standard. The user shall ensure that before each movement of the aerial platform, if repositioning of the platform, that the operator shall ensure:

a) The aerial platform is operated on a surface within the limits specified by the manufacturer.

b) The outriggers, stabilizers, extendible axles, or other stability enhancing means, are used as required by the manufacturer.

c) Guardrails are installed and access gates or openings are closed per manufacturer's instructions.

d)The load and its distribution on the platform and any platform extension are in accordance with the manufacturer's rated capacity for that specific configuration.

e) There is adequate clearance from overhead obstructions.

1) The minimum safe approach distances (M.S.A.D.) to energized power lines and parts, as listed in Table I are maintained. (See Fig. 3, page 23, for examples of safe operating procedures. )

g)The precautions defined in 7.3.3, 7.7, 7.8, 7.9, 7.10, and 7.11 of this standard are followed during operation of the aerial platform.

7.10 Hazardous locations. It shall be the responsibility of the user to determine the hazard classification of any partiCUlar atmosphere or location according to ANSIINFPA 505-1987.

RESPONSmILITIES MANUAL I 7.10.1 Hazardous locations. Aerial platforms operated

in hazardous locations shall be approved and of the type required by ANSIINFPA 505-1987.

7.11 Warnings and instruction. The user shall direct his operating personnel and supervise their work to ensure operation of the aerial platform in compliance with this standard.

7.11.1 Penonnel footing. Personnel shall maintain a frrm footing on the platform floor while working therein. Use of planks, ladders, or any other device on the aerial platform for achieving additional height or reach shall be prohibited.

7.11.2 Precaution from other moving equipment. When other moving equipment or vehicles are present, special precautions shall be taken to comply with local ordinances or safety standards established for the workplace. Warnings such as, but not limited to, flags, roped-off areas, flashing lights, and barricades shall be used.

7.11.3 Reporting problems or malfunctions. The operator shall immediately report to his supervisor any problem or malfunctions which become evident during operation. Any problems or malfunctions that affect the safety of operations shall be repaired prior to continued use.

7.11.4 Altering safety devices. Altering or disabling of interlocks or other safety devices shall be prohibited.

7.11.5 Entanglement. Care shall be taken to prevent rope, electric cords and hoses from becoming entangled in the aerial platform.

7.11.6 Capacity limitation. Rated capacities shall not be exceeded when loads are transferred to the platform at any height.

7.11.7 Work area. The operator shall ensure that the area surrounding the aerial platform is clear of personnel and equipment before lowering the platform.

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

7.11.9 Battery charging. Batteries shall be charged in a well-ventilated area free of flame, sparks, or other hazards which may cause fire or explosion.

7.11.10 Platform positioning. The aerial platform shall not be positioned against another object to steady the platform.

7.11.11 Misuse as a crane. The aerial platform shall not be used as a crane.

7.11.12 Operating area. The aerial platform shall not be operated from a position on trucks, trailers, railway cars, floating vessels, scaffolds, or similar equipment unless the application is approved in writing by the manufacturer.

7.11.13 Travel speed. Under all travel conditions, the operator shall limit travel speed according to conditions of ground surface, congestion, visibility, slope, location of personnel, and other factors causing hazards of collision or injury to personnel.

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7.11.14 Elevated driving requirements. Before and during driving while the platfonn is elevated, the operator shall:

a) Maintain a clear view of the path of travel. b ) Maintain a safe distance from obstacles, debris, drop

offs, holes, depressions, ramps, and other hazards to ensure safe elevated travel.

c) Maintain a safe distance from overhead obstacles. 7.11.15 Stunt driving. Stunt driving and horseplay

shall not be permitted. 7.11.16 Unauthorized use. Means shall be used to

protect against use by unauthorized person( s ). 7.12 Operation of the aerial platform. If a user is

also the operator of an aerial platfonn, he shall have the responsibilities of operators specified in section 8 of this standard as well as responsibilities of users as specified in section 7 of this standard.

7.13 Assistance to operator. If a user is unable to answer an operator's question(s) relating to rated capacity, intended use, maintenance, condition of the aerial platfonn or safety of operation of the aerial platfonn, the user shall obtain the proper infonnation from the dealer, owner, or manufacturer and provide that infonnation to the operator before use of the aerial platfonn in the application of concern.

7.14 Shutdown of aerial platform. The user shall direct his operating personnel to cease operation of the aerial platfonn in case of any suspected malfunction(s) or any potentially hazardous condition(s) that may be encountered. Further infonnation concerning safe operation shall be requested from the owner, dealer, or manufacturer before further operation.

7.15 Record retention. The user shall retain the following records for at least three (3) years:

a) Records of the operator(s) trained on each model of an aerial platfonn.

b) Written records of the frequent and annual inspection shall be kept by the user when he perfonns the inspection( s). The records shall include the date of inspection, any deficiencies found, the corrective action recommended and identification of the person(s) performing the inspection.

c) Written records of all repairs accomplished on the aerial platfonn shall include the date of any such repair, a description of the work accomplished and identification of the person(s) performing the repair.

7.16 Modifications. Modification or alteration of an aerial platfonn shall be made only with prior written permission of the manufacturer.

7.17 Manufacturer's safety bulletins. The user shall comply with safety related bulletins as received from the manufacturer, dealer, or owner.

8. Responsibilities of Operators

8.1 Basic principles. The infonnation in this standard must be supplemented by good judgment, safety control, and caution in eValuating each situation. Since the


operator is in direct control of the aerial platfonn, confonnance with good safety practices in this area is the responsibility of the operator. The operator must make decisions on the use and operation of the aerial platfonn with due consideration for the fact that his own safety as well as the safety of other personnel in the platfonn is dependent on those decisions.

8.2 Manuals. The operator shall be aware that the operating and safety manuals, including the manual which defmes the responsibilities of dealers, owners, lessors, lessees, users and operators are stored on the aerial platfonn and the location where they are stored. The operator shall be familiar with the manuals stored on the aerial platfonn and consult them when questions arise with respect to the aerial platfonn.

8.3 Pre-start inspection. Before use each day or at the beginning of each shift, the aerial platfonn shall be given a visual inspection and functional test including but not limited to the following:

a) Operating and emergency controls. b) Safety devices. c) Personal protective devices, including fall protection. d)Air, hydraulic and fuel system(s) leaks. e) Cables and wiring harness. f) Loose or missing parts. g) Tires and wheels. h) Placards, warnings, control markings and operating

manual(s). i) Outriggers, stabilizers, extendible axles and other

structures. j) Guardrail system. k)Items specified by the manufacturer. 8.4 Problems or malfunctions. Any problems or

malfunctions that affect the safety of operations shall be repaired prior to the use of the aerial platfonn.

8.5 Training. The operator shall be trained on the same model of aerial platfonn or one having operating characteristics consistent with the one to be used during actual work site operation. Under the direction of a qualified person, the trainee shall operate the aerial platfonn for a sufficient period of time to demonstrate proficiency and knowledge in the actual operation of the aerial platfonn. Care shall be taken to ensure the area of such operation has a minimum of obstacles and is conduci ve to training. Only properly trained and authorized personnel shall be permitted to operate the aerial platfonn.

8.6 Before operation. Before being authorized to operate the aerial platfonn, the operator shall have:

a) Been instructed by a qualified person in the intended purpose and function of each of the controls.

b ) Read and understood the manufacturer's operating instruction( s) and user's safety rules, or been trained by a qualified person on the contents of the manufacturer's operating instruction(s) and user's safety rules.

c) Understood by reading or by having a qualified person explain all decals, warnings, and instructions displayed on the aerial platfonn.

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S.7 Work place inspection. Before the aerial platfonn is used and during use, the operator shall check the area in which the aerial platfonn is to be used for possible hazards such as, but not limited to:

a)Drop-offs or holes. b ) Bumps and floor obstructions. c) Debris. d) Overhead obstructions and high voltage conductors. e) Hazardous locations. f) Inadequate surface and support to withstand all load

forces imposed by the aerial platfonn in all operating configurations.

g) Wind and weather conditions. h) Presence of unauthorized persons. i) Other possible unsafe conditions. S.S During operation. The aerial platfonn shall be

used in accordance with this standard. The operator shall ensure the following before each elevation of the platfonn:

a) Ensure the aerial platfonn is operated on a surface within the limits specified by the manufacturer.

b ) Ensure the outriggers, stabilizers, extendible axles, or other stability enhancing means, are used as required by the manufacturer.

c) Ensure that guardrails are installed and access gates or openings are closed per manufacturer's instructions.

d)Ensure the load and its distribution on the platfonn and any platfonn extension( s) are in accordance with the manufacturer's rated capacity for that specific configuration.

e) Ensure there is adequate clearance from overhead obstructions.

f) Ensure that the minimum safe approach distances (M.S.A.D.) to energized power lines and parts are maintained. (See Fig. 3, page 10 for examples of safe operating procedures.)

g) Ensure all personnel in the platfonn are wearing fall protection devices and other safety gear as required at all times.

S.9 Hazardous Locations. It shall be the responsibility of the user to determine the hazard classification of any particular atmosphere or location according to ANSIINFPA 505-1987.

S.9.1 Hazardous locations. Aerial platfonns operated in hazardous locations shall be approved and of the type required by ANSIINFPA 505-1987.

S.10 Warnings and instructions. The operator shall ensure the operation of the aerial platfonn is in compliance with this standard.

S.10.1 Personnel footing. Personnel shall maintain a fum footing on the platfonn floor while working therein. Use of planks, ladders, or any other devices on the aerial platfonn for achieving additional height or reach shall be prohibited.

S.10.2 Precaution for other moving equipment. When other moving equipment and vehicles are present, special precautions shall be taken to comply with local ordinances or safety standards established for the workplace. Warnings such as, but not limited to, flags,


roped-off areas, flashing lights, and barricades shall be used.

S.10.3 Reporting problems or malfunctions. The operator shall immediately report to his supervisor any problems or malfunctions of the aerial platfonn which become evident during operation. Any problems or malfunctions that affect the safety of operation shall be repaired prior to continued use.

S.10.4 Reporting potentially hazardous locations. The operator shall immediately report to his supervisor any potentially hazardous location(s) (environment) which become evident during operation.

S.10.5 Altering safety devices. Altering or disabling of interlocks or other safety devices shall be prohibited.

S.10.6 Entanglement. Care shall be taken to prevent rope, electric cords and hoses from becoming entangled in the aerial platfonn.

S.10.7 Capacity limitation. Rated capacities shall not be exceeded when loads are transferred to the platfonn at any height.

S.10.S Work area. The operator shall ensure that the area surrounding the aerial platfonn is clear of personnel and equipment before lowering the platfonn.

S.10.9 Fueling. The engine shall be shut down while fuel tanks are being filled. Fueling shall be done in a well-ventilated area free of flame, sparks, or other hazards which may cause fire or explosion.

S.10.10 Battery charging. Batteries shall be charged in a well-ventilated area free of flame, sparks, or other hazards which may cause fire or explosion.

S.10.11 Improper platform stabilization. The aerial platfonn shall not be positioned against another object to steady the platfonn.

S.10.12 Misuse as a crane. The aerial platfonn shall not be used as a crane.

S.10.13 Unusual operating support conditions. The aerial platfonn shall not be operated from a position on trucks, trailers, railway cars, floating vessels, scaffolds, or similar equipment unless the application is approved in writing by the manufacturer.

S.10.14 Travel speed. Under all travel conditions, the operator shall limit travel speed according to conditions of ground surface, congestion, visibility, slope, location of personnel, and other factors causing hazards of collision or injury to personnel.

S.10.15 Elevated driving requirements. Before and during driving while the platfonn is elevated, the operator shall:

a)Maintain a clear view of the path of travel. b ) Maintain a safe distance from obstacles, debris, drop

offs, holes, depressions, ramps, and other hazards to ensure safe elevated travel.

c) Maintain a safe distance from overhead obstacles. S.10.16 Stunt driving. Stunt driving and horseplay

shall not be permitted. S.10.17 Unauthorized use. The operator shall

implement means provided to protect against use by unauthorized person( s).

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8.10.18 Misuse as a jack. The boom and platfonn of the aerial platfonn shall not be used to jack the wheels off the ground unless the machine is designed for that purpose by the manufacturer.

8.10.19 Driving on slopes. The aerial platfonn shall not be driven on grades, side slopes or ramps exceeding those for which the aerial platfonn is rated by the manufacturer.

8.10.20 Snagged platform. If the platfonn or elevating assembly become caught, snagged or otherwise prevented from nonnal motion by adjacent structure or other obstacles such that control reversal does not free the platfonn, all personnel shall be removed from the platfonn before attempts are made to free the platfonn using ground controls.

8.11 Assistance to operator. If an operator encounters any suspected malfimction of the aerial platfonn, or any hazard or potentially unsafe condition relating to capacity, intended use or safe operation, he shall cease operation of the aerial platfonn and request further infonnation as to safe operation from his management, or the owner, dealer, or manufacturer before further operation of the aerial platfonn.

8.12 Modifications. Modifications or alteration of an aerial platfonn shall be made only with prior written

ennission of the manufacturer.

9. Responsibilities of Lessors

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

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

9.2.1 Lessor as a dealer. When a lessor uses the aerial platfonn as a dealer, he shall have the responsibilities of dealers as specified in section 5 of this standard.

9.2.2 Lessor as an owner. When a lessor uses the aerial platfonn as an owner, he shall have the responsibilities of owners as specified in section 6 of this standard.

9.2.3 Lessor as a user. When a lessor uses the aerial platfonn as a user, he shall have the responsibilities of users as specified in section 7 of this standard.

9.2.4 Lessor as an operator. When a lessor uses the aerial platfonn as an operator, he shall have the responsibilities of operators as specified in section 8 of this standard.


10. Responsibilities of Lessees

10.1 Basic principles. Sound principles of safety, training, inspection, maintenance, application, and operation consistent with all data available regarding the parameters of intended use and expected environment shall be applied in the perfonnance of responsibilities of lessees with due consideration of the knowledge that the unit will be carrying personnel.

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

10.2.1 Lessee as a dealer. When a lessee uses the aerial platfonn as a dealer, he shall have the responsibilities of dealers as specified in section 5 of this standard.

10.2.2 Lessee as an owner. When a lessee uses the aerial platfonn as an owner, he shall have the responsibilities of owners as specified in section 6 of this standard.

10.2.3 Lessee as a user. When a lessee uses the aerial platfonn as a user, he shall have the responsibilities of users as specified in section 7 of this standard.

10.2.4 Lessee as an operator. When a lessee uses the aerial platfonn as an operator, he shall have the responsibilities of operators as specified in section 8 of this standard.

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Table 1 - Minimum safe approach distance (M.S.A.D.) to energized (exposed or insulated) power lines

Voltage range Minimum safe approach distance

(phase to phase) (Feet) (Meters)

o to 300V Avoid Contact

Over 300V to 50 kV 10 3.05

Over 50 kV to 200 kV 15 4.60

Over 200 kV to 350 kV 20 6.10

Over 350 kV to 500 kV 25 7.62

Over 500 kV to 750 kV 35 10.67

Over 750 kV to 1 000 kV 45 13.72

~ ~ Denotes prohibited zone

Danger: - Do not allow machine personnel or conductive materials inside prohibited zone.

- Maintain M.S.A.D. from all energized lines and parts as well as those shown.

- Assume all electrical parts and wires are energized unless known otherwise.

Caution: - Diagrams shown are only for purposes of illustrating M.S.A.D. work positions, not all work positions.

Figure 3 - Minimum Safe Approach Distance (M.S.A.D.)

PAGE 10

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A div. of TIME Manufacturing Company

MAINTENANCE MANUAL


PLATFORM-MOUNTED

SHIPPING ADDRESS

CONDOR® ADIV. OF TIME MFG. co.

8300 IMPERIAL DRIVE

WACO, TEXAS 76712 (817) 666-4545


D

MAILING ADDRESS


P.O. Box 21447 WACO, TEXAS 76702-1447

(817) 666-4545

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CONDOR® MODEL 58/68/76

MAINTENANCE

TABLE OF CONTENTS .................................................................................................. 1

WARRANTY ................................................................................................................... 3

CHECK-OUT INSTRUCTION ...................................................................................... 10

PREVENTIVE MAINTENANCE .................................................................................. 12

LUBRICATION CHART ............................................................................................... 13

INSTALLATIONIINSPECTIONREPORT ................................................................... 15

MAINTENANCE PROCEDUREIHYDRAULIC CYLINDER ..................................... 19


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Condor® Self-Propelled Booms and Scissors WARRANTY

Time Manufacturing (" Condor Div. ") warrants to the purchaser that each new aerial work platform made by Condor Div. is free from defects in material and workmanship arising under normal use and service-in the case of maj or weldments, ( chassis, turret, and booms), for a period of fi ve (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's, 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 Div, 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 Div. 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 Di vision. This Warranty covers only new and unused aerial work platforms manufactured by Condor Divison. Products or parts manufactured by others are covered only by such warranties as are extended to the purchaser by Condor Division's suppliers.

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

duration to the warranty period.

8300 Imperial Drive, P.O. Box 21447, Waco, Texas 76702-1447·817-666-4545,817-666-4544 FAX

Fonn NO.513-3M-392


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

•

Effective August 27, 1996

W ARRANTYPROGRAM

Warranty is a function of a manufacturing company to back up the product it manufactures. It is a guarantee against defects in design and workmanship of components utilized in the product, and is offered for a certain period of time following purchase by a customer.

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

The warranty policy and discription are depicted on the attached printed policy. For your reference, the following is offered:

A. WARRANTY PERIOD

NOTE:

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

2. The Truck-Mounted unit Warranty Period is one (1) year from shipment of the unit from Condor Divisions plant.

3.

4.

5.

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 Div., whichever comes first, unless the part is furnished to correct a defective part on the original CONDOR® shipment still under Warranty. No labor is paid under Parts Warranty.

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

In addtion to covering the parts replaced under CONDOR® Warranty, Condor Div. will pay a deialer warranty labor rate, which is based on a percentage of your standard shop labor rate.

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

The submittal of a Warranty claim against a stock CONDOR® constitutes it as being "in service," initiating the Warranty Period.


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B.

NOTE:

PRE-DELIVERY INSPECTION SHEET (p.D.I.)

l.

2.

3.

Each Self-Propelled Boom or Scissor CONDOR® shipped from Condor Divisions facility will have a Pre-Delivery Inspection (P.D.I.) sheet enclosed in the Safety Manual holder tube.

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

Failure to complete the P.D.1. sheet and return it to Condor Div. within the time frame given will result in voiding the Warranty on the CONDOR®.

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

C. ITEMS NOT COVERED

Some components are used on the machine which are not warranted by Condor Div .. However, these are warranted by the component manufacturer. Some of these are:

1. Engine: Manufacturers used include Wisconsin, Ford, Deutz, Isuzu, Kubota, Onan, Cummins, John Deere, and others. To apply for warranty on the engine, contact should be made with the engine manufacturer's dealer in your area. Condor Div. can advise you if you need assistance locating a dealer.

2. Tires and Batteries: These are normal wear items and are considered normal maintenance items. However, if they are found to be defective, contact can be made with the manufacturer's local dealer. NOTE: For nternational dealers where tires or batteries are not obtainable from a local in-country supplier, locally supplied tires or batteres can be used. Components must meet or exceed originally-supplied items. Copies of invoices for said items MUST accompany any Warranty Claims to receive parts credit.

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

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

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

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

7. Troubleshooting: Troubleshooting is not covered or reimbursable. However, Condor Div. Warranty will cover reasonable labor charges for the removal and replacement of defective components.


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_D.

NOTE:

PROCESSING OF 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:

2.

3.

a. Issuing an order to our Parts Department through normal channels, which entails your company being invoiced.

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

The above two methods will enable you to indicate on the claim the Condor Div. 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 Div. has the option to ship a replacement part at no charge if the local cost would be greater, in lieu of issing credit for locally purchased parts.

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

Complete the Warranty Claim as noted in the "Warranty Claim Procedure" section. Provide as much information as possible to enable Condorto thoroughly evaluate the claim and process it in the shortest amount of time possible.

CLAIMS NOT RECEIVED BY CONDOR DIVISION WITHIN 45 DAYS OF FAILURE WILL BE DENIED

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.

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E. RETURN AUTHORIZATION

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

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


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NOTE:

3:

4.

NOTE:

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DO NOT SHIP ANY RETURN PARTS WITHOUT A RETURN AUTHORIZATION (RIA) NUMBER

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

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

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

Dueto shipping charges and impart duties imposed on INTERNATIONAL DEALERS, these dealers will not be required to automatically return all parts.

Condor Divison requires that all parts claimed on a Warranty Form be retained by the international dealer for a period of no less than 180 days. After this period, if no instructions have been received form Condor Div., the parts may be scrapped.

Should Condor Division request any part bereurned, it will be shipped to our factory in Waco, Texas, frieght prepaid.


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WARRANTY CLAIM PROCEDURE

INTRODUCTION

This procedure is offered to assist our Dealers in properly completing our Warranty Claim Forms. The more information supplied, the better Condor Divisioin can evaluate the problem and expedite processing the claim.

The form should be TYPED or completed LEGIBLY in ink. Several copies are utilized. Ensure that sufficient pressure is applied to make all copies legible.

PROCEDURE

NOTE:

1.

2.

THE NUMBERS NOTED BELOW CORRESPOND TO THE BLOCK NUMBERS ON THE CLAIM FORM

Where to mail: P.o. Box for mailing claim, street address for RIA parts returns.

Claim information:

a. Dealer's Claim Number: This assigned number is necessary for Dealer and CondorDiv. tracking purposes, since there may be more than one claim for the same unit.

b. Condor Div. Warranty Number: Do not write in this section. It is for CondorDiv. use only.

c. Return Authorization Number: All parts replaced under Warranty MUSTbe returned to Condor Div. freight prepaid. Call the Condor Div. Service Department for Return Authorization Number. Parts returned without proper authorization and gold packing slip will not be accepted.

d. All dates pertinent to the claim and! or RIA are to be entered in the proper locations.

3. Dealer information: Supply the name of the company, address and name of the person submitting the claim. This person will be the contact if a discrepancy occurs, and will be referred to on all correspondence.

4. This section is provided to identify the unit: The date of delivery (date unit was received at your facility); In Service date (date sold to end user or date put into operation); Model and Serial numbers; type of Warranty, (A) Aerial Lift Warranty on a specific unit or (B) Parts Replacement, Warranty on a new part ordered and found to be defective.


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5.

6.

Owner Information: Supply end user company name and address. If it is the same as the dealer' s, ~ write "Same". ~

This area is for part number(s) and description(s). It is VERY important that the Condor invoice number(s) for which the part(s) were purchased be provided along with the amounts in order to properly process the claim. NOTE: All dollar amounts are to be in U.S. currency.

7. Labor Description: A detailed description of the failure along with the work performed is required in order to fully evaluate the hours of your claim and the amount Condor will approve.

8. Condor remarks: This area is completed by Condor. A brief explanation and steps taken in the determination of approval or denial is provided here.

Upon completion of the form, remove the copy for your records. Remove the packing slip copy and send it, along with the parts being returned under warranty. The returned copy must have the RIA number in the proper location and must be packed in with the parts sent back to Condor.

Mail the remaining copies to the Condor P.O. Box located in block #1 for Condor evaluation.

NOTE: CLAIMS NOT RECEIVED WITHIN 45 DAYS OF FAILURE WILL BE DENIED.


CHECK-OUT INSTRUCTION

The following instructions are a step-by step procedure for checking out the self-propelled CONDOR®, as well as for acquainting operating personnel with the unit's operation. This procedure will not take more than one hour and is time well-spent, as it will give both operating and maintenance personnel preliminary experience and a better understanding of the operation of the sdf-propelled CONDOR®.

Prior to placing the unit into service, a full check-out of the unit should be made and the Installation Inspection Report should be completed and returned to Condor Div. Each unit has undergone a thorough Quality Control Inspection, and each unit leaves Condor Div. in first-class condition. Unfortunately, some units may be damaged in transportation; all such damage should be recorded on the consignee copy of the freight bill. Condor Div. is not responsible for daIIlage to units in transit.

1. Visually inspect all exposed components. Check for loose nuts and bolts, damaged hydraulic lines, broken wires, and structural damage.

2. IMPORTANT: Check tire pressure. Tires must be properly inflated before operating the unit. Do not over-inflate. Proper P.S.1. rating appears on decals applied to both sides of the carriage.

3. Check hydraulic oil level and add Shell Tellus T-32 hydraulic oil, if required.

4. Fill fuel tank using unleaded gasoline or diesel fuel.

5. Check battery with an hydrometer. Battery must have a full charge.

6. All hydraulic valves are located on the panel inside the turret, and are exposed by removing the inspection panel. Remove and replace this panel for visual inspection of the turret compartment before putting the unit into service.

7. Tum on the key switch located inside the access door at the lower control station. Depress the start button and allow engine to warm up at idle. After the unit has warmed up, and with the UPPERILOWER control station selector switch in the LOWER position, the unit may be operated by activating the control levers on the lower control console. The red EMERGENCY STOP button will kill the engine. It is not necessary to tum the key switch offbetween running operations. This switch only provides the operator with a means of electrically locking the unit.

8. With the key switch ON, switch to the UPPER control station. Position the unit in an area that is free from any overhead obstruction. Push the BOOM control lever slowly to the UP position and raise the boom approximately six (6) feet. When released, the controller will return to the neutral position automatically. Learn to operate the controller slowly to obtain the smoothest possible operation.


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9. The CONDOR® has been designed to drive with the counterweight over the drive wheels. This configuration will provide the best traction and a familiar driving position.

10. The wheel drive has the following features:

A. There is a HIGHILOW speed selector (toggle switch) on the upper control box.

B. In HIGH speed mode, the vehicle is capable of traveling 0-3 mph (fully propor-tional) in the stowed position. .

c. In LOW speed mode, the vehicle is capable of traveling 0-1.5 mph (fully proportional).

11. Operate the boom at a horizontal position until you are familiar with the operation and feel of the controls. The unit will respond more smoothly to the controls when they are activated properly.

12. Gradually operate the unit up to its maximum elevation and extension.

13. All CONDOR® models are equipped with a slope-sensing device which senses a 5° outof-level condition. This safety system is operational when the ignition circuit is on. When the unit is subjected to an out-of-plumb condition of 5° or more, the operator should correct the condition by reversing the drive direction or by selecting an alternate path. The operator must observe normal safety precautions when operating the equipment. The slope-sensing device must not be disconnected. Should the system be found inoperable, the unit must be grounded and must not be used until the system has been repaired.


A.

B.

C.

PREVENTIVE MAINTENANCE

INTERVAL CHECK LIST

ITEM REQUIRING ATTENTION DAILY (INCLUDE DAILY)

CARRIAGE ASSEMBLY

1. Visible Damage-Weld Cracks, Dents X 2. Steering Cylinder and Pins 3. Steering Tie Rods and Connections 4. Steering Yokes 5. Steering Lube Points 6. Repack Wheel Bearings 7. Visually Inspect Torque Hubs, Motors 8. Check Torque Hub Oil Level 9. Change torque Hub Oil

10. Wheel Mounting, Components 11. Inspect Tires Damage and Wear X 12. Check Tire Pressure (Pneumatic) 13. Check Hydraulic Fittings and Hoses 14. Check Ring Gear Fasteners

TURRET ASSEMBLY

1. Check for Visible Damage X 2. Check Ring Gear Bolts 3. Check Rotary Coupling Bolts 4. Check Rotation Gearbox 5. Change Rotation Gearbox Oil Level 6. Check Rotation Gearbox Oil 7. Check Rotation MotorlPinion 8. Check Hydraulic Valve Mounting 9. Check Hydraulic Fitting, Hoses X

10. Check Wiring, Electrical Connections X 11. Inspect Topping Cylinder, Pins 12. Inspect Master Cylinder, Pins 13. Lube Master Cylinder Pins 14. Check Counterweight Bolts 15. Inspect Covers, Hose Wrap

POWER UNIT

1. Engine (See Manual) 2. Inspect Air Cleaner Connections 3. Change Air Cleaner Oil


50HRS (INCLUDE DAILY)

X X X X

X X

X

X X X

X X X X

X X X X X X X X X

X X

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500 HRS (INCLUDE

DAILY)

X

X

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X

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D.

E.

F.

G.


INTERVAL CHECK LIST

ITEM REQUIRING ATTENTION DAILY 50HRS (INCLUDE (INCLUDE DAILY) DAILY)

BOOM ASSEMBLY

1. Visible Damage-Weld Cracks, Dents X 2. Inspect Install. Boom Pivot Pin X 3. Inspect Install. Ext. Cylinder Pin X 4. Check Boom Wear Pad Clearance, Wear X 5. Check Boom Wear Pad Mounting Bolts X 6. Inspect Hydraulic Hose and Electrical

Cable Routing X 7. Inspect Cable Track 8. Inspect Slave Cylinder X 9. Inspect Slave Cylinder Pin X

SKIRTIPLATFORM

1. Visible Damage, Weld Cracks, Dents X 2. Platform Mounting X 3. Platform Slide Bar - Work Freely X 4. Inspect Rotation Mechanism X 5. Inspect Hydraulic Hoses and Electrical

Cable X 6. Check Controls Valves, Linkage Levers X

LOWER CONTROLS

1. Check Mounting of Enclosure X 2. Check External Electrical Connections X 3. Check Internal Wiring and Connections X 4. Check Seal on Enclosure Cover X 5. Check Slope Sensor Mounting Bolts X 6. Check Toggle Switches Return to Center X 7. Check Control Valves, Linkage Levers X

UPPER CONTROLS

1. Check Mouinting ofEnc1osure X 2. Check External Electrical Connections X 3. Check Internal Wiring and Connections X 4. Check Seal on Enc10sudre Cover X 5. Check Toggle Switch Return to Center X 6. Check Drive Controller, Inerlock,

Returns to Center X 7. Check Power Switch Retains Positions X 8. Inspect Controller Rubber Bellows X

MANUAL 8L~'r-:ow OCTOBER 1996

500 HRS (INCLUDE

DAILY)

X

G.


INTERVAL CHECK LIST

ITEM REQUIRING ATTENTION DAILY (INCLUDE DAILY)

HYDRAULIC SYSTEM

1. Check Hydraulic Tank Fluid Level X 2. Clean Hydraulic TAnk Breather 3. Change Hydraulic Filter (every 100 hours) 4. Check Hydraulic Fittings and Hoses 5. Change Hydraulic Fluid in Tank

(500 hrs. or yearly, whichever comes first)


50HRS (INCLUDE DAILY)

X X X

r 500HRS (INCLUDE

DAILY)

X

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tOt ~6

2

INTERVAL SYMBOL

C~) 50 HOURS OR SEMI-MONTHLY

c=J 100 HOURS OR MONTHLY

~ 500 HOURS OR ANNUALLY

~::~ BOOM PIVOT

~:-0 MASr [R L[VELING

c=J REPLACE ENGINE DIL

~~~ I<INGPINS(4)

STElRIN

CYLIN DER r;:-ri PIN (2) ~9;

@ TORQUE HUB

~9) TIE ROD (2)

@ SPEED REDUCER

~ ROTATION GEA TEETH 8x PINION

~~ RING GEAR

(ROTATE W'HILE LUBING)

(4 PLACES)

CRANK CASE CHECK DAILY

SHEAVE PIN(2)

TYPE OF LUBRICANT

CG- CHASSIS GREASE

SL - OPEN GEAR AND W'IRE ROPE SPRAY LUBE

EO- ENGINE OIL (REFER TO ENGINE MANUAU

GO-- GEAR DIL SAE 90 W'EIGHT EP W'B- W'HEEL BEARING GREASE

HF- HYDRAULIC FLUID SHELL TELL US T 32 OR EQUAL

'-:------HYDRAULIC TANK 0 (CHANGE DIU

HYD FILTER--CHANGE (INSIDE TURRET>

@ SHEAVE PIN (2)

SKIRT IBOOM PIVOT PIN

W'HEEL BEARINGS(2)

BUSHING IN TOP

OF SKIRT W'LDMNT

NOTES


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A dive of TIME Manufacturing Company

BOOM-SUPPORTED ELEVATING WORK PLATFORM

MODEL 58/68/76

INSPECTION REPORT

IMPORTANT: The following form must be completed

and returned to Condor Division to activate the unit's Warranty Account


8300 IMPERIAL DRIVE

WACO, TEXAS 76712 (817) 666-4545


TIME MANUFACTURING SELF-PROPELLED TELESCOPIC AERIAL WORK PLATFORM

CONDOR® INSTALLATION AND INSPECTION REPORT

Dealer's Name Address -----------------------

Model Serial Number Date ----------- -------------------- -------------------This CONDOR® Self-Propelled Telescopic Aerial Work Platform was inspected and tested prior to leaving Condor Division. Due to environmental conditions and the loading, transporting, and unloading of the unit, it will be necessary to perform the following inspection before putting the unit into service. THIS HELPS US HELP YOU.

When complete, this report must be returned to TIME MANUFACTURING-CONDOR DIVISION, P.O. Box21447,Waco, TX 76702-1447, within 45 days of receipt ofunit(s) in order to activate the Warranty Account(s).

ITEM NO. DESCRIPTION OF INSPECTIONITEST

1.

2.

3.

GENERAL APPEARANCE

A. Visible Damage

B. Fluid Leaks

C. Paint Damage

D. Decals (check for proper installation)

E. Visual inspection of all welds

F. Pins and retainers

ENGINE SERVICING

A. Engine oil level

B. Battery condition/level, charging operation

1. Electrolyte level

2. Terminal Security

C. Throttle solenoidllinkage, operation, adjustment

D. Choke solenoidllinkage, operation & adjustment

E. Fuel tank/gauge

F. Radiatorlfluid level

GROUND CONTROL STATION

A.

B.

C.

D.

E.

F.

G.

H. I.

J.

K.

L.

Engine start/anti-restart

Choke operation/glow plug

Starter operation

Governor operation

Alternator operation

Aerial/ground control selector

Boom lifting/lowering

Boom extension/retraction

Turret Rotation

Engine stop

Speed Control

Emergency functions/operation


INITIAL IF O.K. REMARKS

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ITEM NO. DESCRIPTION OF INSPECTIONITEST

3.

4.

5.

6.

GROUND CONTROL STATION (Continued)

M. Wiring condition & security

N. Operator's Manual

TIRE CONDITION

LF LR RF RR A. Tire pressure I I T T

(See decal on carriage)

B. Lug nuts/torque I I I I

AERIAL CONTROL STATION

A. Engine start/stop w/footswitch depressed

B. Boom lifting Up Down

C. Boom extension Out In

D. Turret rotation CW CCW

E. Platform rotation CW CCW

F. Platform tilt Up Down

G. Drive high Forward Reverse

H. Drive low Forward Reverse

I. Steering Left Right

J. Brakes Forward Reverse

K. 2-speed shift Low High

L. Emergency engine stop

M. 5° slope alarm-visible/audible warning

N. Emergency controls operation

HYDRAULIC COMPONENTS

A. Hoses, fittings

B. Topping cylinder

C. Topping cylinder retainers

D. Holding valves

E. Master Leveling Cylinder

F. Slave leveling cylinder

G. Leveling cylinder retainers

H. Boom extension cylinder

I. Extension cyinder retainers

J. Steering cylinder

K. Steering cylinder retainers

L. Drive motors

M. Brake assembly

N. Drive manifold

O. Turret rotation gearbox

Left

Left

Right

Right


INITIAL IF O.K. REMARKS

ITEM NO. DESCRIPTION OF INSPECTIONITEST INITIAL IFO.K

6. HYDRAULIC COMPONENTS (Continued)

Q. Turret rotation motor

R. Hydraulic pump

S. Hydraulic tank

T. Return filter/element

U. Proportional valves

V. Solenoid valves

W. Security of hose retainers

7 .. ELECTRICAL COMPONENTS

A. Motion warning hom

B. Two-speed limit switch, operation/interlock

C. Footswitch

D. Hour meter, amp meter

E. Wiring-condition, security

F. 5° slope sensor, leveling system

8. GENERAL SERVICING

A. Hydraulic oillevellcondition

B. Air cleaner element

C. Turret lubrication points

D. Chassis lubrication points

E. Boom lubrication points

F. Turret ring gear fasteners

9. OPTIONS

A. Isuzu diesel engine, Ford gasoline engine

B. Foam-filled tires

C. Strobe light

D. Hydraulic-driven generator

E. Air line to platform

F. 110-volt line to platform

10. NOTES

INSPECTION PERFORMED BY


REMARKS

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MAINTENANCE PROCEDURES:

TEXAS HYDRAULICS CYLINDERS

The following pages are supplied in order to assist in the maintenance of units equipped with Texas Hydraulics cylinders.


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NOTES:

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APPENDIX A

BASIC STRESS

1. THIS CHART SHOWS RECOMMENDED BOLT TORQUES.

2. TORQUE = R X D X T R = .150 FOR LUB CONDITIONS R = .200 FOR DRY CONDITIONS

SAEGRADE8

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

DIAMETER

M4

M5

M6

M8

M10

M12

M14

M16

M20

M24

M30

APPENDIXB

BOLT TORQUE CHART

FOR METRIC HEX HEAD CAP SCREWS

- RECOMMENDED ASSEMBLY TORQUES IN FOOT-POUNDS (*VALUES IN LB-IN, OTHERS ARE LB-FT.)

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

PROPERTY CLASS 8.8 PROPERTY CLASS 9.8 PROPERTY CLASS 10.9 PROPERTY CLASS 12.9 DRY LUBRICATED DRY LUBRICATED DRY LUBRICATED DRY LUBRICATED THREADS THREADS THREADS THREADS THREADS THREADS THREADS THREADS

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

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

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

19 12 21 13 27 16 37 22

39 23 42 25 53 32 73 44

67 40 73 44 92 55 127 76

107 64 116 69 146 89 203 122

167 100 181 108 230 138 316 190

325 195 352 211 449 269 617 370

562 337 609 386 775 465 1066 640

1117 670 1210 726 1540 924 2188 1271

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1


BOOM-SUPPORTED ELEVATING WORK PLATFORM

MODEL 58/68/76 ARTICULATING

ILLUSTRATED PARTS MANUAL

SHIPPING ADDRESS

CONDOR® A DIV. OF TIME MFG. co.

8300 IMPERIAL DRIVE

VVACO, TEXAS 76712 (817) 666-4545

11\\,~~(c;:OOOO~OOj 1/1 \\'-11 __ D_--------'li ~)' \ ~r \~ ~oo


MAILING ADDRESS


P.O. Box 21447 VVACO, TEXAS 76702-1447

(817) 666-4545

.()

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. Familiarize yourself with the functions and operations of the upper and lower controls. A good understanding of the controls, their limitations, and their capabilities will maximize operating efficiency. The various decals attached to this CONDOR® also contain vital operational instructions. Read the decals before operating this CONDOR®.

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

It is also YOUR RESPONSIBILITY to understand and obey all federal, state, and local regulations regarding the operation and use of aerial work platforms. A copy ofthe ANSI/SIA Manual of Responsibilities is attached for your use: ANSI/SIA A92.5-1992 is provided for Boom-S upported Elevating Work Platforms, and ANSII SIA A92.6-1990 is provided for Self-Propelled Elevating Work Platforms.

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. Our manuals are continually updated to reflect these changes.

DO NOT ALTER OR MODIFY THIS CONDOR® WITHOUT PRIOR WRITTEN APPROVAL FROM THE MANAGEMENT OF THE 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 the 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 Div. Operation, Maintenance, & Parts Manual for information on service and maintenance of the CONDOR®.

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

ii


CONDOR® SERVICE INFORMATION

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

(817) 666-4545 Telephone (817) 666-5125 Voice Mail (800) 443-5803 FAX

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

3. Service and maintenance are not a substitute for trained, qualified service technicians. Condor Div. 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 Div. Service Schools help you provide this training.

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

8300 IMPERIAL DRIVE, P.O. Box 21447, WACO, TEXAS 76702-1447- 817-666-4545, 817-666-4544 FAX


)

)

)

FIGURE

ILLUSTRATED PARTS BREAKDOWN

CONTENTS Models 58/68/76

DESCRIPTION PAGE

A ............................................... Serial Number Location .................................................................. 3 B ............................................... Recommended Spare Parts List ..................................................... 4 C " ............................................. How to Order Parts ............. , .......................................................... 6

1.1 ............................................. FinaIAssembly58/68 ...................................................................... 8 1.2 ............................................. Final Assembly 76 ......................................................................... 12 1.3 ............................................. Decal Installation .................................................. '" ....... '" ........... 14

2.1 ............................................. Carriage Assembly 68 .................................................................. 18 2.2 ............................................. Carriage Assembly 76 .................................................................. 20 2.3 ................................... ~ ......... Drive Manifold Assembly ............................................................. 22 2.4 ............................................. Steering Cylinder Part Breakdown ............................................... 24 2.5 ............................................. Tire & Wheel Assembly, Drive Axle 58/68 .................................. 26 2.6 ............................................. Tire & Wheel Assembly, Drive Axle 76 ...................................... 27 2.7 ............................................. Idler Hub Assembly ...................................................................... 28 2.8 ............................................. Torque Hub Assembly ........ -.................................. _ ........................ 30 2.9 ............................................. Hydraulic Motor Assembly ........................................................... 32 2.10 ........................................... Hydraulic Brake Assembly ........................................................... 34 2.11 ........................................... Hose Kit - 2WD Chassis .............................................................. 36

3.1 ............................................. Gas Turret Assembly 68 ............................................................... 38 3.2 ............................................. Gas Turret Assembly MDC76 ...................................................... 40 3.3 ............................................. Rotation Installation 58/76 ............................................................. 42 3.4 ............................................. RotaryCouplingAssembly58/76 .................................................. 44 3.5 ............................................. Speed Reducer Assembly 58/76 ................................................... 46 3.6 ............................................. BoltKit ......................................................................................... 48 3.7 ............................................. Electrical Installation Turret 58/76 ................................................ 50 3.8 ............................................. Volt Battery .................................................................................. 51 3.9 ............................................. Ford Engine Box Assembly 68/76 ................................................ 52 3.10 ........................................... Ground Control Console ................................................................ 54 3.11 ........................................... Engine Installation ......................................................................... 58 3.12· ........................................... Engine Pump Assembly ................................................................ 61 3.13 ........................................... Ford LRG423 Belt Driven Gov. Kit .............................................. 63 3.14 ........................................... Fuel Tank Assembly ..................................................................... 64 3.15 ........................................... Cover Assembly ........................................................................... 67

4.1 ............................................. Hydraulic Installation, Turret 58/68 ............................................... 68 4.2 ............................................. Hydraulic Installation, Turret 76 ................................................... 69 4.3 ............................................. Valve Mounting Base, Hoses-Turret Assembly ........................... 70 4.4 ............................................. Hydraulic Tank Assembly ............................................................. 72 4.5 ............................................. Topping Cylinder Assembly 58/68 ................................................ 74 4.6 ............................................. Topping Cylinder Assembly 76 ..................................................... 76 4.7 ............................................. Manifold Assembly ....................................................................... 78


•

FIGURE

ILLUSTRATED PARTS BREAKDOWN

CONTENTS Models 58/68/76

DESCRIPTION PAGE

4.8 ............................................. Hose Kit-MDC68 TurretIBoom ................................................... 80 4.9 ............................................. Hose Kit-76 TurretIBoom ............................................................. 82

5.1 ............................................. Boom Assembly 58/68 .................................................................. 85 5.2 ............................................. BoomAssembly76 ....................................................................... 89 5.3 ............................................. Boom Extension Cylinder Assembly 58 ........................................ 93 5.4 ............................................. Master Leveling Cylinder Assembly ............................................. 94 5~5 ............................................. Extension Boom Cylinder Assembly ............................................. 97 5.6 ............................................. Boom Extension Cylinder Assembly ............................................. 98 5.7 ............................................. Slave Cylinder Assembly 58/76 .................................................. 100 5.8 ................................... : ......... Intermediate Boom Assembly 58/76 ........................................... 102 5.9 ............................................. Inner Boom Assembly 58/76 ...................................................... 104

6.1 ............................................. Platform Assembly 58/76 ............................................................ 106 6.2 ............................................. Platform Control Box .................................................................. 108 6.3 ............................................. 110V Line To Platform Assembly 58/68 .................................... 110

7.1 ............................................. Platform 58-Top Mount 6' Wide - Option ................................... 112 7.2 ............................................. Platform 68-Top Mount 6' Wide - Option " ......... '" ..................... 113 7.3 ............................................. Head & Tail Lights - Option 58/76 ............................................. 114 7.4 ............................................. Hom & Signal- Option ............................................................... 115 7.5 ............................................. Strobe Light - Option .......................................................... , .... ... 116 7.6 ................................. ............ 108° Platform Rotation 58 - Option ..... ...... ...................... ........... 117 7.7 .............................................. Platform Installation 58 - Option ................................................. 118 7.8 ............................................. Platform Installation 68 - Option ................................................. 120 7.9 ............................................. Platform Top Mount 8' Wide 58 - Optoin ................................... 122 7.10 ........................................... Platform Top Mount 8' Wide 68 - Option ................................... 123 7.11 ........................................... Air Line To Platform 58 - Option ............................................... 124 7.12 ........................................... Common Part To Air Line 58,76 - Option .................................. 125 7.13 ........................................... Air Line To Platform 68 - Option ............................................... 127 7.14 ........................................... Common Parts To Air Line 68 - Option ..................................... 128 7.15 ........................................... Air Hose To Platform 76 - Option .............................................. 129 7.16 ........................................... Work Light- Platform Mounted- Option ................................... 130 7.17 ........................................... LPI Gas Dual Fuel (Liquid) C68/C76 - Option ........................... 132 7.18 ........................................... LPIGas Fuel (Liquid) 58/76 - Option .......................................... 134 7.19 " ......................................... Isuzu Diesel Engine - Option ... ....................................... .... .... .... 136 7.20 ........................................... EnginelPump Assembly-Isuzu Diesel 58/76 - Option ................. 138 7.21 ........................................... Fuel Line Installation-Isuzu Diesel 58/76C - Option ................... 139 7.22 ........................................... 4-Wheel Drive - Option........................... ......................... .......... 140 7.23 ........................................... Axle Assembly 58/68 Fixed Drive - Option ................................ 141 7.24 ........................................... Hose Kit - 68/76 4WD Chassis - Option .................................... 142

68916 ......................................... Hydraulic Schematic 69564 ......................................... Electrical Schematic


()

()

FIGUREA-SerialNumberLocation •

2

The CONDOR® Model 58/68/76 Serial Number is stamped in three locations on the machine.

1. The first place to find the serial number stamp is on the data plate affixed to the chassis, as indicated on the illustration above.

2. Another serial number stamp is located on the steer axle, as shown above.

3. The third serial number stamp is located on the turret plate, near the lower control console, as shown above.


• FIGUREB-Recommended Spare Parts List


QTY PART NUMBER DESCRIPTION

1 32002 ............................ Slope Sensor 1 32585 ............................ Holding Valve Cartridge 4 33403 ............................ Plastic Track Repair Link 1 35031 ............................ Cartridge 3-Way-2 Position 1 40208 ............................ Switch, Limit Bracket 1 40865 ............................ Controller 12VDC 2 40872 ............................ Toggle Switch, Platform & Ground Controls 1 40876 ............................ Toggle Switch 1 50075 ............................ Toggle Switch 1 58079 ............................ Solenoid Valve 2 Pos - 3 Way 1 67275 ............................ Relay 2-Pole 2 67280 ............................ Bosch Relay 1 67947-010 ..................... Circuit Breaker 4 1 1 1 1 8 4 2 4 1 1 1 2 1 1

67408 ............................ Hydraulic Filter Element 80026 ............................ Toggle Switch - Select Platform/Ground 80045 ............................ Relay 3-Pole GNHOO 113 ................... Pilot Valve Assembly GNHOI019 ................... Shuttle Valve Assembly GNHOI020 ................... O-Ring (Shuttle Valve) GNHOI021 ................... Back-Up Ring (Shuttle Valve) 69329 ............................ Fuel Cap A630-58/68/76 ............. Operator/SafetyiParts Manuals 34354 ............................ Manual Holder (Tube W/Caps) 50316 ............................ HydraulicFillerCap 35031 ............................ Solenoid Cartridge Assembly (Aux. Function) 30289 ............................ Dust Cap (2WD Only) 66751 ............................ FootSwitch Decal Kit *69626-001 ................... Model 58 *69626-002 ................... Model68 *69626-004 ................... Model 76

1 40869 ............................ Upper Control Box Decal 1 36287 ............................ N.C. Logic Cartridge 1 36285 ............................ N.O. Logic Cartridge 1 67401 ............................ FlowDividerCombiner 1 36286 ............................ Counterbalance Cartridge 1 32585 ............................ Counterbalance Cartridge 1 67486 ............................ Circuit Relief Valve


I)

FIGUREB-RecommendedSparePartsList •


Spare Parts if Equipped With Ford 2.3L Gasoline Engine


1 32111 ............................ Throttle Solenoid 4 67957 ............................ In-LineFuelFilter 2 67944 ............................ Engine Mounts 1 NNV01007 ................... ThrottleLinkageBallloint 1 NNV01008 ................... Throttle Linkage Rod End 1 67157-003 ..................... Oil Pressure Switch

Spare Parts if Equipped With Isuzu C240 Diesel Engine


2 1 1 1 1 1 1 1

80303 ............................ Motor Mount 36387 '" ......................... Radiator Cap 80844 ............................ Air Inlet Cap 40808 ............................ Throttle Solenoid 67157-003 ..................... Oil Pressure Switch 15376-012 ..................... Decal, Diesel 67812 ............................ Decal, Glowplug 34995 ............................ Fuel Solenoid


• FIGUREC-HowtoOrderParts

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 partes) you require, and always provide a complete description of all parts.

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

4. Parts needed for a warranty repair must be purchased through the Condor 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-i.e., UPS, Federal Express, or preferred truck line. When shipping Federal Express, your customer account must be given at the time of the order.

6. Condor Div. classifies its orders in the following ways:

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

Order to be shipped within 1 week.

7. 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.


-)

ACCOUNT # ,-

) I NAME

N

D F S 0 ADDRESS

T -R

0 M

M A CITY

E T

R I 0 PHONE

N ( ) CDST. PURCHASE ORDER NO.

SHIPPING INSTRUCTIONS

PART NUMBER

-

- )

-\ ) -

FIGURE C-How to Order Parts

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

I PURCHASER

STATE ZIP

FAX

( ) I ORDER DATE

I

QTY.

SALES ORDER #

NAME

S W>DRESS H T I 0 P ~ITY STATE ZIP

~HONE FAX ( ) ( )

I REQUEST DATE SPECIAL MARKS & NUMBERS

I

DESCRIPTION

FOR ORDER STATUS PLEASE CHECK APPROPRIATE BOX BELOW

EMERGENCY

STOCK


NOTES

•

• FIGURE 1.1: 68FinaiAssembly

4

5 1

3


56

o

o

2

)

FIGUREl.l: 68 Final Assembly •

ITEM PART NUMBER DESCRIPTION QTY Ref. MDC68 ......................... Models 68 ....................................................................................... Ref.

1 68132 ............................ BoomAssembly .................................................................................. 1 2 69503 ............................ Turret, Gas Assembly .......................................................................... 1 3 69071 ............................ Carriage Assembly .............................................................................. 1 4 68564 ............................ Platform Assembly, 5' Top-Mounted/Non Rotation ............................ 1 5 . 38627 ............................ Control Box S-S Platform ....................... : ............................................ 1

-6 68894 ............................ Pin W eldm ent, 58/76 Boom/Turret ...................................................... 1 -7 80258 ............................ Pin, Slave Cylinder to Boom ................................................................ 1 -8 32634 ............................ Pin, Boom to Skirt ................................................................................ 1 -9 ...................................... Paint, Epoxy Gray Finish ............................................................... 3Gal.

-10 69564 ............................ Schematic, MDC 68/76 Electric .......................................................... 1 -11 68916 ............................ Schematic,Models-58/68/76Hydraulic .............................................. 1 -12 40207 ............................ Switch, Limit & Bracket ...................................................................... 1 -13 68241 ............................ Pin, ToppingCylinderBoomEnd ......................................................... 1 -14 BOW34118 ................... Rivet, Pop I/g" x 1/2" ............................................................................ 42 -15 21040-003 ..................... Spacer, 7 5/16" + I/g" .............................................................................. 1 -16 BOW36052 ................... Bolt, Hex.38-16UNCx.75 Gr8 ......................................................... 1 -17 BOW30000 ................... Bolt, Hex .25-20UNC x .50 ............................................................... 20 -18 BOW31325 ................... Washer, Split Lock ,25"ID ................................................................... 8 -19 BOW31431 ................... Washer, Flat .25"ID x .63"OD .......................................................... 12 -20 BOW30077 ................... Bolt, Hex .44-14UNC x .750 ............................................................... 3 -21 BOW31328 ................... Washer, Lock 7/16" ............................................................................... 3 -22 BOW30225 ................... Bolt, Hex .38-24UNF x .50 ................................................................. 1 -23 BOW36727 ................... Lock Washer 3/g" Dia .......................................................................... 2 -24 BOW30062 ................... Bolt, Hex .38-16UNC x 3.00 ............................................................... 1 -25 BOW34274 ................... Nut, Hex Lock 3/g"-16UNC ................................................................. 1 -26 BOW41143 ................... Screw, Set Soc . .38-16UNC c .50 ...................................................... 2 -27 BOW30229 ................... Bolt, Hex.38-24UNFx 1.00 ............................................................... 1 -28 BOW31144 ................... Screw, Slotted Round # 1 0-32UNF x .50 ............................................. 2 -29 ...................................... Fuel, Gasoline, Regular ................................................................. 10GL -30 ...................................... Oil, Hydraulic Tellus T32 .............................................................. 35GL -31 ...................................... Paint, Yellow .................................................................................. 5GL -32 BOW30002 ................... Bolt, Hex .25-20UNC x .750 ............................................................. 14 -33 69262-002 ..................... Decal Kit, R#69574 Model 68 ............................................................. 1 -34 67793 ............................ Clamp, Cable 2 3/4" .............................................................................. 2 -35 34354 ............................. Holder, Safety Manual-Black Caps ..................................................... 1 36 66751 ............................ Foot Switch With Guard + Cable ......................................................... 1 37 34667 ............................ Retainer, Foot Switch 77 Ig" ................................................................. 1

-38 67885 ............................ Pad, Wear ............................................................................................ 2 -39 ...................................... Oil,Motor30-Wt. ........................................................................... 5Qt. -40 67124-003 ..................... Locknut 1.00"NPT ............................................................................... 1 -41 67114-015 ..................... Strain Relief 1 NPT .87/.99 ................................................................. 1 -42 67123-003 ..................... Seal, Connector Elect. 1" ..................................................................... 1 -43 67114-003 ..................... Strain Relief 1/2" NPT .37/.5 ................................................................ 1 -44 67123-001 ..................... Seal, Connector Elect. 1/2" ................................................................... 1 -45 67124-001 ..................... Locknut, 1/2" NPTConduit ................................................................... 1 -46 LBLOI070 ..................... Bumper, Recessed Rubber .................................................................. 2 -47 ...................................... Nameplate ........................................................................................... 1

- Indicates Items Not Shown


• FIGURE!.!: 68 Final Assembly

4

3


56

D

2

)

')

)

)

FIGUREl.l: 68 Final Assembly 0 •


-48 38068 ............................ Cable Assembly, Battery-Emerg. Pump ............................................. 1 -49 21793 ............................ Striker Plate ......................................................................................... 2 -50 . 69541 ............................ Hose Kit, 58/68 TurretIBoom ................. : ............................................ 1 -51 69539 ............................ Hose Kit, 58/68/76 2WD Chassis ........................................................ 1 -52 66323 ............................ Condor Key FOB ................................................................................ 1 -53 69497 ............................ 11 OVoit Line To Platform/Console Assembly .................................. '" 1 -54 A630-68 ........................ Manual OIMIP 58/68/76 ...................................................................... 1 -55 92344-001 ..................... Operator'sManuaI58/68/76 ................................................................ 1 56 69499 ............................ Cover Installation, 58/76 Turret ........................................................... 1

-57 66727 ............................ Manual, LRG-423 Ford Engine Service ............................................... 1



• FIGURE 1.2: MDC 76 Final Assembly

•

4 5

1


48

o

2

3

)

)

i ~)

ITEM

Ref. 1 2 3 4 5

-6 -7 -8 -9

-10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25 -26 -27 -28 -29 -30 -31 -32 -33 -34 -35 -36 -37 -38 -39 -40 -41 -42 -43 -44 -45 -46 -47 48

-49 -50 -51

PART NUMBER DESCRIPTION FIGURE 1.2: MDC76FinalAssembly 48

QTY

MDC76 .......................... Model 76 .............................................................................................. Ref. 68134 ............................. Boom Assembly ........................................................................................ 1 69520 ............................. Turret, Gas Assembly ............................................................................... 1 69073 ............................. Carriage Assembly .................................................................................... 1 68564 ............................. 5' Platform Top MountedINon Rotation ................................................... 1

·38627 ............................. Upper Control Box ..................................... ~ .............................................. 1 ....................................... Oil, Motor 30-Wt. ................................................................................. 5Qt.

68894 ............................. Pin Weldment, 58176 Boom Turret. .......................................................... 1 80258 ............................. Pin, Slave Cylinder To Boom .................................................................... 1 32634 ............................. Pin, Boom To Skirt ................................................................................... 1 ....................................... Paint, Epoxy Gray Finish ............................... '" ................................. 3Gal.

69554 ............................. Schematic C68176 Electric ....................................................................... 1 40207 ............................. Switch, Limit & Bracket ........................................................................... 1 68241 ............................. Pin, Topping Cylinder Boom End ., .................................. , ........................ 1 BOW34118 .................... Rivet, Pop I/g" x 1/2" •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••.•••••••••••• 42 32595 ............................. Pin, Connect Elect Cannon ....................................................................... 2 21040-003 ...................... Spacer, 7 5/16" X I/g" ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••.•••••••••••••• 1 68922 .............. ; .............. Harness, Valve .......................................................................................... 1 BOW30000 .................... Bolt, Hex .25-20UNC x .50 .................................................................... 20 BOW31325 .................... Washer, Split Lock .25"ID ....................................................................... 8 BOW31431 .................... Washer, Flat .25"ID x .63"OD ............................................................... 12 BOW30077 .................... Bolt, Hex .44-14UNC x .75 ...................................................................... 3 BOW31328 .................... Washer, Lock 7/16" •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 3 BOW30225 .................... Bolt, Hex .38-24UNF x .50 ....................................................................... 1 BOW36727 .................... Lock Washer, 3/g"Dia ............................................................................... 2 BOW30062 .................... Bolt, Hex .38-16UNC x 3.00 .................................................................... 1 BOW30002 .................... Bolt, Hex .25-20UNC x .75 .................................................................... 14 BOW34272 .................... Nut, Hex Lock .25-20UNC ..................................................................... 14 99011 ............................. Decal, KitMDL76 R#69574 ..................................................................... 1 67793 ............................. Clamp, Cable 2 31J" .................................................................................. 2 34354 ............................. Holder, Safety Manual, Black Caps .......................................................... 1 66751 ............................. Foot Switch, With Guard + Cable ............................................................ 1 34667 ............................. Retainer, Foot Switch 7 7/g" .......................•.............................................. 1 67885 ............................. Pad, Wear ................................................................................................. 2 67124-003 ...................... Locknut 1.00"NPT .................................................................................... 1 68916 ............................. Schematic MDLS 58/68176 Hydraulic ...................................................... 1 67114-015 ...................... Strain Relief 1 NPT .87/.99 ...................................................................... 1 67123-003 ...................... Seal, Connector Electric 1.00" .................................................................. 1 67114-003 ...................... Strain Relief 112" NPT .37/.5 .................................................................... 1 67123-001 ...................... Seal, Connector Electric 1/2" ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1 67124-001 ...................... Locknut, 1/2" NPT Conduit ....................................................................... 1 LBLOI070 ...................... Bumper Recessed Rubber ......................................................................... 2 ....................................... NamePlate, Boom Identification ............................................................... 1

80027 ............................. Meter, Hour 4/0DC ................................................................................... 1 66323 ............................. Condor Key FOB ...................................................................................... 1 69497 ............................. 110 Line To Platform/Console Assembly ................................................. 1 A630-68 ......................... Manual, OIMIP 58/68176 .......................................................................... 1 92344-001 ...................... Operator's Manual 58/68176 ..................................................................... 1 69499 ............................. Cover Installation 58176 Turret ................................................................ 1 66727 ............................. Manual LRG-423 Ford Engine Service ..................................................... 1 69542 ............................. Hose Kit 76 TurretIBoom .......................................................................... 1 69539 ............................. Hose Kit 58/68176 2WD Chassis .............................................................. 1

- Indicates Items Not Shown MANUAL 92344-003

OCTOBER 1996

'~.

PARTIAL VIEW D

58/68/76 STANDARD

19 5 20

28

2

28

(

VIEW C

13

8 6 8 6

~ ....

·"·OM ". i' l:7' " 0

. -. ".--=-=----

u .~-===_ ==--

Ew A-A PARTIAL VI

i ~ "'0

~ U -~ g (")

> r C/). -r S C/).

~ ..., -~

)

REF

4 PL

ITEM

Ref. Ref. Ref.

*1 *2 *3 *4 *5 *6 *7 *8 *9

*10 *11 *12 *13

14 *15 *16 *17 *18 *19 *20

21 22 23 24

*25 *26

*27

26

~ 11 16

PARTIAL VIEW B CNTRWT IN/LH DOOR

SHOWN OPEN

PART NUMBER


DESCRIPTION

18

7

17 1


26

DecalKitAssembly CD

24 30

/

ooimrn II 15

QTY

69626-001 ...................... Decal Kit 58 ........................................................................................ Ref. 69626-002 ...................... Decal Kit 68 ........................................................................................ Ref. 69626-003 ....................... Decal Kit 76 ........................................................................................ Ref. 21971-002 ...................... Decal, Do Not Lift Wheels ....................................................................... 3 58419 ............................. Tape OrnlRed 5" ............................................................................... 12LF 21850 ............................. Decal, Hydrdaulic Fluid ............................................................................ 1 81417 ............................. Decal, Rated Work Load .......................................................................... 1 21882-001 ...................... Decal, Keep Clear ..................................................................................... 2 35042 ............................. Decal, Forward (ARROW) ...................................................................... 2 21882-003 ...................... Decal, Danger "MUST NOT OP" ............................................................. 1 35043 ............................. Decal, Forward ......................................................................................... 1 21658 ............................. Decal, 58/68/76 Transportation ................................................................ 2 21854 ............................. Decal, Caution Welding ............................................................................ 1 34947 ............................. Decal, Drive ............................................................................................... 1 54984-006 ...................... Decal, 110 Volt Ext. To Platfonn ............................................................. 1 37419 ............................. Decal, Ramping Control Panic Stop ......................................................... 1 BOW34105 .................... Rivet, Pop .093 ........................................................................................ 4 54416 ............................. Decal, Caution Tie Down Ring ................................................................. 2 69573 ............................. Decal, Boom Upper Caution ..................................................................... 1 38533 ............................. Decal Boom Lower Caution ...................................................................... 1 21882-004 ...................... Decal, "DANGER" .................................................................................... 2 21079 ............................. Decal. Lube Fitting .................................................................................... 1 21849 ............................. Decal, Gas ................................................................................................. 1 69437-003 ...................... Decal, Condor -CO- ................................................................................ 2 69437-004 ...................... Decal, Condor -ND- ................................................................................ 2 69473-005 ...................... Decal, Condor -OR- ................................................................................ 2 69473-001 ...................... Decal, Die-Cut Condor ............................................................................. 1 68859 ............................. Decal, Oil Dipstick .................................................................................... 1 37958-125 ...................... Decal, 1250 LB Rated Work Load (Model 58) ....................................... 2 37958-800 ...................... Decal, 800 LB Rated Work Load (Model 68) ......................................... 2 37958-500 ...................... Decal, 500 LB Rated Work Load (Model 76) ......................................... 2 40791-005 ...................... Decal, 58 ................................................................................................... 2 40791-006 ...................... Decal, 68 ................................................................................................... 2

- Indicates Items Not Shown ) * Indicates Items In Essential Decal Kit


19 5 20

I~-- ___ SEE vn (l \ _ ~_ -:;~~ ~ B~~_

\l ~~ ~ ~ ........... -...• _ .. --

PARTIAL VIEW D

SBjSRjJS C;TANDARD

28

B 6

TIAL VIEW A-A PAR

8 6

)

)

Decal Kit Assembly •

24 30

26

10 '

REF 50~ ~ 4 PL 14 U ~

11 16

~, ~

15

ITEM

PARTIAL VIEW B CNTRWT W/LH DOOR

SHOWN OPEN

PART NUMBER


DESCRIPTION


QTY

*28 21971-006 ...................... Decal, Tire Pressure 70 PSI (Model 58) ............................................. .... 2 21971-005 ...................... Decal, Tire Pressure 75 PSI (Model 68) ................................................. 2 58398 .............. : .............. Decal, Tire Re;lacement Foam (Model) .................................................. 2

29 36894 ............................. Decal, 1250 LBS (Model 58) ................................................................... 1 36888 ............................. Decal, 800 LBS (Model 68) ..................................................................... 1 36885 ............................. Decal, 500 LBS (Model 76) ..................................................................... 1

30 58420 ............................. Tape OrnlRed 7" ............................................................................ 4.80LF

50 Ref ................................. Nameplate, Boom Identification ........................................................... Ref.

- Indicates Items Not Shown * Indicates Items In Essential Decal Kit


2 l' Carriage Assembly 68 CIt FIGURE ..

00 no I( i

V o 0 0


00 N

00 ,.......

)

)

/)

)

ITEM:

Ref 1 2 3 4 5 6 7 8 9

10 11 12 13 14 15

16 17 18 19 20 21 22 23 24 25 26 T7 28 29 30 31 32

-33 -34 -35 -36 -37 -38 -39 40 -41 -42 -43 -44 -45 -46 -47 -48

PART NUMBER DESCRIYfION

FIGURE2.1: CarriageAssembly68 CO QfY

69071 ................................ Carriage Assembly 68 ............................................................................... Ref 68929 ................................ Chassis We ldm ent 58/68/76 ........................................................................... 1 35874 ................................ Steering Knuckle Weldment LH .................................................................... 1 35875 ................................ Steering Knuckle WeldmentRH .................................................................... 1 35883 ................................ King Pin ......................................................................................................... 4 35873 ................................ Bearing, Thrust .............................................. : ............................................... 2 29043 ................................ Washer, Flat 1.75"IDx3.75" x 3/16" •••••••••••••••••••••••••••••••••••••••••••••••••••••••••.••••••• 6 35884 ................................ Nut, Hex Slotted 1.75-5-UNC-2 ....................................................................... 4 BOW38253 ....................... Pin, 3/1/ Dia. x 3.00" Long Cotter ................................................................. .4 BOW7586 ......................... Fitting, Grease .250NPT STR ......................................................................... 2 BOW7587 ......................... Fitting,Lube.25NPTElbow ........................................................................... 2 21492 ................................ Torque Hub 54: 1 Ratio ................................................................................... 2 BOW30145-175 ................. Bolt,Hex.63-11UNCx 1.75 ........................................................................... 16 BOW36731 ....................... Washer, SplitLock .63ID ............................................................................. 16 BOW31207 ....................... Nut,Hex 5

/ s"-IIUNC .................................................................................... 16 35821 ................................ Motor, Hydraulic Brake ................................................................................. 2 VRH02102 ......................... Motor ............................................................................................................ 1 VRH01818 ......................... Seal Kit .......................................................................................................... 1 VRH02000 ......................... Brake ............................................................................................................. 1 VRHO 1789 ......................... Seal Kit .......................................................................................................... 1 BOW36106 ....................... Bolt,Hex.50-13UNCx 1.50" ........................................................................... 4 BOW36729 ....................... Washer, Split Lock .50"ID ............................................................................ .4 67466 ................................ Swivel Joint, Elbow ........................................................................................ 4 68934 ................................ Rod, Tie 48 3

/ 16" Lg ..................................................................................... 1 67497 ................................ Tie Rod End RH ............................................................................................. 1 67495 ................................ Tie Rod End LH ............................................................................................. 1 BOW34240 ....................... Nut, Hex Jam 1.13-12UNFRH ......................................................................... 1 BOW34241 ....................... Nut, Hex Jam 1. 13-12DNFLH ......................................................................... 1 B0W7578 ......................... FittingLube 1/4-28UNF ................................................................................. 2 BOW31438 ....................... Washer, Flat 3/4"ID ....................................................................................... 4 92105 ................................ Nut, Spindle M66915 .................................................................................... 2 92106 ................................ CotterPin ....................................................................................................... 2 35088 ................................ Cylinder, Hydraulic-Steering ......................................................................... 1 35887 ................................ Pin-Cyl inder To Steer Knuckle Cyl Bracket ................................................... 2 36855 ................................ Assembly, Hydraulic Tube Steer .................................................................. .4 58425 ................................ Vent,5PSI I

/ 4"NPTRelief .............................................................................. 2 02461 ................................ Straight MP06 FP04 ....................................................................................... 2 BOW30145-275 ................. Bolt,Hex.63-11UNCx2.750 ......................................................................... 16 BOW36707 ....................... Washer, Flat 5/8" ID SAE ................................... , ......................................... 16 BOW36731 ....................... Washer, Split Lock .63 "ID ........................................................................... 16 30288-002 .......................... Nut, Wheelcone 3/4"-17UNF ....................................................................... 40 36707 ................................ Manifold Assembly, Drive ............................................................................ 1 BOW30054 ....................... Bolt,Hex.38-16UNCx 1.00 ............................................................................. 2 BOW30055 ....................... Bolt, Hex.3 8-16UNC x 1.25 ............................................................................. 3 BOW36727 ....................... Lock Washer 3/8" Dia .................................................................................... 3 37676 ................................ Cover, Drive Axle .......................................................................................... 1 36561 ................................ Cover, Axle .................................................................................................... 3 66191-012 .......................... Nut, Hex Thick Slotted 3/4" ............................................................................ 2 BOW38250 ....................... PinCotter.188" Dia.x2.00"Lg ....................................................................... 4 BOW36720 ....................... Washer, Flat 1.00" ......................................................................................... 4 35913 ................................ Assembly, Idler Hub ...................................................................................... 2 21983-R ............................. Tire/Wheel Assembly RightDrive ................................................................. 2 21983-L ............................. TirelWheel Assembly Left Drive ................................................................... 2


OCTOBER 1996

• FIGURE2.2: Carriage Assembly 76


-)

)

)

ffEM

Ref. 1

-2 3 4 5 6

PART NUMBER DESCRIPTION

FIGURE2.2: CarriageAssembly76 0 QTY

69073 ................................ Carriage Assembly 76 ................................................................................. Ref. 68929 ................................ ChassisWeldment58/68176 ............................................................................ 1 68935 ................................ SteerlDrive Installtion .... ........ ......................................................................... 1 35874 ................................ -Steering Knuckle Weldment LH ............... ............................. ...... .................. 1

.35875 ................................ -Steering Knuckle WeldmentRH .................................................................... 1 35883 ................................ -KingPin ........................................................ : ................................................ 4

7 29043 ................................ -Washer, Flat 1.75"IDx 3.75" X 3/16" •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 6 8 35884 ................................ -Nut, Hex Slotted 1.75-5-UNC-2 ...................................................................... 4 9 BOW38253 ....................... -Pin, 3/16" Dia. x 3.00" Long Cotter .................................................................. 4

10 B0W7586 ......................... -Fitting, Grease .250NPT STR ......................................................... , ............... 2 11 BOW7587 ......................... -Fitting, Lube.25NPTElbow ........................................................................... 2 12 21492 ................................ -Torque Hub 54: 1 Ratio ................................................................................... 2 13 BOW30145-175 ................. -Bolt,Hex.63-11UNCx 1.75 ............................................................................ 16 14 BOW36731 ....................... -Washer, SplitLock.63lD .............................................................................. 16 15' BOW31207 ....................... -Nut,Hex 5

/ g"-IIUNC .................................................................................... 16 16 35821 ................................ -Motor, Hydraulic Brake ................................................................................. 2

WH02102 .......................... Motor ............................................................................................................. 1 WH01818 ......................... Seal Kit ........................................................................................................... 1 WH02000 ......................... Brake .............................................................................................................. 1 WHO 1789 . '" ..................... Seal Kit .......................................................................................................... , 1

17 BOW36106 ....................... -Bolt,Hex.50-13UNCx 1.50" ........................................................................... 4 18 BOW36729 ....................... -Washer, Split Lock .50"10 ............................................................................. 4 19 67466 ................................ -Swivel Joint, Elbow ........................................................................................ 4 20 68934 ................................ -Rod, Tie 48 3

/ 16" Lg ...................................................................................... 1 21 67497 ................................ -Tie Rod End RH ............ ...... ..................... ................................... ................... 1 22 67495 ................................ -Tie Rod End LH ............................................................................................. 1 23 BOW34240 ....................... -Nut, Hex Jam 1. 13-12UNFRH ........................................................................ 1 24 BOW34241 ....................... -Nut,HexJaml.13-12UNFLH ......................................................................... 1 25 BOW7578 ......................... -Fitting Lube 1/4"-28UNF ................................................................................ 2 26 BOW31438 ....................... -Washer, Flat 3

/ 4"ID ........................................................................................ 4 n 92105 ................................ -Nut,SpindleM66915 .................................................................................... 2 28 92106 ................................ -Cotter Pin ...................................................................................................... 2 29 35088 ................................ -Cylinder, Hydraulic-Steering ......................................................................... 1 30 35887 ................................ -Pin-Cylinder To Steer Knuckle Cyl Bracket ................................................... 2 31 36855 ................................ -Assembly, Hydraulic Tube Steer ................................................................... 4 32 58425 ................................ -Vent, 5PSI 1/4"NPTRelief .............................................................................. 2 33 02461 ................................ -Straight MP06 FP04 ....................................................................................... 2

-34 66191-012 .......................... Nut, Hex Thick Slotted 3/4" ............................................................................. 2 35 BOW38250 ....................... Pin, Cotter. 188Diax2.00"Lg ........................................................................... 4 36 BOW36720 ....................... Washer, Flat 1.00" .......................................................................................... 4

-37 35913 ................................ Assembly, Idler Hub ....................................................................................... 2 -38 BOW30145-275 ................. Bolt,Hex.63-11UNCx2.750 ........................................................................... 16 -39 BOW36707 ....................... Washer, Flat 5/8" 10 SAE .............................................................................. 16 -40 BOW36731 ....................... Washer, SplitLock.63"ID ............................................................................. 16 -41 68409-R ............................. Tire & Wheel Assembly 76 Right ................................................................... 2 -42 30288-002 .......................... Nut, Wheelcone 3/4"-17UNF ......................................................................... 40 -43 36561 ................................ Cover, Axle ..................................................................................................... 3 -44 BOW30054 ....................... Bolt, Hex.38-16UNCx l.00 .............................................................................. 2 -45 36707 ................................ Manifold Assembly, Drive ................................ , ............................................ 1 -46 BOW30055 ....................... Bolt,Hex.38-16UNCx 1.25 .............................................................................. 3 -47 BOW36727 ....................... Lock Washer 3/g" Dia ..................................................................................... 3 -48 69065 ................................ Folding Step ................................................................................................... 1 -49 68409-L ............................. Tire & Wheel Assembly 76 Left ..................................................................... 2


OCTOBER 1996

• FIGURE2.3: DriveManifoldAssembly

G

82

3

5

TWO WHEEL DRIVE

TO & FROM DIRECTIONAL CONTROL VALVE

FOUR WHEEL DRIVE

-'----- _____ L __ 82 83 A2


A1

) A3

I)

FIGURE2.3: Drive Manifold Assembly •


Ref. 36707 ............................. Drive Manifold Assembly .................................................................... Ref. 1 36287 ............................. Cartridge, Logic Element NC S2 .............................................................. 2 2 66693 ............................. Flow Divider/Combiner ............................................................................ 1 3 . 34967 ............................. Manifold, Drive .......................................... ~ .............................................. 1 4 36286 ............................. Cartridge, Counterbalance Valve .............................................................. 2 5 67401 ............................. Flow Divider Combiner ............................................................................. 1



• FIGURE 2.4: Steering Cylinder Parts Breakdown


17

16

)

)

.)

FIGURE2.4: SteeringCylinderPartsBreakdown •


-1 35088 ., .......................... Steering Cylinder (Texas Hydraulics) ................................................. 1 2 ...................................... Rod End, Female ................................................................................. 1 3 ....................................... Spherical Bearing ................................................................................ 1 4 ...................................... Jam Nut ................................................................................................ 1 5 ...................................... Rod ...................................................................................................... 1 6 ...................................... Cap, Head ............................................................................................ 1 7 ...................................... Head .................................................................................................... 1 8 ...................................... Piston ................................................................................................... 1 9 ...................................... Tube Weldment ................................................................................... 1

10 ...................................... Spherical Bearing ................................................................................ 1 -11 35689 ............................ Seal Kit (includes items 12-21) ............................................................ 1 12 ...................................... Set Screw............................................................................................ 1 13 ...................................... NylonPlug ........................................................................................... 1 14 ...................................... Wiper ................................................................................................... 1 15 ...................................... U-Cup .................................................................................................. 1 16 ...................................... Ring, Back-Up ..................................................................................... 1 17 ...................................... O-Ring ................................................................................................. 1 18 ...................................... O-Ring ................................................................................................. 1 19 ...................................... Wear Ring ........................................................................................... 1 20 ...................................... Seal, AQ .............................................................................................. 1 21 ...................................... Lock Nut .............................................................................................. 1



• FIGURE2.5: Tire & Wheel Assembly, Drive Axle 58/68

2


Ref. 21983 ............................ Tire & Wheel Assembly, Drive (each contains the following) ....... 2 1 21494 ............................ Tire, All-Traction High Flotation......................................... ..... ....... 1 2 21950 ............................ Wheel Assembly, Drive .......................................................... _ ....... 1



)

( )

)

)

ITEM

Ref. -I -2

FIGURE2.6: Tire & Wheel Assembly, Drive Axle 76 •

PART NUMBER DESCRIPTION QTY

68409 ............................ Tire & Wheel Assembly, Drive (each contains the following) " ........... 2 21483-R&L ................... Tire-Wheel Assembly, Drive ................................................................ 1

. PRC00021 .................... Charges to Foam Fill Tries ................................................................... 1



• FIGURE 2.7: IdlerHubAssembly


5

8

)

J

)

:)

FIGURE2.7: IdlerHubAssembly •


Ref. 35913 ............................ Assembly, Idler Hub ....................... '" ............................................. Ref. 1 36811 ............................ Assembly, Hub .................................................................................... 1 2 .92101 ............................ Seal, Grease ......................................................................................... 1 3 92098 ............................ Cone, Bearing...................................................................................... 1 4 92097 ............................ Cone, Bearing .............................................................................. ."....... 1 5 35914 ............................ Weldment, Idler Spindle ....................................................................... 1 6 CHBOOI0l .................... Washer, Non-Keyed ............................................................................ 1 7 92105 ............................ Nut, Spindle ......................................................................................... 1 8 92106 ............................ Pin, Cotter ............................................................................................ 1 9 30289 ............................ Cover, Dust ........................................................................... '" ............ 1



• FIGURE2.8: TorqueHubAssembly


10

1 . 10 42 !

)

:)

FIGURE2.8: TorqueHubAssembly 0 ITEM PART NUMBER DESCRIPTION QTY

-1 21492 ............................ Torque Hub Assembly ......................................................................... 2 2 EQEOI093 .................... Cover Assembly (includes items 3-10) ................................................ 1 3 . BOW39002 ................... -Bolt, Hex .25" - 20UNC x .75" long (Grade 8) ................................ 4 4 QTJ01565 ..................... -Cap, Disconnect .............................................................................. 1 5 QTJ01649 ..................... -Rod, Disconnect .............................................................................. 1 6 EQE01628 .................... --O-Ring ............................................................................................. 1 7 EQE01595 .................... -Pipe Plug ......................................................................................... 1 8 QTJ01583 ..................... -Cap, Cover ...................................................................................... 1 9 EQE01598 .................... --O-Ring ............................................................................................. 1

10 QTJ01639 ..................... -Cover ................................................................................................ 1 11 EQE01603 .................... Bolt, Hex .............................................................................................. 8 12 QTJ01596 ..................... Bolt, Shoulder ...................................................................................... 4 13 QTJ01661 ..................... O-Ring ................................................................................................. 2 14 EQEOI002 .................... RingGear ............................................................................................ 1 15 EQE01583 ..................... Thrust Washer ..................................................................................... 4 16 QTJ01590 ..................... Thrust Bearing ..................................................................................... 2 17 EQEOI051 .................... Gear, Input ........................................................................................... 1 18 EQEOI040 .................... Carrier Assembly (includes items 19-26) ............................................ 1 19 EQEOI086 .................... -Carrier ............................................................................................. 1 20 EQE01584 .................... -RoIIPin ............................................................................................ 3 21 EQEOI087 .................... -Thrust Washer ................................................................................. 6 22 EQEOI090 .................... -Thrust Washer ................................................................................. 6 23 EQEOI045 .................... -Roller, Needle ................................................................................ 84 24 EQEOI088 .................... -Spacer .............................................................................................. 3 25 EQEOI048 .................... --Gear, Cluster ................................................................................... 3 26 QTJ01633 ..................... -Shaft,Pinion ..................................................................................... 3 27 EQEOI050 .................... Thrust Spacer ...................................................................................... 1 28 EQEO 1 049 .................... Shaft, Input............... ........................................................................... 1 29 EQEOII09 .................... Gear, Intemal ....................................................................................... 1

-30 EQEOI085 .................... Hub-SpindleAssembly(includesitems31-41) .................................... 1 31 ~,qq~~.f.71?.3 .............. -RetainingRing ................................................................................. 1 32 QTJ01650 ..................... -Spacer ............................................................................................... 1 33 SHL01594 ..................... -Cone Bearing ................................................................................... 1 34 SHLOI004 ..................... -Cup Bearing ..................................................................................... 1 35 EQEO 1 083 .................... -Hub.................................................................................................. 1 36 EQEOI084 .................... -PipePlug ......................................................................................... 2 37 EQE01961 .................... -Stud ................................................................................................ 10 38 SHLO 1 002 ..................... -Bearing Cup ..................................................................................... 1 39 SHLO 1 003 ..................... -Bearing Cone .................................. ~ ................................................ 1 40 01579 ............................ -Seal .................................................................................................. 1 41 EQEO 1058 .................... -Spindle ............................................................................................. 1 42 EQEO 1618 .................... Retaining Ring ..................................................................................... 1 43 EQE01587 .................... RetainingRing ..................................................................................... 1 44 01600 ............................ Thrust Washer ..................................................................................... 2 45 EQEOI092 .................... Spring ................................................................................................... 1 46 EQEO 1044 .................... Coupling............................................................ ................................... 1


OCTOBER 1996

• FIGURE2.9: HydraulicMotorAssembly

3

7 7 3 8

7---

6=:\ \ 5, \

I

• I I I

\ I I I I I I I I

" \ ''''",- 28 ._29

30


I

i ' .... -l-16

1-17 __ I 18

! 19

20 -, I 10 '-, \)

.,I( ". I

"-24

)

~)

FIGURE2.9: HydraulicMotorAssembly •

ITEM PART NUMBER DESCRIPfION QIY

Ref VRH02101 ......................... Motor Assembly ......................................................................................... Ref Ref VRH01818 ......................... Seal Kit ........................................................................................................ Ref

1 ......................................... Woodruff Key ................................................................................................ 3 2 - ......................................... Drive Pin ........................................................ ; ................................................ 1 3 ......................................... Retaining Ring ................................................................................................ 2 4 .................................. '" .... Gear Drive (Standard) ..................................................................................... 1 5 ......................................... Spacer Washer ............................................................................................... 1 6 ......................................... Retaining Ring ............................................................................................. '" 1 7 ......................................... Bearing Race ................................................................................................... 2 8 ......................................... Thurst Bearing..... .................. .......... ............... ...................... ....... .......... ......... 1 9 ......................................... Needle Bearing ............................................................................................... 2

10 ...................................... ' ... Oil Seal ............................................................................................................ 3 11 ......................................... Rear End Cap .................................................................................................. 1

......................................... Rear End Cap (w/intemal drain) ...................................................................... 1 12 ......................................... TipSealRoller.65 ........................................................................................... 3

12a ......................................... Body Seal Roller .65 ................................................................. ~ ..................... 18 12b ......................................... Tip Seal Roller .98 ........................................................................................... 3 12c ......................................... Body Seal Roller .98 ....................................................................................... 18

13 ......................................... Rotor .98 ......................................................................................................... 1 13a ......................................... Rotor .65 ......................................................................................................... 1

14 ......................................... Seal Plate .98 ................................................................................................... 3 14a ......................................... Seal Plate .65 ................................................................................................... 3

15 ......................................... Abutment Valve .............................................................................................. 4 16 ......................................... Needle Bearing ............................................................................................... 4 17 ......................................... Step Bearing ................................................................................................... 4 18 ......................................... O'Ring ............................................................................................................. 4 19 ......................................... Back-Up Ring ................................................................................................. 4

......................................... Gear Drive (steel)-(-50 option) ........................................................................ 1

......................................... Gear Pinion (steel)-(-50 option) ....................................................................... 2 20 , ......................................... Dowel Pin ....................................................................................................... 2 21 ......................................... Cap Screw ....................................................................................................... 9 22 23 ......................................... Shaft Seal........................................................................................................ 1 24 ......................................... SAE B Front End Cap ........................... ............... .............................. ............. 1

......................................... SAE A Front End Cap ............................ ................ ......................................... 1

......................................... -27 SAE B Front End Cap ................................................................................ 1 25 ......................................... Displacement Housing ................................................................................... 1 26 ......................................... Retaining Ring ................................................................................................ 4 27 ......................................... Gear Pinion (standard) .................................................................................... 2 28 ......................................... K-Shaft 1" Keyed ........................................................................................... 1

......................................... S-Shaft 13 Tooth ............................................................................................. 1

......................................... K-ShaftForBrake ........................................................................................... 1

......................................... S-ShaftFor Brake ............................................................................................ 1 2f) ......................................... Gear Cover............................. ......................................................................... 1 30 ......................................... Cap Screw Self Tap ......................................................................................... 7 31 ......................................... Retaining Ring................................................................................................ 1 32 ......................................... O'Ring used with SAE A ................................................................................ 1

......................................... O'Ring esed with SAE B . ................................ ................................... ............. 1

......................................... O'RingusedwithSAEB-27 ............................................................................ 1 33 ......................................... SAEB-27,Front Sealing Cap ........................................................................... 1



o FlGURE2.l0: HydraulicBrakeAssembly

---'" ---.--..,...,-'..--'

r 11 f t I I \ \ L---"

MANUAL 92344-003

OCTOBER 1996

2

1

)

t)

)

FIGURE 2. 10: Hydraulic Brake Assembly •

IIEM PART NUMBER DESCRIPTION Q1Y

Ref VRII02000 ......................... Brake Assembly .......................................................................... '" '" ........... Ref Ref VRH01789 ........................ Seal Kit ....................................................................................................... Ref

1 ......................................... Housing .......................................................................................................... 1 2 ......................................... Spacer Ring 1.113 * * 2 Brake Code................................................................. 1

......................................... Spacer Ring .997 * * 3 Brake Code ............................... '" ................................ 1

......................................... Spacer Ring .881 * * 4 Brake Code ................ '" ...................................... : ........ 1 3 ......................................... Friction Disc .................................................................................................... .

......................................... * * 2 Brake Code .............................................................................................. 3

......................................... ** 3 BrakeCode .............................................................................................. 4

......................................... **4BrakeCode .............................................................................................. 5 4 ......................................... Plate Driver ...................................................................................................... .

...................... ....... ............ * * 2 Brake Code .................................................................................... '" ....... 2

......................................... ** 3 Brake Code .............................................................................................. 3

......................................... ** 4 Brake Code .............................................................................................. 4 5 ......................................... OlRing ............................................................................................................. 1 6 ......................................... Brass Washer ................................................................................................. 7 7 ......................... : ............... Cap Screw self tap .......................................................................................... 7 8 .. , ...................................... Adapter Plate ................................. ......................................... .............. .......... 1 9 ......................................... Die Spring .......................................................................... , ............................ 8

10 ......................................... Pressure Plate ................................................................................................. 1 11 ......................................... Back-Up Ring ................................................................................................. 1 12 ......................................... O-Ring ............................................................................................................ 1 13 ......................................... Cap Screw Socket Head .................................................................................. 8 14 ......................................... O-Ring ......................................................................... '" ................................ 1 15 ......................................... Back-Up Ring ................................................................................................. 1



• FIGURE2.11: Hose Kit-2WD Chassis 58/68/76

i-;-l -1 ---4'~ I \S

I 0 I ~ -~ I I 0 I ~

I ~(;- +---------~----------------------------~

I

I

4 ---4\~ +---------~--------------------~ \'-::...--

I I " J ----4,~ ..L..-____ --.--______ -,

I 'S

I I ~ I~~

I

I

ROTARY COUPLING

'8 '0

HOSES FOR.. • ... HOSES FOR TURRET CHASSIS

:3 I

t:l JJ I I

U STEERING CYLINDER


11 !

9

I I I

Ilpi I I I L __ Bl

(1Q)

SERIES/PARALLEL VALVE ASSY

8

Ai -------

)

/)

)

FIGURE2.11: Hose Kit-2WD Chassis 58/68/76 •

ITEM PART NUMBER DESCRIPfION QTY

Ref. 69539 ............................. Hose Kit -2WD Chassis58/68/76 ........................................................ Ref. 1 66043-0069.50 ............... Hose Assembly #03 67684 137 ST1-ST1 ........................................... 1 2 66697-069.50 ................. Hose Assembly #08 66675 J37 ST-ST ............................................... 1 3 . 66718-032.00 ................. Hose Assembly #12 66708 137 ST-90 ................................................. 1 4 66718-032.00 ................. Hose Assembly #12 66708 137 ST-90 ................................................ 1 5 66043-032.50 ................. Hose Assembly #03 67864 137 STJ-STJ ........................................... 1 6 66696-062.50 ................. Hose Assemlby #04 66646 137 ST-ST ............................................... 1 7 66696-062.50 ................. Hose Assembly #04 66646 13 7 ST -ST ............................................... 1 8 66082-050.00 ................. Hose Assembly #03 67684 J37 ST -90 ................................................ 1 9 66082-050.00 ................. Hose Assembly #03 67684 137 ST-90 ................................................ 1

10 65080-050.00 ................. Hose Assembly #06 66645 137 STJ-90 .............................................. 1 11 65080-050.00 ................. Hose Assembly #06 66645 137 ST1-90 .............................................. 1 12 66709-065.50 ................. Hose Assembly #12 66708 J37 ST-ST ............................................... 1 13 66718-070.50 ................. Hose Assembly #12 66708 137 ST-90 ................................................ 1 14 66718-066.00 ................. Hose Assembly #12 66708 137 ST-90 ................................................ 1 15 66718-068.00 ................. Hose Assembly #12 66708 137 ST-90 ................................................ 1



• FIGURE3.1: GasTurretAssembly68


7

5

)

i)

)

)

FIGURE3.1: GasTurretAssembly68 •


Ref. 69503 ............................. Gas Turret Assembly 68 .................................................................... Ref. 1 69505 ............................. Turret Weldment 58/68 .......................................................................... 1 2 69535 ............................. Rotation Installation, Turret 58/76 .......................................................... 1

-3 . 69536 ............................. Electric Installation 58/76 ........................................................................ 1 -4 69538 ............................. Hydraulic Installation MOC68 Turret ..................................................... 1 5 69533 ............................. Engine Installation 58/68/76 .................................................................... 1 6 68599 ............................. Assembly, Fuel Tank .............................................................................. 1 7 69511-001 ...................... Counterweight, MOL58/68 ..................................................................... 1

-8 40544 ............................. Bracket, Counterweight Mounting .......................................................... 1 -9 40063 ............................. Mounting Bracket, Counterweight .......................................................... 1

-10 BOW36152 .................... Bolt, Hex .63-11UNC x2.75 .................................................................. 4 -11 BOW36707-HD .............. Washer, Flat .63"10 Hard ....................................................................... 4 -12 BOW36607 .................... Nut, Hex .63-11 UNC .............................................................................. 4 -13 21131 ............................. Pin, Master Leveling Cylinder ................................................................. 1 -14 BOW32777 .................... Screw, Set Sq .. 75-10UNC x 4.00" ....................................................... 1



• FIGURE3.2: GasTurretAssemblyMDC76


7

5

)

-)

I,)

)

ITEM

Ref. 1 2

-3 -4 5 6 7

-8 -9

-10 -11 -12 -13 -14

PART NUMBER DESCRIPTION

FIGURE3.2: GasTurretAssemblyMDC76 0 QTY

69520 ............................. Gas Turret Assembly 76 .................................................................... Ref. 69521 ............................. TurretWeldment76 ................................................................................ 1 69535 ............................. Rotation Installation, Turret 58/76 .......................................................... 1 69536 ............................. Electric Installation 58/76 ....................................................................... 1

. 69537 ............................. Hydraulic Installation 76 Turret ................. : ............................................ 1 69533 ............................. Engine Installation 58/68/76 .................................................................... 1 68599 ............................. Assembly, Fuel Tank .............................................................................. 1 69511-002 ...................... Counterweight, MDL76 .......................................................................... 1 40544 ............................. Bracket, Counterweight Mounting .......................................................... 1 40063 ............................. Mounting Bracket, Counterweight .......................................................... 1 BOW36152 .................... Bolt, Hex .63-11 UNC x 2.75 .................................................................. 4 BOW36707-HD .............. Washer, Flat .63 "ID Hard ....................................................................... 4 BOW36607 .................... Nut, Hex .63-11UNC .............................................................................. 4 21131 ............................. Pin, Master Leveling Cylinder ................................................................. 1 BOW32777 .................... Screw, Set Sq .. 75-10UNC x 4.00" ....................................................... 1



• FIGURE3.3: RotationInstallation58/76

2

Ref. Turret

1

, ; .,

:~ ,

~~~; ====:::;


3

)

/

')

)

)

FIGURE 3.3: Rotation Installation 58/76 •

rrEM PART NUMBER DESCRIPTION QTY

Ref. 69535 ............................. Rotation Installation 58176 ................................................................... Ref. 1 69255 ............................. Assembly, Rotary Coupling 58176 ............................................................ 1 2 68119 ............................. Speed Reducer Assembly ................................ , ........................................ 1 3 , 36250 ............................. Gear Ring ................................................................................................... 1

-4 69576 ............................. Bolt, Kit, 58/76 ................................................................................. , ........ 1



8 FIGURE3.4: Rotary Coupling Assemhly 58/76

2

o


5

8 2

6

11

)

7

3

\ -j

r)

)

FIGURE3.4: Rotary Coupling Assemhly 58/76 •


Ref. 69255 ............................. Rotary Coupling Assembly 58/76 ......................................................... Ref. 1 32554 ............................. Coupling, Rotary 7-Port ............................................................................. 1 2 02525 ............................. Straight, MJ04 M004 ................................................................................ 3 3 -02677 ............................. Elbow, 90° MJ12 M012 ........................... : ............................................... 2 4 00267 ............................. Straight, MJ12 M012 ................................................................................ 2 5 00488 ... '" ....................... Tee, MJ06 F J06 MJ06 ............................. '" ............................................... 2 6 00303 ............................. Straight, MJ08 M012 ................................................................................ 2

-7 02664 ............................. Elbow, 90° MJ08 M012 ........................................................................... 2 8 00388 ............................. Straight, FJ08 MJ06 .................................................................................. 2

-9 00425 ............................. Fitting, MJ04 FJ06 ..................................................................................... 2 -10 00348 ............................. Straight, F J08 MJ04 .......... , ....................................................................... 2

11 02236 ............................. Elbow, 90° MJ04 M004 ........................................................................... 3



• FIGURE3.5: Speed Reducer Assemhly 58/76

I 1.36 REF ~ BRADEN

8 3 4 PL

0 J

4

l14 PL

10

7

19 20 -002

1 REF 1 6 REF 15REF 2 REF

PARTIAL SECTION 'A'

REF TU RRET _75 RE~ J BASE PU\ TE TULSA


12

\

16 2 PL

17

ONLY

1 REF16REF

13

2

lSREF 2 R::F

R::::- TURRET 8';SE PLATE

PARTIAL SECTION 'A'

)

'-j

)

)

FIGURE3.5: SpeedReducerAssemhly58/76 •


Ref. 68119 ............................. Speed Reducer Assembly 58/76 .......................................................... Ref. 1 21739-001 ...•.................. Speed Reducer Turret Rotation - BRADEN ............................................. 1

21739-002 ...................... Speed Reducer Turret Rotation - TULSA ................................................ 1 2 . 69639 ............................. Speed Reducer Plate, Turret ...................................................................... 1 3 32762 ............................. Motor, WHITE ......................................................................................... 1 4 68335 ............................. Assembly, Relief Valve ............................................................................. 1

32763 ............................. -Valve Assembly, Relief Cross Port ........................................................ 1 RTMOI004 ..................... --Valve Body for PIN 32763 Valve ......................................................... 1 67486 ............................. --Relief Valve Cartridge-ll00PSI ............................................................ 2 02338 ............................. -Elbow 90° MJ08 FJ08 .......................................................................... 2 00579 ............................. -Straight MJ08 M006 ............................................................................ 2

5 21906 ............................. Gear, Pinion .............................................................................................. 1 6 AQC23108 ..................... Gasket Top For Hydraulic Motor Mounting ............................................. 1 7 69644-001 ...................... Bolt Kit, Speed Reducer _ BRADEN ......................................................... 1

68644-002 ...................... Bolt Kit, Speed Reducer - TULSA ............................................................ 1 8 BOW46037 .................... -Bolt, Hex .31-18UNC x 3.0 ................................................................... 4 9 BOW31326 .................... -Washer, Lock .31 ID ............................................................................. 4

10 66110-065 ...................... -Washer, Ring Gear .63 ID .................................................................... 4 11 BOW33686-1 ................. -Bolt, Soc. HD .63-11 UNC x 2.0 GR8 - 69644-002 ..... : ...................... 4

BOW33685 .................... -Bolt, Soc. HD .63-11 UNC x 2.5 GR8 - 69644-001 ............................ 4 12 BOW32774 .................... -Screw, SQ HD Set .50-13UNC x 3.0 ................................................... 1 13 BOW32275 .................... -Nut, Jam .50-13UNC ............................................................................ 1 14 BOW39108 .................... -Bolt, Hex .50-13UNC x 2.0 ................................................................... 2 15 BOW36754 .................... -Washer, Flat .50 ID x 1.38 OD GR8 ................................................... 2 16 BOW39172 .................... -Bolt, Hex .75 x 10UNC x 2.0 GR8 ...................................................... 2 17 BOW36772 .................... -Washer, Flat .75 ID x 2.0 GR8 ........................................................... 2 18 BOW36754 .................... -Washer, Flat .50 ID x 1.38 OD - 69644-001 ....................................... 4

BOW36754 .................... -Washer, Flat .50 ID x 1.38 OD - 69644-002 ....................................... 2 19 BOW36110 .................... -Bolt, Hex .50-13UNC x 2.5 GR8 - 69644-001 .................................... 2

BOW36405 .................... -Bolt, Hex .50-20UNC x l.25 GR8 - 69644-002 .................................. 2 20 BOW36784 .................... -Nut, Hex Lock .50-13UNC - 69644-002 .............................................. 2



• FIGURE3.6: SwingBearing-BoltKit58/76

SIZE STEP BOLT HEADS

1/2-13UNC 1 st 25 LB.FT. 2nd 55 ±s LB. FT. 3rd 80 ±5 LB.FT.

5/8-11UNC 1 st :)u LB.FT. 2nd 110 +'" LB.FT. 3rd 170 +'" _J LB.FT.

NOTES:

1. LUBRICATE THREADS, BOLT SHOULDERS AND FLAT SURFACES OF \NASHERS WITH ENGINE OIL.

2. USE IMPACT '/vRENCH ONLY FOR INITIAL ASSEMBLY POSITIONING. DO NOT TORQUE OVER VALUE SHOWN IN 1 ST STEP.

3. APPLY TORQUE IN TWO ADDTIONAL STEPS USING CRISS-CROSS ALTERNATING TORQUE SEQUENCE.

18

I 4---1..-

( 13---r

\

6


7 5

REF CRISS-CROSS AL TERNA TING TORQUE SEQUENCE

SEE NOTE 3.

10 11

16

14

)

)

\)

ITEM

Ref. 1 2 3 4 5 6

PART NUMBER DESCRIPfION

FIGURE3.6: SwingBearing-BoltKit58/76 CD QTY

69576 ............................. Swing Bearing-Bolt Kit 58176 .............................................................. Ref. BOW36705-HD .............. Washer, Flat .50 Hard ............................................................................. 18 BOW36107 .................... Bolt, Hex .50-13UNC x 1.75 .................................................................. 18

.BOW36152 .................... Bolt,Hex.63-11UNCx2.75 .................................................................. 15 66316-063 ...................... 5

/ 8"-11 Hex Nut .......................................... : ............................................ 15 BOW36707-HD .............. Washer, Flat .63"ID Hard ................................................................. ~ ..... 33 BOW36146 .................... Bolt, Hex .63-11 UNC x 1.25 .................................................................... 3



4D FIGURE3.7: Electric Installation, Turret 58/76

Ref. 1 2 3 4 5 6 7 8 9

10 11 12 13


69536 ............................. Electric Installation, Turret 58/76 ............................................... Ref. 36141 ............................. Console, Ground Control .......................................................................... 1 67877 ............................. Plate, Mount-Control Box ......................................................................... 1

. 80188 ............................. Wobbulator And Speaker ........................... ~ .............................................. 1 32691 ............................. Battery, 12 Volt .......................................................................................... 1 81263 ............................. Angle, Battery Hold Down ........................................................................ 1 66270 ............................. 1-Bolt, .31 "ID x .68"OD ........................................................................... 2 67863 ............................. Battery Bracket, Weldment ....................................................................... 1 BOW31202 .................... Nut,Hex.31-18UNC ................................................................................ 2 BOW31432 .................... Washer, Flat .31"ID x .68"OD ................................................................. 2 68922 ............................. Harness, Valve 68-76 ................................................................................ 1 32002 ............................. Slope Sensor 2-Axis .................................................................................. 1 69525 ............................. Box Assembly, Engine Electric Ford LRG423 ......................................... 1 69202-001 ...................... Caplug, .25 x .35 . 1.00 ............................................................................ 2



C~) 27TMc 5.5 78 575 160 12-3/8 6-3/4 9-1/4 WHT 45 T 105 56/44 WT

WACO, TEXAS PROPRIETARY INFORMATION ~

THIS DRAWING ITS DESIGN, DETAIL. DIMENSIONS, TOLERANCES AND DISCLOSURE ARE THE CONFIDETIAL INFORMA liON AND EXCLUSIVE PROPERTY ~blJ[b[Ji;;'iYblJOO

1---+----+----+----1 OF CALAVAR CORPORATION. AND SHALL NOT BE TRACED. REPRODUCED OR CORPORA nON

1--_+-___ +-___ +-_--1 i~~IE~RII~RA~;I~~N~~N~~lDI6~L~1~AJ~RA~r)~~6~~jI6NAR~ILW~I~~~~ i-:T:::cIT=-L-=-E-----------------------------.J RESERVED.

UNLESS OTHERWISE SPECIFIED: BA TTERY, 12 VOLTS DIMENSIONS ARE IN INCHES TOLERANCES ON: ANGLE DECIMALS FRACTIONAL

A 4496 6/26/92 ±1/2' XX=i.O.l XXX=i.OlQ

11/10

-- A I DRAWING IREA

LTR. E.C.N. NO. DATE APPR. DRAWN EYEBARRA 4/24/<)1 NO.

- 2730 4/26/<)1 CHECKED 32691 LTR. E.R.N. NO. DATE APPR. APPROVED SCALE 1/1 I SHEET 1 OF 1

48 FIGURE 3.9: Box Assembly, 68/76 Ford Engine

o

24

o

2 PL

o

SEE NOTE 5 FUEL PUMP RELAY

!~ I --------------__ __ \

ENGINE IGNITION RELAY

i

~

THROTTLE RELAY

LOCKOUT OELAY RELAY

STARTER LOCKOUT

RELAY

LREF RESISTOR IN KIT 81877

HIGH TEMP

STARTER LOCKOUT

RELAY

GRN

HIGH TEMP

SHUTOFF RELAY

SEE NOTES

25A WHT ~ 5 BLK A I GRN REFERENCE: 81878

SEE NOTE 5 ENGINE HARNESS L-____ _

REF STARTER 1=GRN

2=WHT

5=BLK

NOTE:

1. CCNDUCTOR CABLE IS STANDARD. SEE OPTIONS FCR 6 & 8 CONDUCTOR CABLE.

2. CIRCUITS 5, SA, SA TO BE 12GA, ALL OTHERS 16 GA. 3. REe 69522, SCHEMATIC. 4. ITEM 23 IS NOT SHOVVN FOR CLARITY. 5. :SCLATE UNUSED (SPARE) 'NIRES. 6. FUC::L PUMP RELAY USED ONLY IF DUAL FUEL OPTiON

IS RE:OUiRED. OTHER'iYISE, ENERGIZE FUEL PUMP FROM CiRCUIT 31 A.

7. THiS D\"'C SUPERCEDES 69079.


o

2 PL

G 2 PL

12 13 4 PL

23

Q.

SEE NOTE 1

CABLE TO LOWER CONTROL BOX

8=WHT

25=ORN

31=BLK

[ 42=RED

51 =BLUE=CH OKE OR GLO'll PLUG OPTION

62=WHT/BLK=LP DUAL FUEL OPTION

63=RED/BLK=GAS DUAL FUEL OPTION

SPARE=GRN

)

)

Ref. 1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

FIGURE3.9: Box Assembly, 68/76 Ford Engine •

PART NUMBER DESCRIPTION OTY

69525 .............................. Box Assembly, Engine Electric Ford LRG423 .................................. Ref. 69526 ............................. Box, Machined ........................................................................................ 1 34552-012 ...................... Terminal Strip ......................................................................................... 2

·21342 ............................. Solenoid, Starter ........................................ : ............................................ 1 67280 ............................. Relay, Bosch ........................................................................................... 6 67947-012 ...................... Circuit Breaker Auto Reset 12AMP ........................................................ 1 67114-009 ...................... Strain Relief, 31/NPT .625/.750 ............................................................. 2 67123-002 ...................... Seal, Connector Elect 3/4" ....................................................................... 3 67124-002 ...................... Connector Locknut 3/4" ......................................................................... 3 67114-003 ...................... Strain Relief, 1/2" NPT .375/.50 .............................................................. 1 67123-001 ...................... Seal Connector 1/2" .................................................................................. 1 67124-001 ...................... Connector, Locknut 1/2" •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1 BOW31124 .................... Screw, Round Hd 6-32UNC x .50 ......................................................... 6 BOW31231 .................... Nut, Keps #6-32UNF .............................................................................. 6 BOW31144 .................... Screw, Round Hd 10-32UNF x .50Lg ................................................... 6 BOW31233 .................... Nut, Keps #10-32UNF .......................................................................... 13 36380 ............................. OVR Speed Switch ................................................................................. 1 CLROOII0-037 .............. Tube Hyd .. 375" OD .049" W x 1.38" Lg .............................................. 4 BOW34385 .................... Screw, Round Hd Slot 1//-20 x 1.75 ..................................................... 4 BOW31238 .................... Nut, Hex Keps .25-20UNC ..................................................................... 6 67295-021 ...................... Cable, 16Ga/5C SO ........................................................................... 12LF 67295-022 ...................... Cable, 3 Conductor 12 A WG ............................................................ 12LF 67295-002 ...................... Cable, 3 Conductor 12 A WG ............................................................. 4LF 69529 ............................. Decal, 68/76 Ford Relay Tags ............ : ................................................... 1 BOW31533 .................... Plug, Button 7/8" ...................................................................................... 1 58292 ............................. Wire, 16 Ga White ............................................................................. 2LF 58251 ............................. Wire, 12 Ga White ............................................................................. 2LF BOW34378 .................... Screw, Round Hd 1/4"-20UNC x 3/4" ...................................................... 2 67114-007 ...................... Strain Relief 3/4" NPT .37/.50 ................................................................. 1



GJ@ CV(5) Q)@

Sl

GlCVGJ @(5)@

52

G)@ CV(5) (JJ@

53

©

I[ T8 := '00

A e D E F G H

CJ ©

18 '@Q' !=oD

50 50 P 51 -f.5-1 51 51A

55 55 55 55

SPARE F1 F2 ~ i= K 2 3 4 5 6

!illii ;D

S7 CV Q)

\~

CSYC@C@ (i)@)QJ(O CV(5)®0 Q)@®~

56

;

1

CV S8 ej)

re-15

0L2....

'00 14 14 15 15

\ 15 15 1-7 17

I 18 18 19 19 20 20 21 21 22 22

~HI~; 25 26

© ~~ ~~ ~

18

64 64 65 65 67 67 68 681/

~ ~ L'!..0 h

=~--=-iOo""=~/i U 50 \q(;

1'1s0 itl°

.[D ~

6 THIS DRAWING SUPERCEDES 36141.

5. THIS BOX, :18589, MAY BE REWORKED FROM :56141, PER DRAWING :58588.

4. TERM CODE: 1 = VEl" STRIP AND LUG WITH ITEM //51 2 = SOLDER j = V8" STRIP AND LUG WITH ITEM //48 4 = V8" STRIP AND LUG WITH ITEM //49 5 = V8" STRIP AND LUG WITH ITEM #50 6 = 1.3/:52" STRIP AND LUG WITH ITEM #47 7 = USE TUBING MS629 ON LEADS El = 7/16" STRIP 9 = 11/.)2 STRIP AND LUG WITH ITEM #46 10 = 7/16' STRIP AND TIN WIRE

J. CABLE TIE AS REQUIRED USING ITEM #:58.

2. MARK ALL WIRES WI TH WIRE NUMBER PER TABLE.

1. ALL WIRES TO BE 18 GA WHITE PER ITEM #52 EXCEPT THOSE IDENTIFIED AS 12 GA ITEM #5.3 IN THRU COLUMN OF TABLE.

WIRE NUMBER

10 10 10 10 10 10 40 40 40 58

50 55

74 74

25DC 160

26 155

18 19 20 21 17 22

67 26 42 160

25 68 51 55

26DC 26DC 26DC 260C

FROM

56-10 51-3 51-1 S2-.~

52-1 53-4 56-4 51-2 52-2 54-1 54-2 F1-2 58-2 57-2 54-4 56-2 S5-2 F1-1 55-1 54-6 56-1 56-6 57-1 F2-2 M1-2 55-11 M1 1 5.1-1 51-6 51 4 52-4 5., 3 52-6 55-.' 56-12 57-1 M2-2 R1-1 M2-1 57-.1 54-1 58-.1 56-2 51-5 52-5 5.1-2 R1-2 F1-2 K.1-B K3-4

TERM CODE

MANlWACTURER: SAUER-SLJNDSTRAND VENDOR PIN: NOT YET ISSUED.

THRU TO

53-6 51-1 52-3 52-1

53-6 53-5 52-2 5.,-5 54-] 54-5 58-2 57-2 54-2 54-6

12 GA M1-1 55 1 F2-1 R1-2 R1-1 TB-4 K4-A K.l-9

12 GA TB-5 TB 8

12 GA TB 2 TB-18 TB-19 TB-20 T8-21 TB-17 TB-22 TB-5

TB-67 T8-26 TB-42 TB-160

TB-1 TB-25 TB-68 TB-51 TB-55

TB-26DC4 T8-260C.1 TB-260C1 TB-26DC2

T8-.1 K4-B K3-5

TERM CODE

10

WIRE NUMBER

25 5.'i

BLACK WHITE

RED

42 25 25

62 5.,

FROM

TB-W K4-9 K3-6 TA-1 TA-2 TA-3 GND

TB-51 260C1 260C2 260C3

42

K4-9 K3-8

54-5 TB-62 TB-63

TERM CODE THRU TO

TB-H TB-25 T8-55 TB-1A T8-W TB-42 TB-1A

K01744 REF T8-51 A K01744 REF 260C2 K01744 REF 26DC.l KD1744 REF 25DC4 K01744 REF 42A K01744 REF 1 A

K07229 REF -<>+- K4-7 TB-42A K4-7 K4-1 56-8 56-9 56-9

f-~,-TR-'-I' ,-L,-:,-;~_:,-O'-j-D,-A,-TE-I_AP_P,-R'+-:_:;_:_£D ___ ~BCR:I,-AN'-+-f12",-12::::°/'-=195 B I DRAWING NO 38589 lTR. E.R.N. NO. APPR. APPROVEO I :SCALE NONE PLOT 1/1 I SHEET 1 OF 3

TERM CODE

-------13.G22--------

.5.31 0111 MOUNTING HOLES (4)

@ @

000 18.25

@lJ9@lJ

@lJ (1)0 P---0---; I I

b ___ 0 ___ j@

UNLESS OTHERWISE SPECIFIED: DIMENSIONS ARE IN INCHES CONSOLE, GROUND

A~I:tr CI[CNAI..~ rRACnUNAL t 1/"1.' XX- t.Ol J '/I~

LlR. [.C.N NO. DA._T[---II_-f-_____ -'B::.cR-'IA-'N-+-='~::.:.j

5844

DAT[ 2 OF 3

~--------------------------------------------------------------------------------------------------------------------------------,~

@'':)·H++---ss-------'

1'--.- ,1G5] .::l<V1

I~

IO~~ ~ ~o Oiio Oit<)--I~~--c~ ~t__-t__t_.+, 1r,6R n

~I

~ VJ

RED

TA

CONSOLE, GROUND CONTROL UNLES50THER'M5ESPECIFIEO: OlMEN510N5AREININCHES

f--l-----I----f--i TOLERANCEs ON: ,t.NCL[ DEtIIolAl!i rRACllO"'AL

.11/2' x==:t3~o i1

/16

BRIAN REV.

5844 CHECKED

DATE APPR. SHEET j OF .~

) MANUAL 92344-003

OCTOBER 1996

• FIGURE3.11: EngineInstallation


)

~)

()

FIGURE3.11: Enginelnstallation •


Ref. 69533 ............................. Enginelnstallation58/68/76 .................................................... Ref. -1 69512 ............................. Bracket Weldment, Engine Support ........................................................ 1 -2 .69502 ............................. EnginelPump Assembly Ford ................................................................. 1 -3 67944 ............................. Mount, Engine .......................................................................................... 4 -4 69181 ............................. Muffler Weldment ............................................................................. " ...... 1 -5 69182 ............................. Heatshield ................................................................................................ 1 -6 38029 ............................. Gasket, Ford LSG423 Exhaust ............................................................... 1 -7 36388 ............................. Valve, Fuel Shut-Off ............................................................................... 1 -8 BOW24110 .................... Clamp, Hose .313 To .875 ...................................................................... 2 -9 BOW9749-375 ............... Hose, Fuel .375 10 SAE .................................................................... 3LF

-10 CNM00203 .................... Mounting Band ........................................................................................ 2 -11 80844 ............................. Hood, Air Intake ..................................................................................... 1 -12 69270 ............................. Bracket, Air Filter Mounting ................................................................... 1 -13 CNM00202 .................... Air Cleaner Horizontal Mount ................................................................. 1 -14 67099-005 ...................... Hose, Air Intake 2.25"10 ................................................................... 8LF -15 BOW24119 .................... Clamp, Hose 2.00"10 To 2.25"10 .......................................................... 2 -16 81878 ............................. Harness, Ford Gas .................................................................................. 1 -17 69280 ............................. Hardline, 58/68/76 Ford Fuel .................................................................. 1




)-

'J

~)

ITEM

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

FIGURE 3. 12: EnginelPumpAssemhly <It PART NUMBER DESCRIPTION QTY

69502 ............................. Engine/PumpAssemhly ............................................................. Ref. 69500 ............................. Engine Modification Ford LRG423 ........................................................... 1 .38329 ............................. Hydraulic Pump, Variable Disp .................................................................. 1 67900 ............................. Plate, Pump Engine Mounting .................................................................. 1 67857 ............................. Coupling ............................................................................................ : ....... 1 67157-003 ...................... Switch 4 PSI NO R#67809 ...................................................................... 1 32783 ............................. Strap, Ground Engine ............................................................................... 1 81869 ............................. Kit, Ford LRG423 Belt Drive Gov ............................................................ 1 38172 ............................. Elbow, Carburator Air Intake ................................................................... 1




~)

)

)

)

FIGURE3.13: FordLRG423 Belt Driven Gov. Kit <D ITEM PART NUMBER DESCRIPTION QTY

Ref. 81869 ............................. FordLRG423 Belt Driven Gov. Kit ........................................ Ref. -1 81864 ............................. Bracket Weldment, Solenoid Mount ....................................................... 1 -2 81867 ............................. Bracket, Governor Arm Ford LRG423 ................................................... 1 -3 . 32239 ............................. Solenoid ...................................................... : ............................................ 2 -4 38156 ............................. Cable,Gov/Sol ......................................................................................... 1 -5 BOW2032 ...................... Clevis 5/16" ............................................................................................... 2 -6 BOW2121 ...................... Clevis Pin 5/16" x 7/8" ................................................................................ 2 -7 BOW38217 .................... Cotter Pin, 3/32" x 1 Lg ........................................................................... 2 -8 BOW30002 .................... Bolt, Hex .25-20UNC x .75 .................................................................. 10 -9 BOW30003 .................... Bolt, Hex .25-20UNC x .875 .................................................................. 1

-10 BOW31431 .................... Washer, Flat .25"ID x .63"OD ............................................................... 9 -11 BOW31325 .................... Washer, Split Lock .25"ID ................................................................... 12 -12 BOW31211 .................... Nut, Hex 1/4"-28UNF ............................................................................... 3 -13 BOW39601 .................... Nut, Hex .25-20UNC ............................................................................ 11 -14 BOW42058 .................... Bolt, Hex 08mm x 30mm ........................................................................ 2 -15 BOW31326 ..... ~ .............. Washer, Lock .31"ID .............................................................................. 2 -16 BOW30054 .................... Bolt, Hex .38-16UNC x 1.00 .................................................................. 4 -17 BOW31413 .................... Washer, Flat .38"ID x 1.00"OD ............................................................. 4 -18 BOW31327 .................... Washer, Split Lock 3/8"ID ...................................................................... 4 -19 BOW39630 .................... Nut, Hex .375-16UNC ............................................................................ 4 -20 BOW24118 .................... Clamp ...................................................................................................... 2



o FIGURE 3.14: FuelTankAssembly

12 11

0

1-:3

10 9 8

D

=

(~


5 4

0/'- ~o i \ i \0\ 101

~

/ /

3 2 9

D

0 6

=

7

) ~ ~

/ /

(~

)

FIGURE 3.14: Fuel Tank Assembly (8


Ref. 68599 ............................. Fuel Tank Assembly ................................................................. Ref. 1 68595 ............................. Fuel Tank .................................................................................................. 1 2 34925 ............................. -Cover, Tank ........................................................................................... 1 3 ·34926 ............................. -Gasket, Tank Cover ................................ : .............................................. 1 4 BOW31145 .................... -Screw, RD HD Slot #10-32UNF 3// .................................................. 10 5 BOW31400 .................... -Washer, Flat #10 ................................................................................. 10 6 69329 ............................. -Filler Cap-Bayonet .................................................................................. 1 7 69327 ............................. -Gauge, Fuel Tank-Magnetic ................................................................... 1 8 02457 ............................. Elbow, MP06 FP04 .................................................................................. 1 9 02795 ............................. Straight ...................................................................................................... 1

10 04625-001 ...................... Mini Ball Valve .......................................................................................... 1 11 04588 ............................. Straight Mj06 MP04 ................................................................................ 1 12 69638 ............................. Hardline, Fuel Tank (68176 Ford Gas) .................................................... 1 13 BOW13374 .................... Plug 1" ..................................................................................................... 1 14 BOW13371 .................... Plug 3/g" ................................................................................................... 1




)

)

-j

)

,)

FIGURE3.15: CoverAssembly58/76 •


Ref. 69499 ............................. Cover Assembly 58/76 ........................................................................ Ref. -1 69504 ............................. Door, Right Side ...................................................................................... 1 -2 67874 ............................. Door, Left Side ........................................................................................ 1 -3 ·21795 ............................. Hinge,Door ................................................. ~ ............................................ 2 -4 67924 ............................. Angle, Hood Mount RH 52" ., ........................ '" .......................... , ............. 1 -5 67886 ............................. Angle, Hood Mount LH 52" ..................................................................... 1 -6 67875 ............................. Hood, 68/76 Ford Engine ......................................................................... 1 -7 LBL00200 ...................... Latch, Horizontal Mounting ..................................................................... 1 -8 LBL00256 ...................... Bracket ..................................................................................................... 1 -9 69091 ............................. Hinge, BlockWeldmentLH ..................................................................... 1

-10 67908 ............................. Hinge, BlockWeldment ........................................................................... 1 -11 21793 ............................. Striker Plate ................................................................................. , ............ 2 -12 21855 ............................. Spacer, Door Latch 1.75 x lis" ................................................................ 4 -13 69269 ............................. Cover, MDC68 Right Side Turret ............................................................ 1 -14 68230 ............................. Cover, Valve Turret ................................................................................. 1 -15 21797 ............................. Spacer, Striker Plate ................................................................................ 2



• FIGURE4.1: Hydraulic Installation, Turret 58/68

ITEM

Ref. 1 2 3 4


69538 ............................. Hydraulic Installation, Turret 58/68 ........................................... Ref. 35686 ............................. Assembly, Topping Cylinder .................................................................... 1

.68238 ............................. Assembly, Valve Mounting Base, Hoses-Turret ....................................... 1 68598 ............................. Assembly, Hydraulic Tank ......................... · ............................................... 1 68443 ............................. Pin Weldment ................................................................................... ~ ........ 1

5 35659 ............................. Pump/Motor Emergency System ............................................................. 1 6 02566 ............................. Tee, MJ06 MB06 MJ06 ............................................................................ 2 7 02431 ............................. Fitting, Straight MJ06 MB06 .................................................................... 2 8 00425 ............................. Fitting, MJ04 F J06 .................................................................................... 4 9 04625-001 ...................... Valve, Mini Ball ......................................................................................... 1



)

)

)

)

IfEM

Ref. 1

FIGURE4.2: Hydraulic Installation, Turret 76 (8


69537 ............................. Hydraulic Installation, Turret 76 ................................................ Ref. 35659 ............................. Pump/Motor Emergency System ............................................................. 1 35659-100 ...................... -Pump ...................................................................................................... 1

. 35659-101 ...................... -Motor 12V .............................................. : ............................................... 1 35659-102 ...................... -Terminal Strap ........................................................................................ 1 35659-103 ...................... -Coupling ................................................................................................. 1 35659-104 ...................... -Solenoid .................................................................................................. 1

2 68238 ............................. Assembly, Valve Mounting Base, Hoses-Turret ....................................... 1 3 68598 ............................. Assembly, Hydraulic Tank ........................................................................ 1 4 68702 ............................. Pin, Topping Cylinder ............................................................................... 1 5 68757 ............................. Assembly, Cylinder Topping .................................................................... 1 6 02566 ............................. Tee, MJ06 MB06 MJ06 ............................................................................ 2 7 02431 ............................. Fitting, Straight MJ06 MB06 ..................... , .............................................. 2 8 00425 ............................. Fitting, MJ04 F J06 ............................................... '" .................................. 4 9 04625-001 .............. : ....... Valve, Mini Ball ......................................................................................... 1



• FIGURE 4.3: Assembly, Valve Mounting Base, Hoses-Turret

19

26 18 16


3

14 30 14 30

15

y "Z\ ) S E R I ES 9, 10

FIGURE. 11 TURRET PROPORTIONAL VALVE SYSTEM INSTALLATION

)') 40

31

9

VIEW A

6/82

~ TURRET PROPORTIONAL. VALVE SYSTE~1 INSTALU1.TION

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f -t1 ----:y ~

rI\ cb

...... -_ ... , ..

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LIQIO }t(V~ 7f- A/lv l ;oJ 2S/rb4F Pow/OS KJ is

r'- .. -.. ----

L_. __ ... _ ..

OO]£,Z£I ;rNd j

1 u

/

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)

ITEM

Ref. -1 -2 3 4 5

-6 -7 -8 -9

-10 -11 -12 -13 14 15 16

-17 18 19 20 21 22 23 24 25 26 27 28 29 30

-31 -32 -33 34

FI GURE 4.3: Assembly, Valve Mounting Base, Hoses-Turret 0 PART NUMBER DESCRIPTION QTY

68238 ............................. Assembly, Valve Mounting Base, Hoses-Turret ......................... Ref. 58189 ............................. Valve ......................................................................................................... 1 58079 ............................. Valve, 2Pos-3Way .................................................................................... 1

. 32560 ............................. Valve, Prop. Control, 4-Bank ..................... ~ .............................................. 1 50148 ............................. Filter, Inline 3/g"NPT .................................................... : ................... ~ ........ 1 BOW5924 ...................... Clamp, Strap Wrap Lock .......................................................................... 1 68352 ............................. Hydraulic Tube Assembly ......................................................................... 1 68353 ............................. Hydraulic Tube Assembly ......................................................................... 1 68835 ............................. Weldment, Bracket, Valve Mounting ....................................................... , 1 02662 ............................. Elbow, 90° MJ06 M006 .......................................................................... 1 00559 ............................. Straight, MJ04 M004 Long ...................................................................... 4 02448 ............................. Straight, MJ06 M006 ............................................................................... 1 00128 ............................. Elbow, 90° MJ06 MP04 ........................................................................... 2 01160 ............................. Straight, MJ04 MP04 ................................................................................ 1 02698 ............................. Elbow, 900 M008 FPOI0 .......................................................................... 2 02663 ............................. Elbow, 90° MJ08 MOI0 .......................................................................... 2 04070 ............................. Straight, MJ06 MOI0 ............................................................................... 2 02669 ............................. Elbow, 90° MJ12 MOI0 .......................................................................... 1 02675 ............................. Elbow, 90° MJ12 MP12 ........................................................................... 1 68420 .................... , ........ Modified 90° Elbow .................................................................................. 1 02796 ............................. Straight, MJ06 MP06. '" ............................................................................ 1 02699 ............................. Straight, MP06 MP06 ............................................................................... 1 02310 ............................. Straight, MP12 FP06 ................................................................................ 1 02807 ............................. Straight, MJ12 MPI2 ................................................................................ 2 00469 ............................. Tee, MP12 FP12 FP12 ............................................................................. 2 02804 ............................. Straight, MJ06 MPI2 ................................................................................ 1 00394 ............................. Straight, MP04 MJ04 ................................................................................ 1 02674 ............................. Elbow, 90° MJI0 MP12 ........................................................................... 1 02236 ............................. Elbow, 90° MJ04 M004 .......................................................................... 5 02335 ............................. Elbow, 90° MJ06 M004 .......................................................................... 1 02800 ............................. Straight, MJ08 MP08 ................................................................................ 2 BOW30054 .................... Bolt, Hex .38-16UNC x 1.00 .................................................................... 3 BOW31327 .................... Washer, Split Lock 3/g"ID ........................................................................ 3 69184 ............................. Modified Elbow 90° MJ12 M012 LL ....................................................... 1 21368 ............................. Valve, Check ............................................................................................. 1



• FIGURE4.4: Assembly, Hydraulic Tank

23 22 21

11 I

~!~ ~ i ~

17 7


18

10

2

3

4

10

5

'-....'~i'"",'; lit

" ,

@ ~--

)

~)

FIGURE4.4: Assembly,HydraulicTank •


Ref. 68598 ............................. Assembly, Hydraulic Tank ...................................................... Ref. 1 68596 ............................. Hydraulic Tank Weldment .................... '" ., ............................................. 1 2 . BOW36001 .................... Bolt, Hex .25-20UNC x .63" .................................................................... 2 3 BOW36725 .................... Washer, Split Lock .25"ID ..................................................................... 2 4 33430 ............................. Filter ........................................................................................................ 1 5 00307 ............................. Elbow, 45° MJ16 MP12 ......................................................................... 1

-6 02809 ............................. Straight, MJ16 MPI2 .............................................................................. 1 7 69635 ............................. Tube Assembly .................................................. " ................................... 1

-8 BOW13297 .................... Tee, 1.50 ................................................................................................. 1 9 67489-004 ...................... Valve, Gate Bronze 1 1

/ 2" •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1 10 BOW13404 .................... Nipple, 1.50 NPT .................................................................................... 3 11 BOW13381 .................... Plug, Countersank 3/g" .......................................•........................•........... 2

-12 50811 ............................. Fluid Level Gauge ... , .......... , .................................................................... 1 -13 00007 ............................. Fitting ................................................................... , .................................. 1 -14 00401 .............................. Straight, F J08 MJ08 ............................................................................... 1 -15 02803 ............................. Straight, MJ08 MPI2 .............................................................................. 1 -16 02832 ............................. Straight, MJ24 MP12 .............................................................................. 2 -17 02681 ............................. Elbow, 90° MJ20 MP16 ......................................................................... 1 18 21473 ............................. Strainer, Sump ........................................................................................ 1 19 32822 ............................. Cover Plate .............................................................................................. 1 20 32821 ............................. Cover Plate Gasket .................................................................................. 1 21 BOW36725 .................... Washer, Lock 1/4" .....................•.......................................................... 10 22 BOW30175 .................... Screw, Hex HD 1/4"-28UNF x 1/2" LG ................................................. 10 23 67813 ............................. Washer, Seal 1/4" .........•......................................................................... 10



• FIGURE4.5: Topping Cylinder Assemhly 58/68


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)

)

FIGURE4.5: Topping Cylinder Assembly 58/68 •


Ref. 35686 ............................. Topping Cylinder Assembly 58/68 ........................................... Ref. Ref. 35080 ............................. Cylinder/Topping(WithOutValve) ......................................................... 1

.35113 ............................. Seal Kit (Kit includes items 1-8) ................ ~ ............................................. 1 ..................................... .. -Locknut ................................................................................................. 1

2 ....................................... -O-Ring .................................................................................................... 1 3 ....................................... -AQ-Seal Assembly ................................................................................. 1 4 ....................................... -Wear Ring .............................................................................................. 2 5 ....................................... -O-Ring ................................................................................................... 1 6 ....................................... -Back-UP ................................................................................................ 1 7 ....................................... -U-Cup Polypak Type "B" ....................................................................... 1 8 ....................................... -Wiper ..................................................................................................... 1 9 35080-100 ...................... Tube Adapter ........................................................................................... 1

10 35080-101 ...................... Cap Screw ............................................................................................... 2 11 35080-102 ...................... Lock-Washer ........................................................................................... 2 12 67455 ............................. Valve Manifold (Fum. by Condor) ......................................................... 1

13 14 15 16 17 18 19 20 21

-22 -23 -24

58191 ............................. -Manifold ................................................................................................ 1 32585 ............................. -Cartridge Counter Balance Valve ........................................................... 1 67486 ............................. -Relief Valve Cartridge - 1100 psi .......................................................... 1 35080-104 ...................... Spacer ...................................................................................................... 1 35080-105 ...................... Head Cap .................................................................................................. 1 35080-106 ...................... Head ......................................................................................................... 1 35080-107 ...................... Piston ....................................................................................................... 1 35080-108 ...................... Rod Assembly .......................................................................................... 1 35080-109 ...................... Tube Assembly ........................................................................................ 1 SB WO 1036 ..................... Set Screw ................................................................................................ 1 SBWOI037 ..................... Nylon Plug ............................................................................................... 1 SB WO 1 039 ..................... Bronze Bushing ........................................................................................ 4 BOW36061 .................... Bolt, Hex .38-18UNC x 2.75 .................................................................. 2 BOW31327 .................... Washer, Split Lock 3/g" ID ..................................................................... 2 BOW31413 .................... Washer, Flat .38 ID x 1.00 OD .............................................................. 2



• FIGURE4.6: Topping Cylinder Assembly 76

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)

ITEM

Ref. Ref.

2 3 4 5 6 7 8 9

10 11 12

13 14 15 16 17 18 19 20 21

-22 -23 -24

FIGURE4.6: Topping Cylinder Assembly 76 •


68757 ............................. Topping Cylinder Assembly 76 ................................................ Ref. 35090 ............................. Cylinder/Topping(WithOutValve) ......................................................... 1 35113 ............................. Seal Kit (Kit inc1 udes items 1-8) .............................................................. 1

. ....................................... -Locknut ................................................... : ............................................. 1 ....................................... -O-Ring ........................................................................................... , ....... 1 ....................................... -AQ-Seal Assembly ................................................................................. 1 ....................................... -Wear Ring .............................................................................................. 2 ....................................... -O-Ring ................................................................................................... 1 ....................................... -Back-UP ................................................................................................ 1 ....................................... -U-Cup Polypak Type "B" ....................................................................... 1 ....................................... -Wiper ..................................................................................................... 1

35080-100 ...................... Tube Adapter ........................................................................................... 1 35080-101 ...................... Cap Screw ............................................................................................... 2 30580-102 ...................... Lock-Washer ........................................................................................... 2 67455 ............................. Valve Manifold (Fum. by Condor) ......................................................... 1 58191 ............................. -Manifold ................................................................................................ 1 32585 ............................. -Cartridge Counter Balance Valve ........................................................... 1 67486 ............................. -Relief Valve Cartridge - 1100 psi .......................................................... 1 35080-104 ...................... Spacer ...................................................................................................... 1 35080-105 ...................... Head Cap .................................................................................................. 1 35080-106 ...................... Head ......................................................................................................... 1 35080-107 ...................... Piston ....................................................................................................... 1 35080-108 ...................... Rod Assembly ....... , '" ............................................................................... 1 35080-109 ...................... Tube Assembly ........................................................................................ 1 SB WO 1036 ..................... Set Screw ................................................................................................ 1 SBWOI037 ..................... Nylon Plug ............................................................................................... 1 SBWOI039 ..................... Bronze Bushing ........................................................................................ 4 BOW36061 .................... Bolt, Hex .38-18UNC x 2.75 .................................................................. 2 BOW31327 .................... Washer, Split Lock 3/g" ID ..................................................................... 2 BOW31413 .................... Washer, Flat .38 ID x 1.00 OD .............................................................. 2



• FIGURE4 7- M -_ _ amfoldAssembly

)

3

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CR 1 VR 1 1 1 1 1 1

1-- 1

--

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MANUAL OCTO 92344-003 BER 1996

I,)

FIGURE4.7: ManifoldAssembly •


Ref. 67455 ............................. ManifoldAssembly .................................................................. Ref. 1 58191 ............................. Manifold, Lift Cylinder ............................................................................. 1 2 32585 ............................. Cartridge Counterbalance Valve ............................................................... 1 3 ·67486 ............................. RefiefValve Cartridge 1100PSI ................. ~ ............................................. 1



• FIGURE4.8: Hose Kit,MDC68 Turret/Boom

,-t-----uLS

AUX.

17 23

25

\ '---1---'---1 LS

NOTES

T IPE

PUMP

23 GPM A

1C

23 GPM B

1. VENDOR SHALL TAG EACH HOSE ASSY AT BOTH ENDS V·JlTH THE NUMBER 69541-XX-*, 'i,'HERE "XX" IS THE ITEM NUMBER & "*" IS THE REV LETTER.

5 GPM A

PROPORTIONAL VALVE

5 GPM B

TOPPING CYLINDER ASSY

7 GPM 7 GPM

E

ROTATION MOTOR

HOSES FOR CHASSIS


13 GPM

A

7 GPM

E

BOOM EXTENSION CYLINDER ASSY.

SLAVE LEVELING CYLINDER

)

)

'-~

)

FIGURE4.8: HoseKit,MDC68 TurretiBoom 0 IfEM PART NUMBER DESCRIPTION QTY

Ref. 69541 ............................. Hose Kit, MDC68 TurretIBoom .......................................................... Ref. 1 66696-096.50 ................. Hose Assembly #04 66646 J37 ST-ST ............................................... 1 2 66699-097.00 ................. Hose Assembly #04 66646 J37 ST-90 ................................................ 1 3 . 66699-097.00 ................. Hose Assembly #04 66646 J37 ST90 ... ~ ............................................. 1 4 66696-096.50 ................. Hose Assembly #04 66646 J37 ST-ST ....................................... , ....... 1 5 66696-026.50 ................. Hose Assembly #04 66646 J37 ST-ST ............................................... 1 6 66696-026.50 ................. Hose Assembly #04 66646 J37 ST-ST ............................................... 1 7 66696-046.50 ................. Hose Assembly #04 66646 J37 ST-ST ............................................... 1 8 66699-047.00 ................. Hose Assembly #04 66646 J37 ST-90 ................................................ 1 9 66699-022.00 ................. Hose Assembly #04 66646 J37 ST-90 ................................................ 1

10 66699-021.00 ................. Hose Assembly #04 66646 J37 ST-90 ................................................ 1 11 66699-021.00 ................. Hose Assembly #04 66646 J37 ST-90 ................................................ 1 12 66699-020.00 ................. Hose Assembly #04 66646 J37 ST-90 ................................................ 1 13 66697-033.00 ................. Hose Assembly #08 66675 J37 ST-ST ............................................... 1 14 66697-035.00 ................. Hose Assembly #08 66675 J37 ST-ST ............................................... 1 15 66709-031.50 .. ; .............. Hose Assembly #12 66708 J37 ST-ST ............................................... 1 16 66709-033.50 ................. Hose Assembly #12 66708 J37 ST-ST ............................................... 1 17 66709-019.50 ................. Hose Assembly #12 66708 J37 ST-ST ............................................... 1 18 66709-027.50 ................. Hose Assembly #12 66708 J37 ST-ST ............................................... 1 19 66697-044.00 ................. Hose Assembly #08 66675 J37 ST-ST ............................................... 1 20 66711-046.00 ................. Hose Assembly #10 66706 J37 ST-90 ................................................ 1 21 66794-053.00 ................. Hose Assembly #06 66645 J37 ST-90L ............................................. 1 22 66318-067.75 ................. Hose Assembly #20 67669 J37 ST-ST ............................................... 1 23 66747-053.00 ................. Hose Assembly #12 66708 J37 ST-90L ............................................. 1 24 66711-086.00 ................. Hose Assembly #10 66706 J37 ST-90 ................................................ 1 25 66699-074.00 ................. Hose Assembly #04 66646 J37 ST-90 ................................................ 1 26 66697-089.00 ................. Hose Assembly #08 66675 J37 ST-ST ............................................... 1 27 66697-089.00 ................. Hose Assembly #08 66675 J37 ST-ST ............................................... 1 28 66696-018.50 ................. Hose Assembly #04 66646 J37 ST-ST ............................................... 1 29 66696-018.50 ................. Hose Assembly #04 66646 J37 ST-ST ............................................... 1 30 66697-068.00 ................. Hose Assembly #08 66675 J37 ST-ST ............................................... 1 31 66697-068.00 ................. Hose Assembly #08 66675 J37 ST-ST ............................................... 1 32 66043-758.50 ................. Hose Assembly #03 67684 J37 ST-ST ............................................... 1 33 66043-758.50 ................. Hose Assembly #03 67684 J37 ST-ST ............................................... 1 34 66043-758.50 ................. Hose Assembly #03 67684 J37 ST-ST ............................................... 1 35 66043-758.50 ................. Hose Assembly #03 67684 J37 ST-ST ............................................... 1 36 66697-043.00 ................. Hose Assembly #08 66675 J37 ST-ST ............................................... 1 37 66697-043.00 ................. Hose Assembly #08 66675 J37 ST-ST ............................................... 1



• FIGURE4.9: Hose Kit, 76 TurretiBoom

r+-----IlLS

,-AUX PROPORTIONAL VALVE

,---LI~TOP==,PIN~G =---'-0

1

,---LI~ROTA~TIO~N ~ PP PD PP PD PP PD

23 GPM 23 GPM 5 GPM 5 GPM 7 GPM 7 GPM T P T IPB A B A B A B

I

~27 ~25 ~13 ~

~ CROSS

VALVE RELlE,S

ASSY

I 10 CIPR8~~~I~~

TOPPING ROTATION CYLINDER MOTOR ASSY

,

2; ,~ ,~ I

EXTENSION

PP PD

13 GPM 7 GPM

A 8

14 ~ ~31 30

U I HOLDING

VALVE ASSY

~ EXTENSION CYLINDER ASSY

SLAVE LEVELING CYLINDER

PLATFORM ROTARY ACTUATOR

o

V , HIGH

SPEED VALVE GCHECK

( /CHOKE VALVE

1 ~ BULKHEAD ~

~ ~

I

12 15 15 11

20 \ \ \ \ 9

\ \ VU24

,------+-----'-----l

PUMP

CASE~ T DRAIN I.~

",:: I

AUXILIARY

LOVJERING PO\';ER

VAtg~ 1 SUCTION ;.,

STRAINER T

" 2 _____

0\ ~~ ~ r r--"'--"-~---1---i STEER ING

I T P

'" 19 C~0~~~~GI2y ~ 4y 7y ICc) 5(c» 60» I

HY DRAULIC TANK I '------+---j-----+---+---j-----+---+-----' HOSES FOR CHASSIS

NOTES

1. VENDOR SHALL TAG EACH HOSE ASSY AT BOTH ENDS WITH THE NUMBER 69S42-XX, V!HERE "XX" IS THE ITEM NUMBER


ROTATE

SOLENOID VAL VE ASSY

)

)

FIGURE4.9: Hose Kit, 76 TurretiBoom •


Ref. 1 2 3 4 5 6 7 8 9

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

69542 ............................. Hose Kit, 76 TurretIBoom .................................................................... Ref. 66696-096.50 ................. Hose Assembly #04 66646 137 ST-ST ................................................. 1 66699-097.00 ................. Hose Assembly #04 66646 137 ST-90 .................................................. 1

. 66699-097.00 ................. Hose Assembly #04 66646 137 ST-90 .. : ............................................... 1 66696-096.50 ................. Hose Assembly #04 66646 137 ST-ST ................................................. 1 66696-026.50 ................. Hose Assembly #04 66646 137 ST-ST ................................................. 1 66696-026.50 ................. Hose Assembly #04 66646 137 ST-ST ................................................. 1 66696-046.50 ................. Hose Assembly #04 66646 137 ST-ST ................................................. 1 66699-047.50 ................. Hose Assembly #04 66646 137 ST-90 .................................................. 1 66699-022.00 ................. Hose Assembly #04 66646 137 ST-90 .................................................. 1 66699-021.00 ................. Hose Assembly #04 66646 137 ST-90 .................................................. 1 66699-021.00 ................. Hose Assembly #04 66646 137 ST-90 .................................................. 1 66699-020.00 ................. Hose Assembly #04 66646 137 ST-90 .................................................. 1 66697-033.00 ................. Hose Assembly #08 66675 137 ST-ST ................................................. 1 66697-035.00 ................. Hose Assembly #08 66675 137 ST-ST ................................................. 1 66709-031.50 ................. Hose Assembly #12 66708 137 ST-ST ................................................. 1 66709-033.50 ................. Hose Assembly #!2 66708 137 ST-ST ................................................. 1 66709-019.50 ................. Hose Assembly #12 66708 137 ST-ST ................................................. 1 66709-027.50 ................. Hose Assembly #12 66708 137 ST-ST ................................................. 1 66697-044.00 ................. Hose Assembly #08 66675 137 ST-ST ................................................. 1 66711-046.00 ................. Hose Assembly #10 66709 137 ST-90 .................................................. 1 66794-053.00 ................. Hose Assembly #06 66645 137 ST-90L ............................................... 1 66318-067.75 ................. Hose Assembly #20 67669 137 ST-ST ................................................. 1 66747-053.00 ................. Hose Assembly #!2 66708 137 ST-90L ................................................ 1 66711-086.00 ................. Hose Assembly #10 66706 137 ST-90 .................................................. 1 66699-074.00 ................. Hose Assembly #04 66646 13 7 ST -90 .................................................. 1 66697-089.00 ................. Hose Assembly #08 66675 137 ST-ST ................................................. 1 66697-089.00 ................. Hose Assembly #08 66675 137 ST-ST ................................................. 1 66696-018.50 ................. Hose Assembly #04 66646 137 ST-ST ................................................. 1 66696-018.50 ................. Hose Assembly #04 66646 13 7 ST -ST ................................................. 1 66697-230.00 ................. Hose Assembly #08 66675 137 ST-ST ................................................. 1 66697-230.00 ................. Hose Assembly #08 66675 137 ST-ST ................................................. 1 66043-852.00 ................. Hose Assembly #03 67684 137 ST-ST ................................................. 1 66043-852.00 ................. Hose Assembly #03 67684 137 ST-ST ................................................. 1 66043-852.00 ................. Hose Assembly #03 67684 137 ST-ST ................................................. 1 66043-852.00 ................. Hose Assembly #03 67684 137 ST-ST ................................................. 1




)

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® FIGURE4.1: BoomAssembly ..


Ref. 1 2 3 4 5

-6 7 8 9

10 11 12 13

-14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 . 29

-30 -31 32 33 34 35 36 37 38 39

-40 41 42 43 44 45

68132 ............................ BoomAssembly ........................................................................... Ref. 68147 ............................ Boom Weldment, Outer ...................................................................... 1 68145 ............................ Assy, Intermediate Boom ................................................................... 1 68137 ............................ Inner Boom Assembly ........................................................................ 1 30567 ............................ Ext Assy, CylinderlBoom ................................................................... 1 67948 ............................ Cable, 12/13-16/24-18/3 Bulk ........................................................... 78 68256 ............................ Rope (Assy) Retraction Wire ............................................................. 2 68257 ............................ Wire Rope (Assy) Extension .............................................................. 2 33082 ............................ Plastitrak Bulk (6.63 LinkslFt) ........................................................ 126 68161 ............................ Eccentric Boom Pin ............................................................................ 2 21808 ............................ Pin-Main Boom to Ext Cyl ................................................................. 1 68036 ............................ Backup PlateIWear Pd 7"L ................................................................ 1 68179 ............................ Cover Plate, Outer Boom ................................................................... 2 68223 ............................ Cover Plate ......................................................................................... 1 68035 ............................ Wear Pad Top .................................................................................... 1 68164 ........... : ................ Pad, Wear ........................................................................................... 2 68166 ............................ Plate, 8" Mounting .............................................................................. 1 32718 ............................ Wear Pad Adj Plate 7" ....................................................................... 1 68167 ........... ; ................ Wear Pad ........................................................................................... 1

68050 ............................ Pin, Sheave ..................... : .. : ................................................................ 2 68184 ............................ Outer Wear Pad Adjusters ................................................................. 8 68412 ............................ Wear Pad Top ............................................................................. , ...... 1 68185 ............................ Bracket Wear Pad Inter Boom .......................................................... 4 68187 ............................ Wear Pads ........................................................................................ 12

. 68206 ............................ Spacer, 11+1/8" ................................................................................. 4 68183 ............................ Plug ................................................................................................... 12 68067 ............................ Sheave (Assy); Ext ............................................................................ 2 BOW32585-1 ................ Clamp, I"WireLoom ......................................................................... 6 BOW39000 ................... Bolt, 114-20 x 112 Gr8 Hex HD .......................................................... 8 BOW39029 ................... Bolt, 5/16-18UNC x 1 Gr8 HexHd .................................................. 36 BOW36836 ................... Bolt, .3 8-16UNC x 1.50 Fit Soc ......................................................... 4 BOW40562-125 ............ Screw, .50-20UNF x 1.25 Soc Set ................................................... 10 BOW46054 ................... Bolt, 3/8-24UNF xl" L Gr8 Hex ..................................................... 26 BOW39002 ................... Bolt, 114-20 x 3/4 Gr8 Hex Hd ......................................................... 16 BOW31326 ................... Washer, 31 ID Lock ......................................................................... 36 BOW31327 ................... Washer, 3/8'! ID Split Lock .............................................................. 42 BOW31408 ................... Washer, 3/4 Flat ............................................................................... :.4 BOW31325 ................... Washer, .25 ID Split Lock ................................................................ 36 BOW46054 ................... Bolt, 3/8-24UNF xl" L Gr8 HD Hex .............................................. 12 BOW39004 ................... Bolt, 114-20 x 1.00 Gr8 Hd Hex ......................................................... 8 BOW39004 ................... Fitting, -.25-28 Straightlube ............................................................... 2 32536 ............................ Ring Tie Down ................................................................................... 1 BOW40541 ................... Screw, .38-16UNC x .50" Set Soc ..................................................... 4 BOW32285 ................... Nut, 1/2-20UNF Hex Jam ................................................................ 10 68276 ............................ Nut, 3/8-16UNC 4 Prong Tee .......................................................... 12


MANUAL 92367-003 September 1997

34---

38

3

4

. /1 28 47

32

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5

53

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ITEM

Ref. 46 47 48 49 50 51 52 53 54 55

-56 -57 -58 -59 -60 -61 -62 -63 -65 -66 -70 -72 -73 -75 -76 -77 -78 -79 -80

. ~ FIGURE4.1: BoomAssembly ,.


68132 ............................ BoomAssembly ...................................... ~ .................................... Ref. BOW39603 ................... Nut, .38-16UNC Gr8 Hex .................................................................. 4 BOW3960 1 ................... Nut, .25-20UNC Gr8 Hex ................................................................ 12 BOW36608 ................... Nut, .75-10UNC Hex ......................................................................... 8 BOW36722 ................... Waher, 1.25 ID 2.50 OD Flat ............................................................. 3 BOW38252 ................... Pin, .188 x 2.50" Lg Cotter ................................................................. 1 BOW35241 ................... E-Ring-For .500 Dia Shaft .................................................................. 4 68264 ............................ PlateMounting8.5" ............................................................................ 1 68265 ............................ Bracket LH ........................................................................................ 1 68269 ............................ Bracket RH ........................................................................................ 1 68267 ............................ Pin, Evener Brkt Pivot ........................................................................ 1 68600 ............................ Weldment, Evener Brkt ...................................................................... 1 BOW40534 ................... Screw, .31-18 x 1 Headless Set ......................................................... 4 68189 ............................ Pin ....................................................................................................... 4 68270 ............................ Pin, Trunnion Ext, Cylinder ................................................................. 2 58366 ............................ Plug, Top Wear Pad 1/8 ................................................................... 10 68424 ............................ Plate, Outer Boom Cover ................................................................... 2 BOW31046 ................... Screw, #10-32UNF x .75 Truss Hd ................................................... 2 68670 ............................ Bracket, Plastic Track, Female .......................................................... 1 68669 ............................ Bracket, Plastic Track, Male .............................................................. 1 BOW40568 ................... Screw, 1I2-20UNF xl" Lg.Hex Hd ................................................... 6 BOW40569 ................... Screw, 5/8-11UNC x 2 Soc Hd Set ................................................... 2 LBLOI032 ..................... Screw, .63-11UNC x2.00 Soc Set ..................................................... 4 BOW36713-HD ........... Washer, .375 SAE .............................................................................. 4 80995 ............................ Cylinder,MasterLeveling .... ; ............................................................. 1 21847 ............................ Pin, Master Leveling Cylinder ............................................................ 1 68192 ............................ Pin, Leveling Cylinder ......................................................................... 1 30568 ............................ Cylinder Assembly-Slave Leveling ..................................................... 1 02236 ............................ Elbow 90 MJ04 M004 ....................................................................... 2 68892 ............................ Bushing, BoomlTurretPivot ............................................................... 2


MANUAL 92367·003 September 1997

0--FIGURE 4.2: Master Leveling Cylinder

)tSee- O. i-{ ...-- ------

MANUAL 92367-003 September 1997

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)

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1TEM

Ref. -1 -2 -3 -4 -5

-6 -7 -8 -9

-10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25 -26 -27 -28 -29 -30 -31 -32 -33 -34 -35 -36 -37 -38 -39 -40 -41 -42 -43 -44 -45

FIGURE 5.2: BoomAssembly76 •

PART NUMBER DESCRIPfION QTY

68134 ............................. Boom Assembly 76 .................................................................. Ref. 68149 ...................... : ...... Outer Boom Fab 76 .................................................................................. 1 68145 ............................. Intermediate Boom Assembly ................................................................... 1

. 68137 ............................. Inner Boom Assembly ............................... : .............................................. 1 30567 ............................. Assembly, Cylinder Boom Extension 68/76 ............................................. 1 30616-005 ...................... Cable, Control 76 ...................................................................................... 1 67948 ............................. Cable, 12/13-16/24-18/3 Bulk ................................................... : ....... 84LF. 67614-023 ...................... Hose Assembly #03-850.0 IN ST-ST ...................................................... 4 68343 ............................. Cable, Extension ....................................................................................... 2 68342 ............................. Cable, Retraction 76 .................................................................................. 2 33082 ............................. Plastitrak Bulk (6.63 LinkslFt.) ............................................................ 127 68211 ............................. Eccentric 1 1/2" + I/g" ................................................................................ 2 35788 ............................. Pin-Main Boom To Ext. Cyl. .................................................................... 1

68179 ............................. Cover Plate, Outer Boom ............. , ............................................................ 2 68223 ............................. Cover Plate ................................................................................................ 1

68164 .. , .......... '" ............. Wear Pad ..................................................... '" ........................................... 2 68166 ............................. Plate, 8" Mounting .................................................................................... 1 32718 ............................. Wear Pad Adj. Plate 7" .............................................................................. 1 68167 ............................. Wear Pad ................................................................................................... 1

68050 ., ........................... Pin Sheave ................................................................................................. 2 68184 ............................. Outer Wear Pad Adjusters ........................................................................ 8

68185 ............................. Bracket, Wear Pad Inter. Boom ................................................................ 4 68187 ............................. Wear Pad ................................................................................................. 12 68206 ............................. Spacer, 1 x I/g" .......................................................................................... 4 68183 ............................. Plug ......................................................................................................... 12 68067 .. , .......................... Extension Sheave Assembly ..................................................................... 2 BOW32585-1 ................. Clamp, Wire Loom 1" ............................................................................... 6 BOW46000 .................... Bolt, Hex 1/4"-20UNC x 1/2" Gr8 .............................................................. 8 BOW46029 .................... Bolt, Hex 5/16"-18UNC 1 Gr8 ................................................................ 36 BOW36836 .................... Bolt, Soc. Flt .38-16UNC x 1.50 .............................................................. 4 40562 ............................. Set Screw, 1/2"-20UNF x 1.0 Gr8 ......................................................... 10 BOW46054 .................... Bolt, Hex 3/g"-24UNF 1" Gr8 ................................................................. 26 BOW46002 .................... Bolt, Hex 1/4"-20UNC x 3/4" Gr8 ............................................................ 16 BOW36726 .................... Washer, Split Lock .31 "ID ..................................................................... 36 BOW31327 .................... Washer, Split Lock 3/g"ID ...................................................................... 42 BOW31408 .................... Washer, Flat 3/4" ....................................................................................... 4 BOW31325 .................... Washer, Split Lock .25"ID ..................................................................... 48 BOW36055 .................... Bolt, Hex .38-16UNC x 1.250 ................................................................ 12 BOW46004 .................... Bolt, Hex 1/4"-UNC 1" Gr8 ....................................................................... 8 BOW7597 ...................... Fitting, Grease .250NPT STR .................................................................. 2 32536 ............................. Ring Tie Down ......................................................................................... 1 BOW40541 .................... Screw, Set Soc . .38-16UNC x .50 ........................................................... 4 BOW41157 .................... Set Screw, Soc. HD. 5/g"-11 UNC x 1 ...................................................... 6



•


)

)

)

FIGURE 5.2: Boom Assembly 76 •


-46 BOW32285 .................... Nut, Hex Jam 1/2"-20UNF ....................................................................... 10 -47 68276 ............................. Nut, Tee-3

/ g"-I6UNC 4 Prong ................................................................ 12 -48 .BOW36603 .................... Nut, Hex.38-I6UNC ................................................................................ 4 -49 BOW3660I .................... Nut, Hex .25-20UNC ................................. ~ ............................................ 12 -50 BOW36608 .................... Nut, Hex .75-IOUNC ........................................................................ · ...... 8 -51 BOW36722 .................... Washer, Flat 1.25"10 x 2.50"00 ........................................................... 3 -52 BOW38252 .................... Pin, Cotter .188"Oia.x 2.50 .................................................................... 1 -53 BOW3524I .................... E-Ring For .50"Oia. Shaft ...................................................................... 4 -54 68264 ............................. Plate Mounting 8.5" ................................................................................ 1 -55 68265 ....................... , ..... Bracket, LH ................................................................................... '" ....... 1 -56 68269 ............................. Bracket, RH ........................................... , ................................................. 1 -57 68267 ............................. Pin, Evener Bracket Pivot ....................................................................... 1 -58 68600 ............................. Weldment, Evener Bracket ..................................................................... 1 -59 BOW4II30 .................... Screw, Set Soc . .3I-I8UNC x 1.00 ....................................................... 4 -60 68189 ............................. Pin ............................................................................ : .............................. 4 -61 68270 ............................. Pin Trunnion Ext. Cyl. . '" '" ..................................................................... 2 -62 58366 ............................. Plug For Top Wear Pad I/g" x I/g" ......................................................... 10 -63 68424 ............................. Plate Cover, Outer Boom 2.00 ................................................................ 2 -64 BOW3I046 .................... Screw, Truss HO-#IO-32UNF x .75 ...................................................... 2 -65 68670 ............................. Bracket, Plastic Track, Female ............................................................... 1 -66 -67 68669 ............................. Bracket, Plastic Track, Male ..... , ............................ , ............................... 1 -68 -69 68271 ............................. Wear Pad ................................................................................................. 2 -70 BOW32277 .................... Nut, Jam 5/g"-IIUNC ............................................................................ 12 -71 BOW4I36I .................... Screw, Hex HO 1/2"-20UNF x 1.00" ....................................................... 6 -72 BOW41362 .................... Screw, Hex HO 1/2"-20UNF x 1 1/4" ....................................................... 2 -73 LBLOI032 ...................... Screw, Set Soc .. 63-IIUNC x 2.00 ....................................................... 4 -74 BOW36713-HD ............... 357 SAE Washer .................................................................................... 4 -75 BOW3I430 .................... Washer, Flat #1010 ................................................................................ 2 -76 68321 ............................. Cover, Top Outer Boom 6 1/2" •••••••••.•••••••••••••••••••••••••••••••••••••••••••••••••••••• 1 -77 21847 ............................. Pin-Master Leveling Cylinder.................................................................. 1 -78 68192 ............................. Pin, Leveling Cylinder ................................................................ '" .......... 1 -79 30568 ............................. Assembly, Cylinder Slave Leveling ......................................................... 1 -80 02236 ............................. Elbow, 90° MJ04 M004 ........................................................................ 2 -81 02432 ............................. Straight, MJ08 MB08 .............................................................................. 2 -82 80995 ............................. Cylinder, Master Leveling ....................................................................... 1 -83 BOW34991 .................... Pin, Spirol .25"Oia. x 2.00 ...................................................................... 2 -84 68035 ............................. Wear Pad, Top ........................................................................................ 1 -85 68036 ....................... , ..... Backup Plate/Wear Pad 7"L .................................................................... 1




)

)

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ITEM

Ref. -1 -2 -3 -4

FIGURE 5.3: Assembly, Boom Cylinder Extension 58 (8


68259 ............................. Assembly, Cylinder Boom Extension 58 ............................................ Ref. 68190 ............................. Wear Pad ................................................................................................... 1 68191 ............................. Wear Pad ................................................................................................... 1 68121 ............................. ExtensionCylinder ..................................................................................... 1 40817 ............................. Valve, Counterbalance, Dual ..................................................................... 1 58190 ............................. -Mainifold - Counterbalance Ext. ............................................................. 1 32585 ............................. -Cartridge Counterbalance Valve ............................................................. 2 67486 ............................. -Relief Valve Cartridge - 1100PSI ........................................................... 1



o FIGURE5.4: Master Leveling Cylinder

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FIGURE5.4: Master Leveling Cylinder •

IrEM PART NUMBER DESCRIPTION QTY

Ref. 80995 ............................. Assembly, Master Leveling Cylinder ................................................... Ref. 1 80995-102 ...................... Tube Assembly ......................................................................................... 1 2 SBWOI003 ..................... Rod Assembly ........................................................................................... 1 3 SBWOI018 ..................... Piston ......................................................................................................... 1 4 80995-103 ...................... Head .......................................................................................................... 1· 5 80995-104 ...................... Set Screw ................................................................................................. 1 6 80995-105 ...................... Port Plug ................................................................................................... 2 7 SBWOI032 ..................... Lock Nut ................................................................................................... 1

80995-101 ...................... Seal Kit (includes items 8-15) ................................................................... 1 8 ....................................... -Wiper ...................................................................................................... 1 9 ....................................... -U-Cup, Dual Lip ..................................................................................... 1

10 ....................................... -Wear Ring ............................................................................................... 2 11 ....................................... -Back Up .................................................................................................. 1 12 ....................................... -O-Ring .................................................................................................... 1 13 .......... ........ ..... ..... .... ..... .. -Wear RIng ............................................................................................... 2 14 ....................................... -AQ Seal Assembly .................................................................................. 1 15 ....................................... -O-Ring .................................................................................................... 1




)

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)

)

FIGURE 5.5: Boom Extension Cylinder Assembly 68/76 •


Ref. 30567 ............................. BoomExtension Cylinder Assembly 68/76 ................................ Ref. -1 68190 ............................. Wear Pad ................................................................................................... 1 -2 36125 ............................. Pad, Extension Cylinder Bottom Wear ..................................................... 1 -3 . BOW36823 .................... BoIt, Soc. FIt .31-18UNC x .75 ................. ~ .............................................. 2 -4 BOW36826 .................... Screw, FIt. HD 5/16"-18UNC x 1 1

/ 2" ................................................ , •••••••• 4 -5 35079 ............................. Cylinder, Boom Extension w/o Val 68 3sec ............................................. 1 -6 40817 ............................. Valve, Counter Balance, Dual ................................................................... 1

58190 ............................. -Mainifold - Counterbalance Ext .............................................................. 1 32585 ............................. -Cartridge Counterbalance Valve ............................................................. 2 67486 ............................. -Relief Valve Cartridge - 1100PSI ........................................................... 1

-7 BOW36781 .................... HexNut.31-18UNC ................................................................................. 4



• FIGURE 5.6: BoomExtensionCylinder68/76

8

7

bl--l------t- 6

2

4


5

3

1 Torque To 400-500 Ft./Lhs.

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J

FIGURE 5.6: BoomExtensionCylinder68/76 •

lfEM PART NUMBER DESCRIPTION QTY

Ref. 35079 ............................. Cylinder, Boom Extension wlo Val 68 3sec ................ "l! .................... Ref. 35702 ............................. Seal Kit (Includes Items 1-8) ... ;[f.. .... f;.¥..(".t:.er. ... f.f: ...... -;J.~?.f.:':./l!i ....................................... Lock-Nut .................................................................................................... 1

2 ........................................ AQSealAssembly ..................................... ; .............................................. 1 3 ....................................... O-Ring ............................................................................................... : ....... 1 4 ....................................... Wear Ring ................................................................................................. 2 5 ....................................... O-Ring ....................................................................................................... 1 6 ....................................... Back-Up .................................................................................................... 1 7 ....................................... U-Cup (Dual Lip) ... , ......... " .............................................................. '" ...... 1 8 ....................................... Wiper ........................................................................................................ .



4lm) FIGURE5.7: SlaveCylinderAssembly58/76


)

)

FIGURES.7: Slave Cylinder Assembly 58/76 •


Ref. 30568 ............................. SlaveExtensionCylinderAssembly58/76 .................................. Ref. 1 35085 ............................. Cylinder, Slave .......................................................................................... 1 2 32611 ............................. Hydraulic Tube Assembly ......................................................................... 2 3 -30322 ............................. Valve, Holding ............................................ ~ .............................................. 1 4 BOW31373 .................... Washer, Split Lock 1/4"10 ......................................................................... 3 5 BOW31431 .................... Washer, Flat .25"10 x .63"00 ................................................................. 3 6 BOW36006 .................... Bolt, Hex .35-20UNC x 1.50 .................................................................... 3 7 BOW5924 ...................... Clamp, Strap Wrap Lock .......................................................................... 1



~ FIGURE 5.8: Intermediate Boom Assembly 58/76

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FIGURE5.8: Intermediate Boom Assembly 58/76 •

ffEM PART NUMBER DESCRIPTION QTY

Ref. 68145 ............................. Intermediate Boom Assembly 58/76 ......................................... Ref. 1 68146 ............................. Intermediate Boom .................................................................................... 1 2 68421 ............................. Wear Pad Guide Plastitrack ...................................................................... 2 3 68248 ............................. Wear Pad .................................................................................................... 2 4 68067 ............................. Extension Sheave Assembly ..................................................................... 2

68048 ......... ,. ... .... ........... -Sheave, Extension .................................................................................. 1 68051 ............................. -Bushing, Sheave ..................................................................................... 1

5 68050 ............................. Pin, Sheave ............................................................................................... 2 6 68274 ............................. Cover Plate ................................................................................................ 2 7 68272 ............................. Wear Pad ................................................................................................... 2 8 68180 ............................. Wear Pad ................................................................................................... 2 9 BOW7600 ...................... Fitting, Lube STR 1//-28 .......................................................................... 4

10 BOW36835 .................... Bolt, Soc. FIt. .38-16UNC x 1.25 ................................... ; ......................... 4 11 BOW36782 .................... Lock Nut, 3/s"-16UNC .............................................................................. 8 12 68717 ............................. Bracket, Guide 3"L .................................................................................... 1 13 BOW36838 .................... Bolt, Soc. FIt. .38-16UNC x 2.00 ............................................................. 4 14 BOW36817 .................... Bolt, Soc. FIt. .25-20UNC x 1.50 ............................................................. 2 15 BOW36780 ...... ~ ............. Nut, Hex Lock .25-20UNC ....................................................................... 2 16 BOW41502 .................... Bolt, Soc. HD .25-20UNC x 1.00 ............................................................. 6 17 BOW36000 .................... Screw, Cap Hex HD .25-20UNC x .50 .................................................... 8 18 BOW33604 .................... Bolt, SoHD 1/4-20UNC x 1.00 ............................................................... 14 19 68857 ............................. Wear Pad, MDL68 Intermed. Boom ................................................... ~ ..... 2 20 68613 ............................. Spacer, Guide Bracket 3.75 ...................................................................... 1 21 BOW36814 .................... Bolt, Soc. FIt. 1/4"-20UNC x 3// ............................................................... 6 22 68422 ............................. Bracket, Guide .......................................................................................... 1



G FIGURE 5.9: Inner Boom Assembly 58/76

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FIGURE 5.9: Inner Boom Assemhly 58/76 G ITEM PART NUMBER DESCRIPTION QTY

Ref. 68137 ............................. Inner Boom Assemhly 58/76 ................................................... Ref. 1 68138 ............................. Inner Boom Fab 58,68,76 ........................................................................ 1 2 68182 .................... : ........ Wear Pad .................................................................................................. 1 3 68180 ............................. Wear Pad .................................................... ~ ............................................. 2 4 68273 ............................. Wear Pad ................................................................................................... 2 5 BOW36835 .................... Bolt, Soc. FIt. .38-16UNC x 1.25 ............................................................ 8 6 BOW36782 .................... Lock Nut, 3/g"-16UNC ............................................................................. 8 7 36898 ............................. Pad, Wear ................................................................................................ 2 8 BOW36834 .................... Bolt, Soc. FIt. .38-16UNC x 1.00 ............................................................ 4 9 BOW36833-750 ............. Bolt, Soc. FIt. .38-16UNC x .750 ............................................................ 2

10 68228 ............................. Dead End Bracket, Assembly, Inner Boom ............................................. 4



• FIGURE6.1: Platform Assembly 58/76

7


3

3

) 2

\)

)

Ref. 1

FIGURE6.1: Platform Assembly 58/76 G PART NUMBER DESCRIPfION QTY

68564 ............................. Platform Assembly 58/76 .......................................................... Ref. 32723 ............................. Platform Weldment '" ................................................................................ 1

2 32536 ............................. Ring, Tie Down ........................................................................................ 2 3 . 68453 ............................. Skirt Weldment .......................................... : .............................................. 1

-4 BOW30112 .................... Botl,Hex.50-13UNC x3.00 .................................................................... 4 -5 BOW36729 .................... Washer, Split Lock .50"ID ....................................................................... 8 -6 BOW31205 .................... Nut, Hex .50-13UNC ................................................................................ 4 7 68937 ............................. LadderWeldment ...................................................................................... 1

-8 BOW36072 .................... Bolt, Hex .38-16UNC x 7 .......................................................................... 2 -9 69205 ............................. BRG. 2"ID .25"W 2.31 "L R#81368 .......................................................... 1

-10 34147 ............................. Bushing Self Lube ..................................................................................... 2



~ FIGURE6.2: PlatformControlBox

SEE DETAIL 'B'

"A" -r ! 18 i ~

Ii II 1\ 1\1

1

\ \/ ! \

1\ \

1\0 j I ~

U/ ,I , \ \

TO BOOM \ '. \ \,

\ I I I

\ \.

"A"

;' k NUT II ~ LOCKING RING ~ SWITCH GUARD

I

" '~ PANEL LOCKING RING \ LOCK WASHER

NUT

SvJITCH DETAIL TYP (9) PLCS

00 / I

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SVVI TCH

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ITEM

Ref. 1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30

FIGURE 6.2: PlatfonnControlBox •


....................................... Platform Control Box .................................................................... Ref. 38627 ............................. Upper Control Box For Booms .......................................................... 1 66751 ............................. Foot Switch w/Guard & Cable .......................................................... 1

"34667 ............................. Retainer Foot Switch ................................. : ....................................... 1 BOW36004 .................... Bolt, Hex .25-20UNC x 1.00 ............................................................ 2 BOW31444 .................... Washer, Flat .25 ID x .63 OD .......................................................... 2 BOW31201 .................... Nut, Hex .25-20UNC ........................................................................ 2 67114-015 ...................... Strain Relief 1 NPT ............................................................................ 1 67114-002 ...................... Strain Relief 1/2NPT .......................................................................... 1 67123-001 ...................... Seal, Connector Electrical 1/2" ......................................................... 1 67123-003 ...................... Seal, Connector Electrical 1" ............................................................ 1 67124-003 ...................... Connector, Locknut 1" ..................................................................... 1 40870 ............................. Control BoxWeldment ....................................................................... 1 40867 ............................. Base Assembly ................................................................................... 1 38015-001 ...................... ControlHandle ................................................................................... 3 40880 ............................. Guard, Switch .................................................................................... 9 40872 ............................. Switch ................................................................................................ 1 40875 ............................. Switch ................................................................................................ 3 40876 ............................. Switch ................................................................................................ 1 67758 ............................. Switch ................................................................................................ 1 50075 ............................. Switch ................................................................................................ 1 50077 ............................. Switch ................................................................................................ 1 BVDOI030 ..................... Socket ................................................................................................ 1 BVDOI031 ..................... Lamp .................................................................................................. 1 40877 ............................. Switch Assembly ............................................................................... 1 92113 ............................. -Retaining Ring 1.00 ID ................................................................... 1 92114 ............................. -Boot, Start - Stop Switch ................................................................ 1 92115 ............................. -Operator, Start - Stop Switch ......................................................... 1 92116 ............................. -Black Con., Start-Stop Switch ........................................................ 1 92117 ............................. -Red Knob Start-Stop Switch ................. ; ......................................... 1 RTNOI052 ..................... -Mounting Ring 9

/ 16" x lis" ............................................................... 1 40869 ............................. Decal .................................................................................................. 1 37029-100 ...................... ControlHandle ................................................................................... 1 BVDOI032 ..................... Lens .................................................................................................... 1 80377 ............................. Relay .................................................................................................. 1 34644 ............................. Alarm .................................................................................................. 1 67208 ............................. Relay - 12V ........................................................................................ 1



o FIGURE6.3: 110VLineToPIatfonnAssembly

fr UPPER CONTROL CONSOLE - REF

70 WHT WHT 68 YEL GRN 69 BLK BLK

GREEN SCREW

2 REF

V- 4-0 CONDUCTOR MAl N CON TROL 3 REF

I CABLE THRU I BOOM - REF.

SI L VER SCREW 2 REF GOLD SCREW

69 LIVE HOT BLK 70 NEUTRAL WHT 68 GROUND GRN

LOWER CONTROL BOX - REF 0

REF GREEN SCREW

ELECTRICAL CONNECTION DIAGRAM

9~:

J-BOX INSTALLATION - PLATFORM


J

~)

)

-)

)

FIGURE6.3: 110VLineToPIatfonnAssembly •


Ref. 69497 ............................. 110VLineToPlatfonnAssembly58/68176 ............................. Ref. 1 40956 ............................. Box, Rain Tight Single Gang .................................. ~ .......................... 1 2 67295-022 ...................... Cable, 3 Conductor 12 AWG ....................................................... 4LF. 3 80361 ............................. Receptacle 15 AMPI125V .......................... ~ ....................................... 1 4 29161 ............................. Cover, Weatherproof-Duplex ............................................................ 1 5 67114-003 ...................... Strain Relief 1/2NPT .37/.5 ............................................................... 2 6 67123-001 ...................... Seal, Connector Elec. 1/2" ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 2

-7 52710 ............................. Plug, 110 Volt .................................................................................... 1 -8 52735 ............................. Decal, 110 Volts ................................................................................ 1 9 29163 ............................. Breaker, Circuit 15 AMP ................................................................... 1

10 BOW31146 .................... Screw, Slot Round #10-32UNF x 1.00 ............................................. 4 11 BOW31430 .................... Washer, Flat #IOID ......................................................................... 16 12 BOW31362 .................... Washer, Split Lock #10ID ................................................................. 4

-13 BOW23075 .................... Connector, Butt 12-10Ga Wire .......................................................... 5 -14 BOW31147 .................... Screw, Slot, Round #10-32UNF x 1.50 ............................................ 4 -15 15376-024 ...................... Decal, 110 Volts ................................................................................ 1



8 FIGURE7.1: Platform58-TopMount6'Wide-Option

PART NUMBER DESCRlPfION QTY

Ref. A202-58 ......................... Platform 58 -Top Mount 6' Wide - Option ............................................ Ref. -1 32723 ............................. Platform Weldment ................................................................................... -1 -2 .32769 ............................. Platform Weldment .................................................................................... 1 -3 80934 ............................. Decal-1200LB Platform Load Cap ............................................................. 1 -4 80935 ............................. Decal-1250LB Platform Load Cap .................................................... ; ....... -1 -5 36893 ............................. Decal, 1200LBS ........................................................................................ 1 -6 36894 ............................. Decal- 1250LBS ....................................................................................... -1



)

)

)

I)

)

)

ITEM

Ref. -1 -2 -3 -4 -5 -6

FIGURE 7.2: Platform 68-Top Mount 6' Wide - Option •


A202-68 ......................... Platform 68 -Top Mount 6' Wide - Option ........................................... Ref. 32723 ............................. Platform Weldment .................................................................................. -1 .32769 ............................. Platform Weldment .................................................................................... 1 37958-800 ...................... Decal- 800LBS Rated Work Load .......................................................... -2 80931 ............................. Decal- 750LBS Platform Load Cap ................................................. ~ ........ 1 36888 ............................. Decal- 800 LBS ...................................................................................... -1 36887 ............................. Decal-750 LBS ........................................................................................ 1



~ FIGURE 7.3: Head&TailLights-Option58/76


Ref. A302-58/76 .................... Head & Tail Lights - Option .................................................................. Ref. -1 21060 ............................. Head & Tail Lights Construction ............................................................... 1 -2 .40953 ............................. -Light, Tail Assembly ............................................................................... 2 -3 40952 ............................. -Headlight (Assy) R#67260 ..................... ~ ............................................... 2 -4 21933 ............................. -Bracket - Tail Light 6066 ........................................................................ 2 -5 50077 ............................. -Switch R#67760 ..................................................................................... 1 -6 BOW36725 .................... -Washer Split Lock .25 ID ...................................................................... 2 -7 BOW23462 .................... -Wire, Primary I2GA I-Cond. Bulk ................................................... 22LF -8 80045 ............................. -Relay 12 Volt ........................................................................................... 1 -9 BOW3260I ............ :....... -Clamp, Wire Loom .25 ID ..................................................................... 5

-10 BOW30I75 .................... -Bolt Hex .25-28UNF x .5000 ................................................................. 2 -11 21978 ............................. -Decal Lights ............................................................................................ 1



)

)

)

FIGURE7.4: Hom Signal-Option •


Ref. A304-N/Q/C ................... Hom Signal ............................................................................................ Ref. 1 80335 ............................. Hom Auto Type ......................................................................................... 1 2 . 67280 ............................. Relay Bosch ..... ....... ...... ..... .... ....... ........ ..... ... ................ .... ........... ......... ..... 1 3 80305 ............................. Switch R#67760 ....................................... : ............................................... 1



~ FIGURE7.5: Strobe Light-Option

2 3

\

E~;=r===~-/~::::::::=\ \

H----+---H--- qJ

;

3/16 DIA THRU NEAR SIDE 3 HOLES EO-SP 4.562 B.C.


Ref. A310-58/76 .................... Strobe Light ........................................................................................... Ref. 1 58395 ............................. Light, Amber Strobe 12-72 VDC .............................................................. 1 2 BOW30002 .................... Bolt, Hex .25-20UNC x .750 .................................................................... 3 3 BOW36725 .................... Washer, Split Lock .25 ID ....................................................................... 3 4 67295-019 ...................... Cable 2 Condo 16A WG Type SO ........................................................... 8LF



)

)

)

)

)

ITEM

Ref. 1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

FIGURE7.6: l08°PlatfonnRotation58-0ption G PART NUMBER DESCRIPTION QTY

A400-58 ......................... 180° Platform Rotation .......................................................................... Ref. 35460 ............................. Actuator #TRI5 ........................................................................................ 1 68402 ............................. Bearing Thrust - 180 Deg. .... ......................... ........ ............. ....................... 1

-32775 ............................. Washer - Zinc Coated Stepped .................. ~ ............................................... 1 40976 ............................. Spacer 1.25 x I/g" ..................................................................................... 1 68456 ............................. Shaft .., Actuator 180° Rotation............................ ................................ ...... 1 21479 ............................. Valve, Needle 1/4" ....................................................................................... 2 21480 ............................. Valve, Holding ............................................................................................ 1 68885 ............................. Tube Assembly, Platform Rotation Actuator ............................................ 2 CLKOOOII-001 .............. Bar, Flat .500 x .500 2.000L .................................................................... 1 CLKOOOII-005 .............. Bar, Flat .500 x .500 5.000L .................................................................... 1 02236 ............................. Elbow 90° MJ04 M004 ........................................................................... 2 01160 ............................. Straight MJ04 MP04 ................................................................................. 2 03120 ............................. Elbow 90° M004 MP04 ........................................................................... 2 00314 ............................. Elbow 90° MJ04 MP04 ............................................................................ 2 BOW36854 .................... Bolt, Socket Flat .50-13UNC x 1.00 ........................................................ 1 BOW36196 .................... Bolt, Hex .88-09UNC x 2.50 .................................................................... 1 BOW46105 .................... Bolt, Hex 1/2"-13 UNC 11/4 GR8 ................................................................ 4 BOW36754 .................... Washer .5 x 1.38 OD Flat USS GR8 ........................................................ 4 BOW36719 .................... Flat Washer, 7/g GR8 SAE ......................................................................... 1 BOW30007 .................... Bolt, Hex .25-20UNC x 1.75 .................................................................... 2 BOW36701 .................... Washer Flat 1/4" ......................................................................................... 4 BOW30002 .................... Bolt, Hex .25-20UNC x .75 ...................................................................... 1 BOW31201 .................... Nut, Hex .25-20UNC GR5 ...................................................................... 3 BOW32585-1 ................. Clamp, Wire Loom I-IN ............................................................................ 1 BOW36705 .................... Washer .50 x 1.06 OD Flat SAE GR8 ...................................................... 4 BOW30112 .................... Bolt Hex .50-13UNC x 3.00 .................................................................... -4 BOW31205 .................... Nut Hex .50-13UNC ................................................................................ -4


MANUAL 92344·003 OCTOBER 1996

~ FIGURE7.7: Platfonnlnstallation58-0ption

10

9

18

19

1

2

36 37

3 4

38 2 PL

~ \ \

7 2 PL

8 2 PL

11 17 20 12 5


6

)

16

)

)

FIGURE7.7: PlatforrnInstallation, Flush-Mount Hyd.-Rotation 58-Option •

ITEM -PARTNUMBER DESCRIPTION QTY

Ref. 69336 ............................. Platfonn Installation, Flush-Mount Hyd.-Rot. A415/418-58 - Opt. ...... Ref. 1 70094-002 ...................... Skirt Installation, A415-68 ......................................................................... 1

. 70094-003 ...................... Skirt Installation, A418-68 ......................................................................... 1 2 68453 ............................. Skirt,68 STD .............................................. : .............................................. -1 3 69320 ............................. Pin, 68 T.M. Skirt/Cyl. ............................................................................. -1 4 80258 ............................. Pin, Skirt/Cyl. ........................................................................................... -1 5 70105 ............................. Platfonn Weldment, MDL66 ... ........ ............. ................ .... ... .......... .... ........ 1

70046 ............................. Platfonn Weldment, MDL66 ..................................................................... 1 6 32723 ............................. Platfonn, STD 68 ..................................................................................... -1 7 BOW30145-375 ............. Bolt, Hex .63-11UNC x3.750 .................................................................. 2 8 BOW34277 .................... Nut, Hex Lock 5/8-11 ................................................................................ 2 9 69319 ............................. Bracket Weldment, Upper Box Mounting .................................................. 1

10 37958-650 ...................... Decal, 650 LB Rated Work Load A418-68 .............................................. 2 37958-700 ...................... Decal, 700 LB Rated WorkLoad A415-68 .............................................. 2 37958-750 ...................... Decal, 750 LB Rated Work Load A418-58 .............................................. 2 37958-800 ...................... Decal, 800 LB Rated Work Load A415-58 .............................................. 2

-11 81368-11-024 ................ Bearing 2.0 ID x 2.250 D x 1.5 L ............................................................ 1 -12 34062 ............................. Manifold, Dual Counter Balance Valve ...................................................... 1

13 68937 ............................. Ladder Weldment ........................................... .-.......................................... -1 14 36888 ............................. Decal, 800 LBS A415/418-68 .................................................................. -1

36894 ............................. Decal, 1250 LBS A415/418-58 ................................................................ -1 15 37958-800 ...................... Decal, 800 LB Rated Work Load A415/418-68 ...................................... -2

37958-125 ...................... Decal, 1250 LB Rated Work Load A415/418-58 .................................... -2 16 36886 ............................. Decal, 650 LBS A418-68 .......................................................................... 1

69337 ............................. Decal, 700 LBS A415-68 .......................................................................... 1 36887 ...................... t ...... Decal, 750 LBS A418-58 .......................................................................... 1 36888 ............................. Decal, 800 LBS A415-58 .......................................................................... 1

17 02857 ............................. Elbow 90° MJ04 M006 ........................................................ ~ .................. 2 18 02236 ............................. Elbow 90° MJ04 M004 ........................................................................... 2 19 66043-042.00 ................. Hose Assembly #03 67684 137 ST-ST ................................................. 2 20 36996-424 ...................... Orifice Fitting Assembly 02857/.029 ........................................................ 2 21 66136-003 ...................... Cable Strain Relief 45° 112 - .3 75 ........................................................... -1 22 67114-003 ...................... Strain Relief 112 NPT .37/.5 ................................................................... -1

35 35365 ............................. Decal, Caution Aerial Operation ............................................................. Ref. 36 40130 ............................. Decal, Travel Speed ............................................................................... Ref. 37 34947 ............................. Decal, Drive ........................................................................................... Ref. 38 34147 ............................. Bushing, Self Lube ................................................................................. Ref.



f.Ei) FIGURE 7.8: PlatfonnInstallation68-0ption

36 37

10

CONSOLE TOP FACE

A IT ACH DECAL TO CONTROL 35

(ALSO ON LOWER CONTROL)

r-: 9

7 2 PL

8 2 PL

3 5

4 6

38 2 PL


)

) \ \

\ \ \ \

\ \ \ \

\ \ ~

\ \

)

)

)

FIGURE 7.8: PlatfonnInstallation, Flush Mount Manual-Rotation58/68-0ption ® ITEM PART NUMBER DESCRIPTION QTY

Ref. 69583 ............................. Platform Installation, Flush-Mnt. Man-Rot. A425/A428-58/68 - Opt. .. Ref. 1 69584-001 ...................... Skirt Installation, A425-68 ......................................................................... 1

69584-002 ...................... Skirt Installation, A428-68 ......................................................................... 1 2 . 68453 ............................. Skirt,68 STD .............................................. ~ .............................................. -1 3 69320 ............................. Pin, 68 T.M. SkirtiCyl. ............................................................................. -1 4 80258 ............................. Pin, SkirtiCyl. ........................................................................................... -1 5 70105 ............................. Platform Weldment, MDL68 A428-68 ..................................................... 1

70046 ............................. Platform Weldment, MDL68 A425-68 ..................................................... 1 6 32723 ............................. Platform, STD 68 ..................................................................................... -1 7 BOW30145-375 ............. Bolt, Hex .63-11UNC x 3.750 .................................................................. 2 8 BOW34277 .................... Nut, Hex Lock 5/8-11 ................................................................................ 2 9 69627 ............................. Bracket Weldment, Upper Box Mounting .................................................. 1

10 37958-650 ...................... Decal, 650 LB Rated Work Load A428-68 .............................................. 2 37958-700 ...................... Decal, 700 LB Rated Work Load A425-68 .............................................. 2 37958-750 ...................... Decal, 750 LB Rated Work Load A428-58 .............................................. 2 37958-800 ...................... Decal, 800 LB Rated Work Load A425-58 .............................................. 2

-11 68937 ............................. Ladder Weldment ...................................................................................... -1 -12 36888 ............................. Decal, 800 LBS ......................................................................................... -1

36894 ............................. Decal, 1250 LBS ....................................................................................... -1 -13 37958-800 ...................... Decal, 800 LBS Rated Work Load A425-68 ........................................... -2

37958-125 ...................... Decal, 1250 LBS Rated Work Load A428-68 ......................................... -2 -14 36886 ............................. Decal, 650 LBS .......................................................................................... 1

69337 ............................. Decal, 700 LBS .......................................................................................... 1 36887 ............................. Decal, 750 LBS .......................................................................................... 1 36888 ............................. Decal, 800 LBS .......................................................................................... 1

-15 66136-003 ...................... Cable, Strain Relief 1/2, .375 45° ............................................................ 1 -16 67114-003 ...................... Strain Relief 1/2 NPT .37/.5 ....................................................................... -1

35 35365 ............................. Decal, Caution Aerial Operation ............................................................. Ref. 36 40130 ............................. Decal, Travel Speed ............................................................................... Ref. 37 34947 ............................. Decal, Drive ........................................................................................... Ref.

-38 34147 ............................. Bushing, Self Lube ................................................................................. Ref.



~ FIGURE 7.9: Platform Top Mount 8' Wide 58 - Option


Ref. A203-58 ......................... Platform Top Mount 8' Wide 58 - Option ............................................. Ref. -1 32723 ............................. Platform Weldment ................................................................................... -1 -2 32770 ............................. Platform Weldment .................................................................................... 1 -3 80935 ............................. Decal-I 250 LB Platform Load Cap ............ ~ .............................................. -I -4 80936 ............................. Decal-Platform Capacity-II 00 LB ............................................................. 1 -5 36894 ............................. Decal- 1250 LBS ...................................................................................... -1 -6 36892 ............................. Decal, 1100 LBS ............................................................................ , ........... 1



)

)

)

)

FIGURE7.10: PlatformTopMount8'Wide68-0ption •


Ref. A230-68 ......................... Platform Top Mount 8' Wide 68 - Option ............................................. Ref. -1 32723 ............................. Platform Weldment ................................................................................... -1 -2 32770 ............................. Platform Weldment .................................................................................... 1 -3 37958-800 ...................... Decal, 800 LBS Rated Work Load ............ ~ .............................................. -2 -4 37958-650 ...................... Decal, 650 LBS Rated Work Load ............................................................ 2 -5 36888 ............................. Decal, 800 LBS .......................................................................................... -1 -6 36886 ............................. Decal, 650 LBS .......................................................................................... 1



e FIGURE 7.1 1: AirLineToPlatform58-0ption

TIEM

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


A401-58 ......................... Air Line To Platform 58 - Option .......................................................... Ref. 68631 ............................. Option-Air Line To Platform 58 ................................................................ 1 21057 ................... .......... -Parts, Common To Airline Opt ............................................................... 1 67100-004 ...................... -Hose Assembly, .500 Airline 600" .......................................................... 1 67100-007 ...................... -Hose Assembly, .500 Airline 93 IN ........................................................ 1 67101 ............................. -Guide, Roller, Hose ................................................................................. 1 CMP02365 ..................... -Bracket - Airline Option ........................................................................... 1 BOW31135-1 ................. -Screw, Slotted, Rnd. #10-24UNC x .63 ................................................ 4 BOW31246 ........ , ............ -Nut, Hex #10-24UNC ............................................................................. 4 BOW31323 .................... -Washer, Split Lock #10 ID .................................................................... 4



)

)

)

)

FIGURE 7.12: CommonPartsToAirline58,76-0ption •


Ref. 21057 ............................. Common Parts To Airline - Option ...................................................... Ref. 1 33370 ............................. Bracket, Platform Airline-Opt. ................................................................... 1 2 . 68626 ............................. Weldment, Hose Reel Mtg. ....... ......... ...... ......... ........ ............. ...... ....... ... .... 1 3 67102 ............................. Guide, Roller, Hose .................................... : ............................................... 1 4 BOW30176 .................... Bolt, Hex .25-28UNF x .625 ..................................................................... 4 5 BOW31325 .................... Washer, Split Lock .2510 ......................................................................... 4 6 21394 ............................. Assembly, Air Hose Reel ........................................................................... 1 7 67051 ............................. Coupling Quick Disconnect Male 1/2" •.•.•••••.•••••....••••••••.••••••••.••••••••.••••••.••• 1 8 67052 ............................. Coupling Quick Disconnect Female .......................................................... 1 9 67053 ............................. Cover Dust Quick Disconnect. .................................................................. 1

10 67054 ............................. Cap, Dust, Quick Disconnect .................................................................... 1 11 04021 ..................... , ....... Elbow 45° MJ08 MP08 .................... , ....................................................... 1 12 BOW30050 .................... Bolt, Hex .38-16UNC x .5000 .................................................................. 4 13 BOW31327 .................... Washer, Split Lock 3/g" 10 ........................................................................ 4 14 33371 ............................. Bracket, Boom Airline - Opt. ..................................................................... 1 15 CMP02365 ..................... Bracket - Airline Option .... ........ ... ..... ..... .............. ......... ........ ... .... .............. 1 16 00562 ............................. Elbow 90° MP08 FP08 ............................................................................. 2 17 . BOW31135-1 ................. Screw, Slotted Rnd. #10-24UNC x .63 .................................................... 4 18 BOW31246 .................... Nut, Hex #10-24UNC ............... ~ ............................................................... 4 19 BOW31323 .................... Washer, Split Lock #10 10 ....................................................................... 4




)

)

)

)

FIGURE7.13: AirLineToPlatform68-0ption •


Ref. A401-68 ......................... Air Line To Platform 68 - Option .......................................................... Ref. -1 68632 ............................. Option-Air Line To Platform 68 ................................................................ 1 -2 68842 ............................. -Parts, Common To Airline Opt. .............................................................. 1 -3 ·67100-005 ...................... -Hose Assembly, .500 Airline 720" .......... ~ ............................................... 1 -4 67101 ............................. -Guide, Roller, Hose ................................................................................. 1 -5 CMP02365 ..................... -Bracket - Airline Option ........................................................................... 1 -6 BOW31135-1 ................. -Screw, Slotted, Rnd. #10-24UNC x .63 ................................................ 4 -7 BOW31246 .................... -Nut, Hex #10-24UNC ............................................................................. 4 -8 BOW31323 .................... -Washer, Split Lock #10 ID .................................................................... 4



fD FIGURE 7.14: CommonPartsToAirline68-0ption


Ref. 68842 ............................. Common Parts To Airline 68 - Option .................................................. Ref. -1 33370 ............................. Bracket, Platform Airline - Opt. ................................................................. 1 -2 67100-7 .......................... Hose Assembly, .500 Airline 93 IN .......................................................... 1 -3 -67101 ............................. Guide, Roller, Hose .................................... ; ............................................... 1 -4 CMP02365 ..................... Bracket - Airline Option .... ..... ..... ...... ............ ............. .... ................. ...... ..... 1 -5 BOW31135-1 ................. Screw, Slotted, Rnd #10-24UNC x .63 .................................................... 4 -6 BOW31246 .................... Nut, Hex #10-24UNC ............................................................................... 4 -7 BOW31323 .................... Washer, Split Lock #10 10 ....................................................................... 4 -8 BOW31327 .................... Washer, Split Lock 3/8" 10 ....................................................................... 4 -9 02475 ............................. Elbow 90° MJ08 MP08 ............................................................................ 1

-10 67102 ............................. Guide, Roller, Hose .................................................................................... 1 -11 BOW30176 .................... Bolt, Hex .25-28UNF x .625 ~ .................................................................... 2 -12 BOW31325 .................... Washer, Split Lock .2510 ......................................................................... 4 -13 33371 ............................. Bracket, Boom Airline-Opt. ....................................................................... 1 -14 21394 ............................. Assembly, Air Hose Reel ........................................................................... 1 -15 68626 ............................. Weldment, Hose Reel Mtg ......................................................................... 1 -16 67051 ............................. Coupling Quick Disconnect Male 1/2" ........................................................ 1 -17 67052 ............................. Coupling Quick Disconnect Female .......................................................... 1 -18 67053 ............................. Cover Dust Quick Disconnect. .................................................................. 1 -19 67054 ............................. Cap, Dust Quick Disconnect ..................................................................... 1



)

)

)

FIGURE 7.15: AirHoseToPlatfonn 76-0ption •


Ref. A401-76 ......................... Air Line To Platform 76 ......................................................................... Ref. -1 68633 ............................. Airline To Platform - Option ...................................................................... 1 -2 21057 ............................. -Common Parts To Airline Opt. ................ : .............................................. 1 -3 67100-008 ...................... -Hose Assembly .500 Airline 744 IN ....................................................... 1 -4 67100-007 ...................... -Hose Assembly .500 Airline 93 IN ........................................................ 1 -5 67101 ............................. -Guide, Roller, Hose ................................................................................. 1 -6 CMP02365 ...... ..... .... ...... - Bracket - Airline Option ....... ............... ... .... .... ............. .... ..... .... .... .......... 1 -7 BOW31135-1 ................. -Screw, Slotted Rnd #10-24UNC x .63 .................................................. 4 -8 BOW31246 .................... -Nut, Hex #10-24UNC ............................................................................. 4 -9 BOW31323 .................... -Washer, Split Lock #10 ID .................................................................... 4



• FIGURE 7. 16: Worklight-PlatformMounted-Option

; 1

NOTES:

1. REFER TO ELECTRICAL SCHEMATIC FOR NUMBER OF CIRCUIT THAT FEEDS THE PLA TFORM WORK LIGHT.


)

)

FIGURE 7.16: Worklight-PlatformMounted-Option •


Ref. A406 ............................... WorkLight - Platform Mounted ............................................................. Ref. 1 67260-027 ...................... Work Lamp - 12V AS115 .......................................................................... 1 2 . 58282 ............................. Wire, 12Ga. Black .................................................................................. 3LF 3 67114-001 ...................... Connector Strain Relief.............................................................................. 1 4 67123-001 ...................... Seal, Connector Electrical 1/2" .................................................................... 1 5 67124-001 ...................... Locknut - 1/2" NPT Conduit ....................................................................... 1 6 69338 ............................. Plate - Work Light Mounting ..................................................................... 1 7 69339 ............................. Clamp - Work Light ................................................................................... 1 8 BOW36780 .................... Nut, Hex .25-20UNC x 1/2" GR8 ............................................................ 6 9 BOW36701 .................... Washer Flat 1/4" .......................................................................................... 6

10 BOW46000 .................... Bolt, Hex 1/4"-20UNC x 1/2" GR8 .......................................................... '" 4 11 BOW30010 .................... Bolt, Hex .25-20UNC x 2.500 .................................................................. 2



fD FIGURE7.17: LP/GasDualFuel(Liquid)C68/C76-0ption

----------- 1-_______________ -.l--I~


18

)

14

)

)

)

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

-10 -11 -12 -13 14

-15 -16 -17 18

-19 -20 -21 -22 -23 -24 -25 -26 -27 -28

FI GURE 7.17: LP /Gas Dual Fuel (Liquid) C68/C76 - Option •


A506-C68/C76 ............... LP/Gas Dual Fuel-Option ..................................................................... Ref. 36430 ............................. Carb-Adapter Dual Fuel ............................................................................. 1 68096 ............................. Switch, Vacuum Dual Fuel ........................................................................ 1 -51630 ............................. FilterlockFL-218 LP-Gas .......................................................................... 1 36427 ............................. VaporizerRegulatorLiquid ........................................................................ 1 36649 ............................. Adapter, Hose/Carburetor 2" x I/g" ............................................................ 1 BOW40523 .................... Screw, Set, Soc .25-20UNC x .50 ........................................................... 4 BOW31202 .................... Nut, Hex .31-18UNC ................................................................................ 4 BOW36726 .................... Washer, Split Lock .31 ID ....................................................................... 4 BOW30004 .................... Bolt, Hex .25-20UNC x 1.00 .................................................................... 2 BOW31201 .................... Nut, Hex .25-20UNC GR5 ..................................................................... 2 BOW36725 .................... Washer, Split Lock .25 ID ....................................................................... 2 BOW36815 .................... Bolt, Soc. Flat .25-20UNC x 1.00 ............................................................ 2 69524 ............................. Bracket, Ford LP Vaporizer Mounting ...................................................... 1 67586-002 ...................... Tank, LP Fuel Liquid 43.5LB .................................................................... 1 67075 ............................. Coupling, Quick Disconnect ...................................................................... 1 67075-002 ...................... Coupling, Quick Disconnect ...................................................................... 1 02795 ............................. Straight MJ06 MP04 ....... , ............. ... ......... ... ... ........ ....... ... .... ...... .... ... ....... 1 69624 ............................. Turret Mod., MDC68 LP Bracket Mount... ......... ........... ...... ..... ....... ...... ... 1 69625 ............................. Turret Mod., MDC76 LP Bracket Mount .................................................. 1 00498 ............................. Elbow 90° MJ06 MP06 ............................................................................ 1 38501-108.00 ................. Hose Assembly #06 04167LPG ................................................................ 1 BOW13350 .................... Bushing 3/g" x 1/4" ...................................................................................... 1 36428 ............................. Valve, Liquid Lp Gas Relief ....................................................................... 1 54094 ............................. U-Bolt 1/4"-20UNC ..................................................................................... 1 02543 ............................. Tee, FP6 FP6 FP6 .................................................................................. 1 02699 ............................. Straight, MJ06 MP06 ................................................................... , .......... 1 BOW9749 ...................... Hose, Fuel Line .25 Dia ............................................................................ 1 04688 ............................. Tee, Barbed Plastic 1/4" ............................................................................ 1 69505 ............................. Turret MWeldment, MDC68 .................................................................... -1 69521 ............................. Turret MWeldment, MDC76 .................................................................... -1



® FIGURE 7. 18: LPlFuel(Liquid)58/76-0ption

5

10

~ ~

""'-""'-~


)

~ ~ ~

~ ~

11 13 12

)

)

)

')

FIGURE 7.18: LPlFuel(Liquid) 58/76-0ption CD ITEM PART NUMBER DESCRIPfION QTY

Ref. A507/A508-58/76 .......... LP/Gas Dual Fuel-Option ..................................................................... Ref. -1 67586 ............................. Tank, LP Fuel Liquid A508-58/76 ............................................................ 1

67103 ............................. Tank, LP Fuel Vapor A507-58/76 ............................................................ 1 -2 . 67075-001 ...................... Coupling, Quick Disconnect ...................................................................... 1 -3 67075-002 ...................... Coupling, Quick Disconnect ...................................................................... 1 -4 02795 ............................. Straight MJ06 MP04 ............................................................................... 1 5 67105 ............................. Bracket, LP Tank Mounting, Vertical ........................................................ 1

-6 00498 ............................. Elbow 90° MJ06 MP06 ........................................................................... 1 -7 04167 ............................. Hose, Bulk #06 LPG ............................................................................. 9LF -8 04558 ............................. Straight #06 LPG, Hose End .................................................................... 2 -9 36428 ............................. Valve, Liquid LP Gas Relief A508-58/76 .................................................. 1 10 37990 ............................. Bracket, Mounting LPG Converter ............................................................ 4 11 BOW30027 .................... Bolt, Hex .31-18UNC x .75 ...................................................................... 4 12 BOW31202 .................... Nut, Hex .31-18UNC ................................................................................ 4 13 BOW46052 .................... Bolt, Hex 3/g-16UNC x .75 ....................................................................... 4



• FIGURE 7. 19: IsuzuDieselEngine-Option


)

)

)

ITEM

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

-10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25 -26 -27 -28 -29 -30 -31 -32 -33 -34 -35 -36 -37 -38 -39 -40 -41 -42 -43

FIGURE 7. 19: IsuzuDieselEngine-Option •


A517-58176C .................. Isuzu Diesel Engine - Option ................................................................. Ref. 69546 ............................. EnginelPump Assembly 58176 Isuzu ...................................................... '" 1 69502 ............................. EnginelPump Assembly 58176 Ford ........................................................ -1

. 67944 ............................. Mount - Engine .......................................... ; .............................................. -4 69203-001 ...................... Mount, MDL58176 Engine Stud ............................................................... 4 69181 ............................. Muffler Weldment, MDL681F0rd ............................................................. -1 69512 ............................. Bracket Weldment, Engine Support .......................................................... -1 38068 ............................. Cable Assembly Battery-Emergency Pump .............................................. -1 69525 ............................. Box (Assy) - 68176 Ford Engine El. ......................................................... -1 69527 ............................. Box (Assy) - 68176C Isuzu Engine ............................................................ 1 BOW24119 .................... Clamp, Hose 2 ID to 2.25 ID .................................................................... 2 67471-001 ...................... Fuel, Gasoline, Regular ...................................................................... -1 OGL 67471-002 ...................... Fuel, Engine, Diesel #2 ....................................................................... 10GL 67804 ............................. Hose Radiator 1.5 x .75 x 22 LG ............................................................... 1 38029 ................. ' ........... Gasket, Ford LSG4.23 Exhaust. ............................................................... -1 69280 ............................. Hardline - 68176 Ford Gas ........................................................................ -1 69204 ............................. Brace, Radiator Isuzu Rear 11" ................................................................. 1 69084 ............................. Weldment, Radiator Diesel ......................................................................... 1 36568 ............................. Hose - Isuzu C240 Radiator ....................................................................... 1 21849 ............................. Decal- Gas ............................................................................................... -1 15376-012 ...................... Decal-Diesel ............................................................................................. 1 67812 ............................. Decal- Glowplug ....................................................................................... 2 69226-001 ...................... Tube, Muffler A517-58176, Half ............................................................... 1 81878 ............................. Harness - 58/68176 Ford Gas ................................................................... -1 BOW23399-3 ................. Battery Terminal, Mil. Type ....................................................................... 1 BOW23399-4 ................. Battery Terminal, Mil. Type ....................................................................... 1 80399 ............................. Clamp, Muffler U-Bolt6" ........................................................................... 2 69240 ............................. Support Weldment - Exhaust Pipe ............................................................. 1 67169-019 ...................... Clamp, Muffler U-Bolt 6" ........................................................................... 2 67860 ............................. Muffler, Donaldson.. ..... ...... ..... ........ ..... ............. .... .... ........... ......... ... ......... 1 69227 ............................. Tube, Exhaust A517-58176 ........................................................................ 1 69237 ............................. Heat Shield Weldment ................................................................................ 1 69292 ............................. Weldment, Air Intake ................................................................................. 1 69222 ............................. Flange Weldment - Isuzu Exhaust .. ....... ..... ..... ...... ... .............. ..... .............. 1 67099-005 ...................... Hose - Air Intake 2.25 ID ..................................................................... 8LF 69295 ............................. Fuel Line Installation - A517-5876C .......................................................... 1 BOW24110 .................... Clamp, Hose .313 to .875 ......................................................................... 2 BOW9749-375 ............... Hose, Fuel .375 ID SAE30R7 Bulk .................................................... 50LF 54247-049.00 ................. Cable Assembly, 49" LG Battery .............................................................. 1 54247-025.00 ................. Cable Assembly, 25" LG Battery .............................................................. 1 69182 ............................. Heatshield, 68 Ford ............. ' ..................................................................... -1 66727 ............................. Manual: LRG-423 Ford Engine Service ................................................... -1 66127 ............................. Workshop Manual, Isuzu Diesel ................................................................ 1 69226 ............................. A517 - Muffler Tube Assembly ................................................................. 1


CD FIGURE 7.20: Engine/PumpAssembly-IsuzuDiesel58/76-0ption

ITEM

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

-10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24


69546 ............................. EnginelPump Assembly - Isuzu Diesel 58/76 - Option ......................... Ref. 38414 ............................. Engine - C240-PW Diesel Isuzu ................................................................ 1 67906 ............................. Coupling Assembly .................................................................................... 1

·67817 ............................. Plate; Pump Mounting R67817 ................................................................. 1 38329 ............................. Hydraulic, Pump, Varible Disp .................................................................. 1 67910 ............................. Mount, Rear Diesel................ ........................................................ ............ 1 67911 ............................. Motor Mount Weldment ..... ..... ........ ....... ............... ........ ............... ............. 1 67157-003 ...................... Switch 4 PSI NO R#67809 ...................................................................... 1 36540 ............................. Wire, Throttle 12.0 .................................................................................... 1 04600 ............................. Elbow 90° MJ20 M024 ............ ..................... .............. ............... ............. 1 02668 ............................. Elbow 90° MJ16 M012 ........................................................................... 1 67923 ............................. Mount, Rear Diesel - Left Hand.. ............ .......... ............. ............... ...... ....... 1 BOW42331 .................... Bolt, Hex MI0 x 1.25 x 25mm ................................................................. 2 69258 ............................. Tube, Dipstick ........................................................................................... 1 30469 ............................. Dipstick................ ............... ..................... ........... ............... .............. .......... 1 BOW9749-375 ............... Hose, Fuel .37510 SAE30R7 Bulk ...................................................... lLF BOW24110 .................... Clamp, Hose .313 to .875 ......................................................................... 3 BOW32602 .................... Clamp. Wire Loom .375 Dia .................................................................... 1 BOW44071 .................... Bolt, Hex 10mm x 20mm ......................................................................... 1 BOW43964 .................... Washer, Lock 1 Omm ................................................................................ 1 69309 ............................. Brace, Dipstick Tube ................................................................................. 1 BOW9697 ...................... Grommet, Rubber, .38 10 x .75 00 ........................................................ 1 BOW39002 .................... Bolt, Hex Hd. 1/4"-20 x 3/4" GR8 ............................................................... 1 BOW31325 .................... Washer Split Lock .25 10 ......................................................................... 1 40808 ............................. Solenoid - 12V DC ..... ................. ....... .................... ........ ............... ............. 1



)

-)

)

(~)

FIGURE 7.21: Fuel Line Installation-IsuzuDiesel58/76C - Option e ITEM PART NUMBER DESCRIPTION QTY

Ref. 69295 ............................. Fuel Line Installation-Isuzu Diesel- A517-58/76C ................................ Ref. -1 69293 ............................. Tube - A517-58/76C Isuzu Fuel ................................................................ 1 -2 69294 ............................. Hardline -68/76 Isuzu Diesel ...................................................................... 1 -3 . 00313 ............................. Elbow 90° MJ06 MP02 ..... ..... .... ........ ... ....... ...... ..... ...... ...... ... .... ..... ..... .... 1 -4 04030 ............................. Straight MP02 MP02 ................................................................................ 1 -5 04656 ............................. Elbow 90° MP04 FP02 ...... ......... ............................ ............. ....... ..... .......... 1 -6 02795 ............................. Straight MJ06 MP04 ................................................................................. 1 -7 04625-001 ...................... Valve, Mini Ball .......................... ......................................................... ....... 1 -8 BOW32601 .................... Clamp, Wire Loom .25 10 ........................................................................ 8 -9 BOW30001 .................... Bolt, Hex .25-20UNC x .625 ................................................................... 5

-10 BOW31444 .................... Washer, Flat .25 10 x .63 00 .................................................................. 5 -11 BOW9749-375 ............... Hose, Fuel .375 10 SAE30R7 Bulk ...................................................... 2LF -12 BOW24108 .................... Clamp, Hose 1/8 _5/16" ................................................................................. 4 -13 01219 ............................. Sleeve, Tube .306 ..................................................................................... 1 -14 04012 ............................. Nut, Cap #06 ............................................................................................ 1



• FIGURE 7.22: 4-Wheel Drive - Option


Ref. A604-58/68 .................... 4-Wheel Drive - Option ......................................................................... Ref. -1 35913 ............................. Hub Assembly - Idler ................................................................................ -2 -2 .68930 ............................. Axle Assembly, 58/68 Fixed Drive ............................................................ 1 -3 68931 ............................. Schematic, Hydraulic 4WD 68/76 ............................................................. 1 -4 36922 ............................. Valve, Check/Choke .040 Dia .................................................................. 1 -5 37030 ............................. Decal 4 x 4 ................................................................................................ 2 -6 69547 ............................. Hose Kit - 68/76 4WD Chassis .................................................................. 1 -7 69539 ............................. Hose Kit - 58/68/76 2WD Chassis ............................................................ -1



)

)

)

()

FIGURE7.23: Axle Assembly, 58/68 FixedDrive-Option ® ITEM PART NUMBER DESCRIPTION QTY

Ref. 68930 ............................. Axle Assembly, 58/68 Fixed Drive ........................................................ Ref. -1 21492 ............................. Torque Hub 54:1 Ratio ............................................................................. 2 -2 BOW30145-175 ............. Bolt, Hex .63-11UNC x 1.75 .................................................................. 16 -3 . BOW36731 .................... Washer Split Lock .63 ID ....................................................................... 16 -4 35821 ............................. Motor, Hydraulic wIBrake #RSB05S ........................................................ 2 -5 BOW36105 .................... Bolt, Hex .50-13UNC x 1.250 .................................................................. 4 -6 BOW36729 .................... Washer, Split Lock .50 ID ....................................................................... 4 -7 58425 ............................. Vent 5PSI 1/4 NPT Relief ......................................................................... 2 -8 02461 ............................. Straight MP06 FP04 ................................................................................. 2 -9 02333 ............................. Elbow 90° . MJl 0 M012 ........................................................................... 4

-10 04538 ............................. Elbow 90° FP04 F J04 .............................................................................. 2 -11 02662 ............................. Elbow 90° MJ06 M006 ........................................................................... 2 -12 02593 ............................. Tee MJ04 MJ04 M004 ............................................................................ 2



8 FIGURE 7.24: Hose Kit- 68/76 4WD Chassis - Option

;r::; ~

r-..

;r::; ~

ROTARY COUPLING

HOSES FOR .. TURRET

·5

/ 4

3

6

7

HOSES FOR CHASSIS

2

\

STEERING CYLINDER

\ 23

22


16

11

9

10

8

13 21

19

18 17

12

FIXED AXLE MOTORS (2)

15

62

I P1

61

NOTES

63 .42

SERIES/PARALLEL

VAL VE ASSY

.43

.41

1. VENDOR SHALL TAG EACH HOSE ASSY AT BOTH ENDS WITH THE NUMBER 69S47-XX, WHERE "xx" IS THE ITEM NUMBER

2. ITEMS 1-13 ON THIS D'NG ARE THE SAME AS ITEMS 1-13 ON DRAWING 69539. ITEMS 12 & 13, HOWEVER, CONNECT TO DIFFERENT PORTS.

)

)

ITEM

Ref. 1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20 21 22 23

FIGURE7.24: HoseKit-68/764WDChassis-Option ® PART NUMBER DESCRIPTION QTY

69547 ............................. Hose Kit - 68/76 4WD Chassis - Option ............................................... Ref. 66043-069.50 ................. Hose Assembly #03 67684 137 ST1-ST1 ............................................. 1 66697-069.50 ................. Hose Assembly #08 66675 137 ST-ST ................................................. 1 66718-032.00 ................. Hose Assembly #12 66708 137 ST-90 .................................................. 1 66718-032.00 ................. Hose Assebmly #12 66708 137 ST-90 .................................................. 1 66043-032.50 ....... , ......... Hose Assembly #03 67684 137 ST1-ST1 ............................................. 1 66696-062.50 ................. Hose Assembly #04 66646 137 ST-ST ................................................. 1 66696-062.50 ................. Hose Assembly #04 66646 137 ST-ST ................................................. 1 66082-050.00 ................. Hose Assembly #03 67684 137 ST-90 .................................................. 1 66082-050.00 ................. Hose Assembly #03 67684 137 ST-90 .................................................. 1 65080-050.00 ................. Hose Assembly #06 66645 137 ST1-90 ................................................ 1 65080-050.00 ................. Hose Assembly #06 66645 137 ST1-90 ................................................ 1 66709-065.50 ................. Hose Assembly #12 66708 137 ST-ST ................................................. 1 66718-070.00 ................. Hose Assembly #12 66708 137 ST-90 .................................................. 1 66718-102.50 ................. Hose Assembly #12 66708 137 ST-90 .................................................. 1 66718-100.00 ................. Hose Assembly #12 66708 137 ST-90 .................................................. 1 66709-042.25 ................. Hose Assembly #12 66708 137 ST-ST ................................................. 1 66082-050.00 ................. Hose Assembly #03 67684 137 ST-90 .................................................. 1 66082-050.00 ................. Hose Assembly #03 67684 137 ST-90 .................................................. 1 65080-050.00 ................. Hose Assembly #06 66645 137 ST1-90 ................................................ 1 65080-050.00 ................. Hose Assembly #06 66645 137 ST1-90 ................................................ 1 66709-061.50 ................. Hose Assembly #12 66708 137 ST-ST ................................................. 1 66043-069.50 ................. Hose Assembly #03 67684 137 ST1-ST1 ............................................. 1 66697-069.50 ................. Hose Assembly #08 66675 137 ST-ST ................................................. 1



(

58

D ~ptl!GS

COMPONENTS ON TURRET

EH

HOUR

SlOW~ 280C FAST

RED

~

1. FOR SIMPLICITY, 40 INTERCONNECTlN~ LINES, REPRESENTING CONTROL CABLE BETWEEN TURRET .AND PLATFORM, HAVE BEEN OMITTED. THE INDIVIDUAL CONDUCTORS IN THE CABLE IS IDENTIFIED BY CIRCUIT #/CABLE.

2. LINES REPRESENTING ENGINE HARNESS (EH) ARE CONTINUED ON SHEET 2. THE VALVE HARNESS IS IDENTIFIED BY CIRCUIT #/YH.

3. SEE SHEET 2 OF 40865 FOR ELECTRICAL SCHEMATIC OF FOUR CON TROLLERS.

4. FOR EXPLANATION OF SYMBOLS, SEE DWG 58371. 5. STEER SWITCH, J5, IS ATOP DRIVE CONTROL HANDLE. 6. THIS DRAWING SUPERCEDES 69522.

~n:-----o~r-----------oJ'lfO---------!-+ HPI AUX. VALVE

~1'r----o~r----------oJ'l,o---------!-+ S1£ER lEFT

~1'r---o~r---------~I\,o-------~-+S1£ERm~T

~n:----o~r---------~~----------!-+~~~

~~---o~r-----------~I\,o-------------!-+~~UP

~~---o~r_----------~I\~--------~-+~~un

~n:----o-ttr_------------~'\~---------+ ~1FORW m~T

COMPONENTS ON PLATFORM

5

3 510 0 ~OW PLUGS

Q ~- reDew 3 " elBt!"IfPRY RlGHJ

6lHlFOIN I fEI

MARE "SO! UFO J}IfRf IS NO mylN!! 55)

~"RE ~ARE (ISOlAnD. lHERE IS NO JERMlNA!. 83)

c ~ ENGINE f2 fopDON fOB MOl M ONt l'

C ~JS - OPDON M()!IND Of ,,0 V"C {JHfRE IS NO 1fRMINAlo...ft6L

~O VAC (Of>DON) (JHERE IS NQ IfR\IINAI fi) __

7!J.Bf1.0 YAC <opnclNl <JHfRE IS NO IfRLIINA! ~

58-EMERGENCY

OJ

51t sa..GAS --*&crmn~~4?"'-O"'a~ CAat£ DUAL FUEl. OPilON

~a~~~~----------------

PRopRIETARY INFORMADQti ~ 1---+-----+-----+-----1 ~-:~~:a.~~~ ~ WACO, TEXAS r--1------~----~r-~~~~~~~~~~~~~----------------------------------------~

~n:--~~--------~~~----~~

~I'r---o~r--------------~I\~-----~-+~ARO

t--;-------t-----~r---____1 ~ 1RTD COSNT IE CNJ..VM caa>a!AlIIlI. /U JIIJf1S 11RE

SCHEMATIC, MDC68/76 ELECTRICAL UNLESS OlHERWiSE SPECIFIED: DlII£NSKlNS ARE IN INCHES

j------------i WOBIIUt.ATOR

TOLERANCES ON: ANQ..E DECIIIAU. ~

~~~~_nr_----------------------------~~M~D A 9698 ±1/'r ~~O ±1/1e

LTR. E.C.N. NO. SIZE DRA'MNG NO.

B 69564 DAlE: APPR. DRAVttI BRIAN 1/19/96

5844

REV.

A 5/5/96 RAK CHEO<ED MCB 3/6/96

LTR. E.R.N. NO. DAlE: APPR. APPROVED RAK 5/5/96 SCALE NONE PLOT 1/1 SHEET 1 OF 2

(

(

23 GPM 23 GPM 5 GPM 5 GPM 7 GPM

BOOM EXTENSION CYUNDER ASSY,

2 58079

36503(S) 350790)

3.75 BORE 2.72 ROD 187.5 STROKE

~HIGH SPEED VALVE

~----~--------~r_------------------------------------_;======~====~~~====~~t. ~3 i 'T

36922 n CHECK/CHOKE u VALVE

33430 RETURN FILTER

10

<>

32524SS 38CC/REV I 37198RR 35CC/REV

P

21368 CHECK VALVE

50148 PRESSURE -

FILTER

~~? i\r---c 1---- ------l

2~SqO(~ ~ I i I I ~\_ ENGINE i '~ I

'----r-/'--;Xrr-I --' 2800 RPM i..-____ -+! __ ---'y \ ~ !

67585-007 BALL VALVE

I L ___________ J i

~7 ~~rJON

AUXILIARY LOVERING PDVER 35659

STRAINER

HYDRAULIC TANK CAPACITY = 36.0 GALLONS

NOTE: FOR CYLINDER PART NUMBERS (T) DESIGNATES TEXAS HYDRAULICS (S) DESIGNATES SIERRA HYDRO-LINE

i i

F

E 0

C

B A

LTR.

LTR.

10047

7130

6616

4748

4544

4036

E.C.N. NO.

2374

E.R.N. NO.

(Z.17.19~ 10/5/94

6/1/94

9/15/92

7/28/92

9/10/91

DATE

OATE

DATE

-

RAK RAK

32554 ROTARY

COUPLING

II

35086(T) 36499(S) STEERING CYLINDER

TOPPING CYUNDER ASSY, MODEL 58 8. 68 MODEL 76

35080(T) 35080(T)

36501(S) 36502(S)

~--- ---~-- --l i8~l~~:OKE I --- \ I , 1400 , , PSI 3000' I PSI I 67455 , I , HOLDING VALVE

J A MOTOR

ASSY.

21479

36490(S) r;:::,----:-l NEED~LE VALDVE. 35085<T) I "'\ ... / I 58340(S) ~-- :.

SLAVE LEVELING : .,l' : 1 ~~~~~~T) ~r;; L,

CYLINDER T l;: ,_~ tt' LEVELING I ~--~ 30322 CYLINDER I I 21480 PLATFORM

P.O. CHECK P.O. CHECK ROTARY

!sT~~:;~-~~-~~- ~tj~ ~ ~~l~~f;;rr: '3c~OrnR

Ii

! r=t1~(~ ~ ~ '~~~~~OJD : I VALVE ASSY.

i : : L ______________________________ --.J

T P OPTIONAL 4W'D I-----------------------~

j ~ ~Ii 5CIPR I I STEER AXLE MOTORS (4) , , 3~~'

L~~~~~,~~;~;~_~ ~ I 54.;. , HUBS (2) 21492

: DRIVE ~ .~ I

MANIFOLD I I ASSY. ~ (-.;)'

I 36707 .. -... ".,...- ..

L __ -1ll ___ ----=~<:__::_.:-_=_ __ AlW

PROPRIETARY INFORMATION lHlS ORAY>1NG ITS DESIGN. DETlllo DI~SlONS. TOLERANCES AND ~~ WACO, TEXAS OISQJISlllE ARE 11£ ~ '/E(RIIAl1OO AND EXClUSIVE PIKffRTY COIIPOItAT1ON Cf ClJ..AVAR call'CRA11OO . .\NO SIi.ll.l NOT 1'£ TRACrn. REPIlOllCID III crPED IN 00 IWIBI NO! DlSQCsro TO ,\Ny OOTSi!lf PARTY IIlHOOT THE PRIOR IImTEN CQ/SEIIT Cf ClJ..AV~R CORPORATION. All RIGHTS RESERVED.

TITLE

RAK JNLESS OTHE.<W1SE SPECIFIED: SCHEMATIC, MDLS 58/68/76 HYD DIMENSIONS .~RE !N INCHES RAK TOLERANCES ON: AN!1LE OEClJ,4,t.LS FRACTIONAL

RAK ±1/2- XX_±.03 XXX_±.OI0

±1/18

APPR. DRAWN C:YBARRA 4/4/90 SIZE DRAWING NO. REV.

APPR CHECKED NAME DATE1 C 68916 F APPR. APPROVED NAME DATE2 SCALE NONE SHEET 1 OF 1

\)

11-1 A div. of TIME Manufacturing Company

VENDOR MANUAL


PLATFORM-MOUNTED

SHIPPING ADDRESS


8300 IMPERIAL DRIVE

VVACO, TEXAS 76712 (817) 666-4545

MANUAL 92344 OCTOBER 1996

D

MAILING ADDRESS


P.O. Box 21447 VVACO, TEXAS 76702-1447

(817) 666-4545

o

(

(

(


VENDOR TABLE OF CONTENTS

FORD LRG-423 SERVICE MANUAL

HYDRAULIC ROTARY COUPLING

WHTE - HYDRAULIC MOTOR

ROTARY ACTUATOR

SUNDSTRAND - MULl-AXIS TILT ALARM MCAlOOA

WHITE - HYDRAULIC DRIVE MOTOR

SYNCHO-START D.C. SOLENOID

COUNTERBALANCE VALVE CARTRIDGE

WATER PROOF LIMIT SWITCHES

~) FAIRFIELD - TORQUE HUB

)

H.P.1. - PROPORTIONAL CONTROL VALVE

PARKER - MCV -ISO VALVE SYSTEMS

H.P.1. - MANIFOLD ASSEMBLY

REXROTH-VARIBLEPUMP

WSI - ROL-SEAL MOTOR

WSI - ROL-SEAL BRAKE

MANUAL 92344 OCTOBER 1996

, )

HYDRAULIC ROTARY COUPLING (Calavar Part No. 32554)

INSTALLATION PROCEDURE FOR TEflON RINGS

• EQUIPMENT NEEDED:

1. Heating container (N£SCO oven or equivalent).

2. ·One (1) pair of heat resistant gloves.

• OPERATION:

1. Insure coupling 1s free of foreign matter.

2. Place teflon rings in oven until 300 0 F to 350 0 F is reached.

CAUTION---Do not exceed 5000 F

{Rings should turn dark in color and become elastic.}

3. Grasp a ring (using gloves) and slip over end of coupling to groove.

CAUTION--~o not stretch rings. as they will NOT return to size.

Speed is essential before contracting occurs.

4. Insure ring is not tWisted when installed in groove.

• NOTE: Rings that are loose on coupling can be sized by compressing with suitable hose clamp.

HYDRAULIC ROTARY COUPLING

(CALAVAR PART NO. 32554)

-\ )

l. )

c )

4

5 O't' 1///

"0 /

I lelther blckup in -NOTE: Earlier model. hive nd old Ihl" lei' sel' carrier. Lelther I ahlft Ital Ind should be replaced bV new spring.

L'

I~(I f~ . I

J2 II JJ

Figure 1 ~

(~ .~ \ .'

LJ

J4

IS

II

I. DUll SI.I 2. Wlr. Ring 3. Shim 4. SI.I 5. Hauling 8. Sial Clrrllr AllY.

10. Thrull B.arlng II. Shan 12. Drivi Link 13. Wur Plall 14. S.11131 15. Rollir Stalor II. Pin 17. End Caver 18. 801114J

.. / ...... : .. , ! '. '11 . ~i'~:'

JULY 11,1988

WHITE HYDRAULICS, INC. Bill Bryan Boulevard Box 1127, Hopkinsville, KY 42240 502-885-1110 I TWX 757178 FAX 502-886-8462

SERVICE BULLETIN

HS & RS SERIES SERVICE AND SEAL KIT INSTALLATION

THESE INSTRUCTIONS COVER BOTH THE HS & RS SERIES MOTORS. NOTE CAREFULLY THE DIFFERENT TIMING PROCEDURES FOR EACH SERIES.

PRIOR TO DISASSEMBLY, ClEAN OFF THE EXTERIOR OF THE MOTOR IF NECESSARY AND MARK A VERTICAL UNE UP ONE SIDE OF THE MOTOR WITH A FELT MARKER FOR LOCATION REFERENCE WHEN REASSEMBUNG.

HAVE A CLEAN WORK BENCH AVAIlABLE.

DISASSEMBLY

1. PLACE MOTOR IN VISE AROUND PORT AREA.

2. REMOVE 4 BOLTS AND END COVER.

3. SUCE WEAR PLACE OFF CENTER AS NECESSARY TO ClEAR THE DRIVE UNK SPUNES AND REMOVE THE ROTOR SET AND WEAR P~TE AS ONE PIECE TO PREVENT ROllS FROM FAWNG OUT.

4. REMQVE DRIVE UNK AND PIN.

5. REMOve SHAFT UP THROUGH HOUSING. BE CAREFUL NOT TO LOSE THE COOUNG PLUG LOCATED INSIDE THE SHAFT.

6. REMOVE HOUSING FROM VISE AND PLACE WITH MOUNTING FlANGE UP ON WORK BENCH. THIS ALLOWS THRUST BEARING (AND THRUST WASHER IN MAY, 1988 AND NEWER MODElS) TO FALL FREE. CAREFUllY INSERT A SCREWDRIVER BETWEEN DUST SEAL AND SEAL'CARRIER AND PRY OUT DUST SEAL

7. PRESS THE SEAl CARRIER SACK THROUGH THE HOUSING, BEING CAREFUL NOT TO SCORE THE HOUSING BORE.

S. REMOVE RETAINING RING, BACK UP SHIM AND LATHE CUT SEAL FROM GROOVE IN HOUSING WITH A SMALL SCREWDRIVER.

REASSEMBLY AND SEAL KIT ASSEMBLY

THIS COVERS REASSEMBLY USING SEAL KIT NUMBER PS222001, WITH VlTON SEAL AND THRUST WASHER. PS222001 IS A UNIVERSAL KIT COVERING BOTH HS & RS SERIES MOTORS SO THERE WILL BE 2 EXTRA BODY SEALS LEFT WHEN REASSEMBLY IS ANISHED.

EACH PART SHOULD BE WASHED IN CLEAN SOLVENT PRIOR TO REASSEMBLY. INTERNAL WORKINGS OF MOTOR MUST BE TOTALLY FREE OF DIRT OR DEBRIS. ALL SEALS SHOULD BE UGHTLY OILED PRIOR TO INSTALlATION. .

1. PLACE HOUSING IN VISE WITH MOUNTING FlANGE UP.

2. INSTALL 1.735- 1.0. LATHE CUT SEAL

3. INSTALL BACK-UP SHIM. THIS SHIM MUST BE FOLDED AND BENT SUGHTLY AND THEN WORKED INTO PLACE WITH A SMAll SCREWDRIVER.

4. INSTALL WIRE RING AND TURN HOUSING OVER SO IT IS IN VISE WITH FlANGE DOWN.

5. SEE ATTACHED DRAWING C10014 FOR INSTALlATION OF SEAL CARRIER COMPONENTS.

6. CAREFULLY SUCE SHAFT ASSEMBLY INTO HOUSING. BE SURE THE COOUNG PWG IS STILL PROPERLY PLACE IN HOLE IN BOTTOM OF THE SHAFT.

IMPORTANT - TIMING INSTRUCT10NS

(STEPS 7-10) FOR HS MOTOR

7. USE TIMING DOT ON DRIVE UNK END AS A REFERENCE OR MARK ANY SPUNE ROOT WITH A PENCIL CAREFULLY LOWER DRIVE UNK INTO SHAFT WITH

REFERENCE MARK 'DIRECTLY IN UNE WITH THE CENTER OF ANY OF FO.UR THROUGH HOLES IN SHAFT. AS DRIVE UNK SPUNES CONTACT THE SHAFT SPUNES, SLOWLY TURN DRIVE UNKS, COUNTERCLOCKWISE UNTIL SPUNES ENGA~E IN SHAFT SPUNE. TAPUGHTlY ON DRIVE UNK END TO SEAT THE SHAFT ASSEMBLY INTOTHE WIRE SNAP RING. SHAFT END SHOULD BE SUGHTL Y ABOVE FLUSH FLUSH WITH HOUSING SURFACE. (APPROXIMATElY .010--.020-) BUT Will

SEAT AS MOTOR IS BOLTED TOGETHER.

8. INSTAll BODY SEAL INTO GROOVE IN HOUSING.

9. INSTALL BODY SEAL INTO GROOVE IN ROTOR SET.

10. PLACE WEAR PLATE ONTO SEAL SIDE OF ROTOR SET WITH THE CENTER HOLE OF WEAR PLATE DIRECTLY CENTERED ON ROTOR SPUNES. (BE SURE THE WEAR PLATE IS LOCATED SUCH THAT THE NOTCH ON ONE SIDE OF WEAR PLATE PERIMETER WILL UNE UP WITH TAB ON ROTOR SET PERIMETER WHEN BOLT HOLES ARE AUGNED). LOCATE ANY ONE OF THE FOUR ROTOR SPUNES THAT ARE Cl· RECTL Y 0,... A CENTER UNEWITH THE HIGH (CONVEX) LOBE OR ROTOR. PLACE THE WEAR PLATE AND ROTOR SET ONTO DRIVE UNK SPUNE AS ONE PIECE WITH THE HIGH LOBE SPUNE ENGAGING THE PREVIOUSLY DETERMINED DRIVE SPUNE. WEAR PLATE SHOULD BE BETWEEN HOUSI:JG AND ROTOR SET. AUGN PLATE ANC

ROTOR SET BOLT HOLES WITH HOUSING BOLT HOLES. THE WEAR PLATE NOTCH AND ROTOR SET TAB MUST BE IN UNE AND MUST BE LOCATED ON THE PORT SIDE OF THE HOUSING.

( ')

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IMPORTANT - RS SERIES TIMING INSTRUCTIONS

SEE STEPS 7-10 FOR HS SERIES TIMING

11. USE TIMING DOT ON DRIVE UNK END AS A REFERENCE OR MARK ANY SPUNE ROOT WITH A PENCIL CAREFULLY LOWER THE DRIVE UNK INTO THE SHAFT WITH REFERENCE MARK DIRECTlY IN UNE WITH THE CENTER OF ANY OF THE 6

THROUGH HOLES IN SHAFT. AS DRIVE UNK SPUNES CONTACT THE SHAFT SPUNES, SLOWLY ROTATE THE DRIVE UNK CLOCKWISE UNTIL SPUNES ENGAGE IN SHAFT SPUNES. (NOTE: THIS APPUES TO TIMING PROCEDURE

FOR MOTORS WITH STANDARD CN ROTATION CODE '0'. FOR REVERSE CC:N ROTATION CODE 'I' ROTATE THE DRIVE UNK CCN UNTIL SPUNE ENGAGES. ROTA

TION CODE IS SEVENTH DIGIT OF SPEC. NUMBER). TAP UGHTL Y ON DRIVE UNK END TO SEAT THE SHAFT ASSEMBLY INTO THE WIRE RING. SHAFT

END SHOULD BE SUGHTLY ABOVE FLUSH WITH HOUSING SURFACE. BUT WILL SEAT AS MOTOR IS BOLTED TOGETHER.

12. INSTALL BODY SEAL INTO GROOVE IN HOUSING.


14. PLACE WEAR- PLATE ONTO SEAL SlOE OF ROTOR SET WITH THE CENTER HOLE OF WEAR PLATE DIRECTLY CENTERED ON ROTOR SPUNES. (BE SURE THE WEAR PLATE IS LOCATED SUCH THAT THE NOTCH ON ONE SIDE OF WEAR PLATE PERIMETER WILL UNE UP WITH TAP PROTRUDING ON ONE SIDE OF ROTOR SET PERIMETER WHEN BOLT HOLES ARE AUGNED). LOCATE ANY ONE OF THE 6 ROTOR SPUNES THAT ARE DIRECTLY ON A CENTER UNE WITH ANY OF THE 6 ROTOR VALlEYS (MINOR DIAMETER OF ROTOR). PLACE THE WEAR PLATE AND ROTOR SET ONTO THE DRIVE UNK AS ONE PIECE WITH THE ROTOR VAUEf SPUNE ENGAGING THE PREVIOUSLY MARKED DRIVE UNK SPUNE. WEAR PLATE

MUST BE BETWEEN HOUSING AND ROTOR SET. AUGN WEAR PLATE AND ROTOR SET BOLT HOLES WITH HOUSING BOLT HOLES. THE WEAR PlATE NOTCH AND ROTOR SET TAB MUST BE IN UNE AND MUST BE LOCATED ON THE PORT SIDE OF THE HOUSING.

15. PlACE PIN IN DRIVE UNK NOTE THAT PIN HAS ONE CONVEX END AND ONE CONCAVE END. CONVEX END MUST GO INTO THE DRIVE UNK

16. INSTAll BODY SEAL INTO END COVER GROOVE AND PLACE THE END COVER ON THE MOTOR SO THAT CONCAVE END OF PIN ENGAGES INTO THE HOLE IN

CENTER OF END COVER. AUGN BOLT HOLES.

17. INSTALL BOLTS AND TORQUE DOWN TO 50 FT. LSS.

18. CHECK TO SEE THAT REF. UNE YOU MARKED ON THE EXTERIOR OF THE MOTOR PRIOR TO DISASSEMBLY, MATCHES UP THROUGH ALL THE PARTS.

[10014 R

SERVICE PROCEDURE SUPPLEMENT FOR SEAL KIT PS222001 W/VITON

SEAL AND THRUST WASHER.

SERVICE PROCEDURE SUPPLEMENT FOR SEAL KIT PS222001 W/VITON 5EAL AND THRUST WASHER.

1. PLACE THRUST BEARING ON SHAFT.

2. PLACE THRUST WASHER (5) ON SHAFT. '

3. INSTALL SHAFT SEAL (4) ONTO SHAFT AND DOWN AGAINST THRUST WASHER (5) ORIENTED AS SHOWN. (NOTEI TAKE CARE NOT TO DAMAGE SEAL WHEN SLIDING OVER SHAFT SLINES OR KEYSLOT.)

4. INSTALL TEFLON BACK-UP (3) ONTO SHAFT ORIENTED AS SHOWN. THE LIP ON THE TEFLON BACK-UP (3) SHOULD ENGAGE WITH SHAFT

SEAL I. o. ( 4 )

5. INSTALL BACK-UP SHIM (2) ONTO SHAFT AN8 DOWN AGAINST TEFLON BACK-UP (3)

6. CAREFULLY PUSH THE SEAL CARRIER (1) STRAIGHT DOWN OVER SHAFT SEAL ASSEMBLY, ORIENTED AS SHOWN, TAKING CARE NOT

TO COCK THE CARRIER WHILE INSTALLING.

1. RET' r'TO STEP 6 Of REA55EHBL Y SECT i ON'OF SERY ICE /1'7: PR~ ,<f.' ~

(0 (0

8 8 ~)

8080

SEAL CARRIER - - - - - - RS01S991

BACKUP SHIM - - - ~ - - - RSOIB020

TEFLON BACKUP - - - - - - RS018058

SHAFT SEAL - - - - - -' - RS018053

, .. ' .. " r-THRUST WASHER - - - - - - p- 1059

Ji

SERVICE PROCEDURE

Disassembly Procedure ...

"j Prior to removing roller stator motor trom unit. clean off all dirt. Disconnect hydraulic connections

. and plug ports. Remove the motor from unit. After removal. wash the motor with solvent to remove all excess djrt from outside of the motor. Remove the woodruff key· from shaft (11). place the motor in a vise as shown in Fig. 2 taking care to clamp at port area of housing (see Fig. 2). Place newspapers or a sheet of cardboard on top of bench to obtain a clean work area.

DISASSEMBLY OF ROLLER STATOR (reference Fig. 1)

1. Remove four bolts (18) [9/16 socket or boxed end] and end cover (17).

2. Shift wear plate to cJear end of drive link and lift group (rotor assembly (15) and wear plate (13)] from housing assembly (5).

3. Remove shaft (11) and drive link (12) from housing by pushing up on shaft end with palm of one hand and lifting shaft with the other hand. Items 6, 10. 11. 12 a"d 16 usuaUy will come out from assembly.

4. Remove housing (5) from vise and place upside down on work bench. This allows thrust bearing (10) to fall free. Next place fingers through dust seal (1) of hauling and push seal carrier (6) out the opposite end from the dust seal. Care should be taken to keep the seal carrier from marring the housing bore. This procedure will remove items 6 and 10 from hOUSing.

5. Mount housing assembly (5) in vise. uSing the grip end of a large screw driver. tap dust seal (1) until it faUs free.

6. With smatl Icrew driver remove retaining ring (2). seal (4) and shim (3).

ASSEMBLY PROCEDURE

(reference Fig. 1) IMPORTANT

Before assembling. wash aU parts off in clean solvent. It is advisable to use a new seal kit containing items 1. 3. 4 and 14 (3 seals).

1. Place housing with mounting flange end up on newspaper, install seal (4) in groove.

2. Install shim (3) into groove next to seal.

3. Push retaining ring (2) into position. 4.

~J 5.

Place housing (5) in vise as shown in Fig. 4 with groove side up clamping at ports.

Place thrust bearing (10) on shaft (11) followed by the seat carrier assembly (6) with large diameter of seal carrier towards thrust bearing.

6. Assemble the drive link (12) into shaft ("). Care must be taken to align mark at root ot drtve link tooth with mark on cupped end of shaft. See Fig. 3. Fill drive link end with grease. Note. if markings are indistinguishable the root of the drive link tooth Should be placed with the deeper slot of the output shaft to the right and 1/4H thru hole to the left. (Mark alignment as described on drive link end with soft pencil if no marks appear.) .

1. Slide output shaft assembly (6. 10, 11 and 12) into housing Fig. 4. (Shaft must be flush or Slightly below housing.)

8. Place lightly·oiled seal (14) in groove of housing.

9. Place wear plate (13) on top of drilled end of housing, insuring alignment of seven feed holes. See Fig. 5. Note alignment groove of wear plate to be in direction of ports.

10. Install lightly oiled seal (14) into groove at roller stator (15). With seal side down place roller stator (15) over drive link with mark on drive link root in line with rotor valley (min: diameter). See Fig. 6. Mark on stator must be in line with slot in wear plate. Note alignment of seven feed holes with wear plate and housing. See Fig. 1. Align four bolt holes with housing. Care must be taken to insure that seal stays in place. Note: Counterbore on rotor is away from housing"

LONG MILLED OR

ANGLE DRILLED

SlOT

Fig. 3

Fig. 5

Fig. 2

Fig. 4

11. PIle. lightly oiled selt (14) Into end cover (17).

12. Pile. gr.u.'n rec •••• d cent.r at end cover face. In.t.U pin (18) Into gr.u.d rec ••• If rece •• Is flll.d with aU. wipe cf •• n b.tor. loading with gr..... End cov.r ot new mod.,s (built after M.rch, 1983) cont.in •• pres •• d stee' b.1I .nd • pin (18) with. concav. end .. M.k.sur. concave .nd·of pin 1.ln •• rted Into .nd cov.r (17) In th ... mod.' ••

13. Car.fully Invert .nd cover •••• mbly (17. 18 .nd 14) and pl.ce Into po.itlon on top of roU.r st.tor .... mbly. Take c.r. not to dlalodg. s • ., or pin from .nd cover. .

14. Check .,de. for se ... that m.y be out of pl.ce. 1!. InMt't four bolta (18) and torque to 50 foot pounds.

.L

,.. ~ I' \ =~':::US&a._ I r: .

16. Place usembly on sid. (porta up) In vi .. anc rot.te shaft with k.y in piae. Ind Ch.ek·tO{·· t

the suction port I. In the s.m. direct \ rot.tlon. )

Fig. S Fig. 7

e-. SIIl.lNE (SA • .1411' ( )

I-&8UC .......... ~--. .... ~~ . .......... 2 ..... .... ,.... ......

'-=~AI

WHIT! HYDAAUUcs, IN TELEPHONE 502-.... 1,·

P.O. BOX 1127 HOPKINIVILL2. KY 4D

TWX 157178 Attn: White

Mounting Dimensions DIMENSION •• ,.-

MOTOR DISPLACEMENT 4 Hale Flange 2 Hofe Ftar SERIES

Cu.ln./Rev. Cu.Cm./Rev. In. "' ... 'ft. ..... RS·AA.1 3 50 5.41 137." 5.41 137.·

RS·AS·l 4.5 74 5.41 137." 5..' 131.'

RS·AC·l 6.8 110 553 137.41 5.53 RS·Ae·l 10 164 5.87 155.45 5.8"' RS·AG·l 12 200 8.12 155.45 6.12 - ) RS·AK·l 146 268 8.e8 169.UI 6.68 t •. ,

RS·AM·1 18 295 8.645 189.16 6.61 1891

RS·AP.1 24 393 1.31 181.20 1.37 '.7.:

)

)

GENERAL

ROTARY ACTUATOR (Calavar Part No. 68460)

FOR 1800 PLATFORM ROTATION OPTION:

MAINTENANCE INSTRUCTIONS (Refer to Figure 35A)

The Rotary Actuators are designed for a maximum operating pressure of 3,000 p.s;i. non-shock load.

The rotator consists of a Pinion. 118, to which a shaft attaches and one (1) Rack •• 17, combined with Piston. '9. located within a Housing. #19. Cylinders. #16. and End Caps. *5. Pressurization of the port(s) results in pinion rotation.

The gear chamber has b~en packed with a moly grease with a mini-mum fflSZ contents of 3: which ; s sufficient for one to two mi 11 ioncycles.

In the event that maintenance is required, the steps outlined below should be followed.

A. INSPECTION AND REPLACEMENT OF END CAP SEALS, 17

1. Place actuator in the mid-stroke position. Remove Nuts. ,14, from Tie Rods, 115.

2. Pull End Cap, IS, free from Cylinder. 116.

3. Inspect or replace O-Ring. 17. and Back-Up Ring. #6. Locate the O-Ring toward the pressure side of the End Cap and lubricate Seal and End Cap before re-instal1ing.

4. Replace End Cap. IS. into Cylinder. 116. and assemble Nuts, 114." to Tie Rods, 115.

B. INSPECTION AND REPLACEMENT OF PISTON SEAlS, '10

1. Repeat Steps Al and A2.

2. Remove Rack Bolt. ,e.

B. Ins1ection and Reolacement of Piston Sea s, lID - continued:

3. Screw two (2) eye bolts or threaded rods in the tapped holes in Piston, 19; use 110-24 UNC threads.

4. Pull Piston, 19. from Cylinder. #16.

S. Replace Piston Seal, 110, making certain the O-Ring portion of the Piston Seal faces the pressure side.

6. Inspect and replace (if necessary) Rack Bolt a-Ring, Ill, and Sack-Up Ring, 112. Locate the O-Ring, Ill, toward the pressure side of the Piston.

7. Replace Piston, 19, into Cylinder, *16, until Piston is tight against end of Rack, ;17. To ease Piston installation and to protect Piston Seals. cylinder bore should be coated with suitable oil.

B. Re-assemble Rack Bolt.

9. Repeat Steps A3 and A4.

C. INSPECTION AND REPLACEM-ENT OF PINION AND BUSHING O-RING. ~1 AND 13 l. ) 1. Remove Snap Ring. 14.

2. Force Bushings, 12, and Pinion, lIB, from Housing, w19.

3. Inspect or replace a-Ring, II and 13. Put oil or O-Ring lube on seals and bushings.

4. Replace Bushings, 12. and Pinion, 118, into Housing, 119.

S. Replace Snap Rings, '4.

o. COMPLETE o ISASSEMBl Y OF ACTUATOR

1. Repeat Steps Al and Al.

2. Repeat Steps B2. 83 and 84.

3. Remove Cylinder. 116. from Housing, 119.

4. Repeat Steps Cl and C2.

S. CAUTION: Before removing rack from housing, with actuator still in mid-stroke position, match mark the center valley of rack to assure the right timing after re-assembly.

6. Push rack from either end to remove from housing.

\ )

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E. RE-ASSEMBlY OF ACTUATOR

1. Follow previous procedures for re-assembling of all actuator parts and refill the gear chamber with a moly grease with a minimum MOSz contents of 3%.

NOTE: Tightening torques for:

• Tie Rod Nut, 114 ~ 20 lbs-ft.

• Rack Bolt, #8 ~ 55 lbs-ft.

FIGURE 3SA 180 0 ROTARY ACTUATOR (with hollow pinion and SAE ports

\ )

17 9 8

\ )

20

) .

11/

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FIGURE 35A 180 0 ROTARY ACTUATOR (with hollow pinion and SAE ports)

REF DESCRIPTION PART NUMBER QTY

I 1800 Rotary Actuator (with hollow pinion) 35460 1 1--+ a-Ring (Pinion) -------------+---- * -----...j..-2 2 --r-Bushing (Pinion) -----------~-- 93076 -------i--2 3~a-Rin9 (Pinion Bushing) ---------4---- * ------+-2 4 Snap Ring --------------+--- 93077 ------4--2 5 End Cap ---------------+--- 93078 ------+--2 6 Back-Up Ring (End Cap) ----------;--- '* ------+--2 7 O-Ring (End Cap) ------------+----- '* -----+- 2 8~bck~lt-------------~---~OOO----~-2 9---r Piston ---------~-------+--- 93071------..;.--4--2

10 Piston Seal--------------+--- '* ------+-2 11 ! a-Ring (Rack Bolt)-----------+----'* -----~2 12=F' Back-Up Ring {Rack Bolt)---------+----'* ------2 13 O-Ring (Cylinder Tube)----------+---'* -----....--2 14 Nut (Tie-rod)-------------+---93070------+--8 15 Tie-Rod ---------------+---93072 -----+--8 16 Cyl inder Tube 93079 2 17 Rack 93081 1 18 Pinion 93082 1 19 Housing 93074 1 20 Thrust Ring 93075 2 21----r-Relief Valve 93073 1

'* Seal Kit, Calavar Part No. 93083, includes I items 1, 3, 6, 7, 10, 11, 12 and 13 above.

I I

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11/84

)

~ SUNOSTRRNO

~

APPLICA TION------The MCA 1 OOA Multi-Axis Tilt Alarm provides a signal to the operator of self-propelled aerial lifts, cherry pickers, truck cranes, etc. that warns when the base vehicle is off level. When the alarm is tilted 4.5

0 from null the

output signal activates both medium and high current alarms, sirens, bells or lights. The warning alarm indicates an imminent danger that must be rectified before work continues.

The Mult-Axis Tilt Alarm is easily mounted in a convenient location on the machine frame. It can be wired and leveled quickly and will provide years of trouble-free service.

FEATURES--------------• Complies with ANSI aerial lift standard A 92.5

• High reliability with solid state load switch ing

• Easy to install

• LED si mplifies leveling of time delayed alarms

• Damped response ignores normal machine vibrations

• Operates in either 12, 24 or 36 volt systems

• Time delay option available

• Reverse polarity and short circuit protected

• Tough housing withstands the elements

• Spring-loaded base allows for operational tests

SPECIFICATIONS---

ELECTRICAL

POWER SUPPLY 11 to 30 Vdc (12/24 volt model) 24 to 40 Vdc (36 volt model)

MCA100A Multi-Axis Tilt Alarm

BULLETIN 95-8954-2

-

Alarms used in rechargeable battery-operated electrical systems will not sound if the system voltage drops below the input voltage rating for the relay to the alarm.

OUTPUT CURRENT .2 amps, nominal; .5 amps, maximum

OUTPUT LOAD INDUCTANCE .5 henries, maxi mum

SHORT CI RCUIT PROTECTION Indefinite (output to ground or output to power supply l.

LOAD SWITCHI NG RATE 60 cps maximum at rated inductance and current

TIME DELAYED (OPTIONAL) 2.5 ±.5 seconds

ENVIRONMENT AL OPERATING TEMPERATURE

.340

to +710

C (_30° to +160° F)

STORAGE TEMPERATURE _34

0 to +66° C (_30° to +150° F)

SPECIFICA nONS (continued page 2)

Sundstrand Mobile Controls

SPECIFICA nONS (continued from page 1)

VIBRATION Withstands a vibration test designed for mobile equipment controls that includes two parts:

1. Cycling from 5 to 2000 cycles in each of the three major axes.

2. Resonance dwell for one million Hz for each resonance point in each of the three major axes.

SHOCK 50 g for 11 milliseconds. Three shocks in both directions of the three major axes for a total of 18 shocks.

HUMIDITY After being placed in a controlled atmosphere of 95% humidity at 1200 F for 10 days the alarm will perform within specification limits,

RAIN After being showered from all directions by a high pressure hose down the alarm will perform within specification Ii mits.

0P~IONAL MOUNTING HOLES IN SASe:

",- / a mm .4PL 28

I so O.S mm ·2PL 197

GND (SLACK) ~I

EMI/RFI Radiated fields of 10 volts per meter from 30 MHz to 200 MHz.

MECHANICAL LIFE

10,000 operations at a single alarm point

01 FFERENTIAL +1

9 _1.5° differential between diametrically opposite switch-on points.

For non-time delayed units, a maximum of 2.5 seconds and a minimum of .15 seconds from null to 6:l tilt angle over a temperature range of -300 to 160° F.

For time delayed units, 2.5 ±.5 seconds (0° to 160° F) and 5.0 seconds or less (-300 to 0° F) from null to 6° tilt angle.

GENERAL DIMENSIONS

See Figure 1.

'I, ·28 ADJUSTING NUTS ·3PL

I I

SO '0.5 mm 3.15

I i

I 83.18 mm MA)( 327

..-.=:s-. ____ ~====~ __ t_'

2

.~ LEO ONLY ON TIME DELAYED UNITS

5ASE~ i .1.8 mm 19

FIGURE 1. Dimensions of the MCA 100A in millimeters (inches).

Sundstrand Mobile Controls 95-8953-3

)

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THEORY OF OPERATION---------------The Mult-Axis Tilt Alarm functions as a switch. It con· sists of a molded nylon housing containing a steel ball bearing, an incandescent lamp, a photo detector and a printed circuit board. The ball bearing is free to roll in a clear silicone damping fluid on a transparent, spherical basin. The bearing normally acts as an interruption between the lamp and the photo detector, but when the alarm is tilted 4.5

0 from horizontal the ball no longer

blocks the light. The detector then recei ves the light and switches a VMOS transistor from a high i mpedence (OFF) to a low impedence (ON) state, activating the alarm. If the unit is time-delayed, an RC timing circuit is allowed to charge towards a threshold voltage before the transistor switches to the ON state. The timer is reset when the alarm is releveled back to less than 4,50

• Should the filament break, the circuit will close to warn the operator.

In everyday use, some shaking of the machine's frame is to be expected. To prevent an inter· mittent alarm that would normally sound during use, the Tilt Alarm response is damped with silicone fluid. The resulting lag can be several sec· onds. Therefore, the alarm should not and can not be expected to give the operator sufficient warning time in dynamic movement situations. Angular boom and ground velocities should be kept to reasonable rates to ensure operator safety. Nor should the alarm be expected to warn the Ope erator in the event of machine lurches due to un· tamped earth fills, ditches, drop·offs, holes, etc. Good safety practi ces demand a thorough inspec' tion of the ground surrounding the vehicle base. When properly performed, this inspection should preclude possibilities of unforeseen machine movements.

INSTALLATION-----------------

WIRING

Three wires must be connected to put the Tilt Alarm in the alarm circuit. The red wire is the high (positive) side of the alarm, the black wire is the chassis ground and the white wire is the output lead. The Tilt Alarm and load are powered by 12, 24 or 36 volts.

In a very few applications, machinery equi pped with the Tilt Alarm wi II be subjected to the high accelerations and decelerations associated with quick stops, starts and turns. Since its sensing princi pie responds to gravity, the alarm will also respond to these accelerations and tri p the horn or light. In order to avoid annoying the operator with false alarms, the owners of tight-cornering and/ or high-grounded·speed vehicles should interlock the operation of the Tilt Alarm with the work (as opposed to travel) mode. If the alarm has the time delay feature, this precaution is necessary.

Two typical wiring schemes are illustrated in Figures 2 and 3. Figure 3 uses a separate remote horn as the load. The horn should be a solid state device such as the Mallory SC616N with a volume of 80 db or better. It should draw no more than one-half amp. Figure 3 uses the vehicle's own alarm system (generally the horn) as the load. The horn relay should typically be from 200 to 600 ohms. Also pictured is the interlock switch.

MOUNTING Three welds, one on each corner, are sufficient to mount the base for the Multi-Axis Tilt Alarm. Or the device can be bolted to the frame through the four·bolt pat-

95-8953-3

tern on the base (see Figure 1). If the device is welded the base should be detached from the housing and th~ alarm assembled subsequent to the mounti ng. This wi II avoid accidentally overheating the housing. Since the alarm is leveled after mounting, a smooth, flat weld is not critical for correct operation.

The location of the mounting will vary from machine to machine. In all cases it should be on a level, horizontal area of the main frame. It should also be isolated from the operator (outside of the cab) but accessible for day-to-day use, since the alarm should be field tested for proper working condition every day before the machine is run.

11 ~o<lOV -

RED

TIL T "'LARM

~'JHI TE

RE"'OTE ,.,OR"4

1')02

FIGURE 2. Wiring scheme using remote horn.

INSTALLA nON (continued page 4)

Sundstrand Mobile Controls 3

INSTALLA nON (continued from page 3)

SLACK HORN BUTTON

FIGURE 3. Wiring scheme using vehicle horn.

LEVELING

Use the following procedure to bring the Tilt Alarm into gravitational null:

CJ 1. Park the veh i cle on a flat surface. Be sure it is as level as possible, with tires filled to rated pressure.

o 2. Level the base of the alarm by tightening the three flange nuts with a screwdriver-type socket wrench. Each nut should be tightened through approximately one half of its spring's travel. During the remainder of the procedure do not adjust the nut on the 90° corner.

o 3. With the electrical connections complete, slowly tighten the nut on one of the two corners adjacent to the 90° corner until the circuit is closed.

For non-time delayed units, the alarm will sound. For time delayed units, the LED on the underside of the housing will turn on.

o 4. Note the angular position of the socket Loosen the nut, counting the number of turns until the circuit is closed again.

o 5. Divide this number in haif. Tighten the nut by this many turns. The line determined by this nut and the nut on the 90° corner is now parallel to the ground.

o 6. Repeat steps 3 through 5 for the remaining nut. The alarm is now level.

C 7. Individually push down on one corner at a time; there should be enough travel to cause the alarm to trip. If the alarm does not trip in all three tests, the flange nuts have been tightened too far. Loosen the nut on the 90° corner and repeat steps 3 through 6. This push-to-test feature enables the operator to test the alarm without losing the alarm adj ustment.

ORDERING INFORMATION---------------------------SPECIFY

Model name (MCA 100A)

Input voltage (12, 24 or 36)

Instantaneous or time-delayed turn-on

For non·standard tri p angles, or different tri p angles in the X and Y axes, consult the Customer Service Depart

. ment.

ORDER FROM

SUNDSTRAND MOBI LE CONTROLS 3900 Annapolis Lane North Minneapolis, Minnesota 55441 (612) 559-2121

4 Sundstrand Mobile Controls

DeVICE REPAIR

For devices in need of repair, include a description of the problem, a copy of the purchase order and your name and address.

RETURN TO SUNSTRAND MOBILE CONTROLS Return Goods Department 3900 Annapolis Lane North Minneapolis, Minnesota 55441

95-8953-3

)

)

)

CORPORATION

RETURN LINE SPIN-A-FILTER (Calavar Part No. 32522)

GENERAL INFORMATION

• Spin-A-Filter from AMBAC Industries Incorporated is designed for fast and simple maintenance.· Twist off the old element. Twist on the new. No bolts to remove. No time-consuming cleaning operations. Takes less than a minute to change a Spin-A-Filter element.

• Disposable filter element pays for itself with lower maintenance and downtime costs. Designed for return line applications up to 20 GPM (76 L/Min.). For use with petroleum-based oils in mobile equipment operations.

• Filter ass~mblies are furnished standard with a by-pass valve in the cast aluminum housing head. The integral by-pass valve protects element against line surges.

• 10 micron filter element is standard (Calavar Part No. 67408).

RETURN LINE SPIN-A-FILTER

FILTER ASSEMBLY (Calavar Part No. 32522)

REPLACEMENT FILTER ELEMENT - 10 MICRON (Calavar Part No. 67408)

D IMENS IOrlAL DATA

!/4-Z0UNCx!4! (13MA//)t?€E? rwo Mt::'VNrIN(:i Ht::1L.b..s

I. {3e.

(70MM

ENGINEERING DATA

Po r t s i z e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 111 N PT F

.7. SO (19IMM)

By-pass valve setting, factory set ....... ~ ...... 25 PSID (1.7 BAR) Nominal size particle retention rating .......... 10 MICRON Operating pressure .............................. 100 PSI (6.9 BAR) MAX. Operating t~mperature ........................... +250°F (121°C) MAX. Performance. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .. 160 SSU @ 100°F (37 8C C)

FLOW AVERAGE PRESSURE DROP GPM L/MIN 10 MICRON

5 19 2.0 PSI 0.14 BAR 10 38 5.5 PSI 0.38 BAR 15 57 9.9 PSI 0.68 BAR 20 76 14.7 PSI 1.01 BAR

)

)

)

)

)

GENERAL

COfUJOfUTION

ROTARY ACTUATOR (Calavar Part No. 68460)

FOR 180 0 PLATFORM ROTATION OPTION:

MAINTENANCE INSTRUCTIONS

(Refer to Figure 35A)

The Rotary Actuators are designed for a maximum operating pressure of 3,000 p.s.i. non-shock load.

The rotator consists of a Pinion, #18, to which a shaft attaches and one (1) Rack, ~17, combined with Piston, #9, located within a Housing, ~19, Cylinders, #16, and End Caps, #5.

Pressurization of the port(s) results in pinion rotation.

The gear chamber has been packed with a moly grease with a mlnlmum MOS2 contents of 3% which ;s sufficient for one to two million cycles.

In the event that maintenance is required, the steps outlined below should be followed.

A. INSPECTION AND REPLACEMENT OF END CAP. SEALS, #7

1. Place actuator in the mid-stroke position. Remove Nuts, #14, from Tie Rods, 115.

2. Pull End Cap, #5, free from Cylinder, #16.

3. Inspect or replace O-Ring, #7, and Back-Up Ring, #6. Locate the O-Ring toward the pressure side of the End Cap and lubricate Seal and End Cap before re-installing.

4. Replace End Cap, #5, into Cylinder, #16, and assemble Nuts, #14,· to Tie Rods, #15.

B. INSPECTION AND REPLACEMENT OF PISTON SEALS, #10


2. Remove Rack Bolt, #8.

B. Insyection and Replacement of Piston Sea s, #10 - continued:

3. Screw two (2) eye bolts or threaded rods in the tapped holes in Piston, #9; use #10-24 UNC threads.

4. Pull Piston, #9, from Cylinder, #16.

5. Replace Piston Seal, #10, making certain the a-Ring portion of the Piston Seal faces the pressure side.

6. Inspect and replace (if necessary) Rack .Bolt a-Ring, #11, and Back-Up Ring, #12. Locate the O-Ring, #11, toward the pressure side of the Piston.

7. Replace Piston, #9, into Cylinder, #16, until Piston is tight against end of Rack, '17. To ease Piston installation and to protect Piston Seals, cylinder bore should be coated with suitable oil.

8. Re-assemble Rack Bolt.

9. Repeat Steps A3 and A4.

C. INSPECTION AND REPLACEMENT OF PINION AND BUSHING O-RING, #1 AND #3

1. Remove Snap Ring, #4.

2. Force Bushings, #2, and Pinion, #18, from Housing, #19.

3. Inspect or replace O-Ring, #1 and #3. Put oil or a-Ring lube on seals and bushings.

4. Replace Bushings, #2, and Pinion, #18, into Housing, #19.

5. Replace Snap Rings, #4.

D. COMPLETE DISASSEMBLY OF ACTUATOR


2. Repeat Steps 82, 83 and B4.

3. Remove Cylinder, #16, from Housing, #19.

4. Repeat Steps Cl and C2.

5. CAUTION: Before removing rack from housing, with actuator still in mid-stroke position, match mark the center valley of rack to assure the right timing after re-assembly.

6. Push rack from either end to remove from housing.

)

)

~ E. RE-ASSEMBLY OF ACTUATOR

1. Follow previous procedures for re-assembling of all actuator parts and refill the gear chamber with a moly grease with a minimum MOS2 contents of 3%.

NOTE: Tightening torques for:

• Tie Rod Nut, #14 = 20 lbs-ft.

• Rack Bolt, #8 = 55 lbs-ft.


I I

qEF DESCRIPTION PART NUMBER I

QTY !

I 180 0 Rotary Actuator (with hollow pinion) I 35460 I 1 I I

1 I O-Ring (Pinion) I * ! 2 I j j 2~BUShing (Pinion) . I 93076 2 3 O-Ring (Pinion Bushing) I * I 2 4 Snap Ring I 93077 ! 2 5 End Cap 93078 1 2 6~BaCk-UP Ring (End Cap) I * I 2 I

7 O-Ring (End Cap) ! * j 2

8 I Rack Bolt I 93080 i 2 I

I

9 i Piston 93071 I

2 10 i Piston Seal j * 2 11 ! O-Ring (Rack Bol t) *

j 2

I I

12 I Back-Up Ring (Rack Bol t) * I 2 13 ; O-Ring (Cylinder Tube)

I *

I

2 93070 I 8 14 I Nut (Tie-rod) i 93072 i 8 15 Tie-Rod I

! 16~CY1;nder Tube I 93079 2 I

I 17 Rack I 93081 1 I I

18 Pinion 93082 I 1 I

i

19 Housing 93074 I 1 20 ! Thrust Ring I 93075

I 2

21 I Rel ief Val ve I 93073 1

I l) * Seal Kit, Calavar Part No. 93083, includes items 1, 3, 6, 7, 10, 11, 12 and 13 above. I

! ! I


15 19 17 9 8

20

)

11/84

c-::> "'tJ en ::x:::- :0 m ----t :x:=- 0:0 r--n~ c:::':)

c:::;-:) m('") ~ Om c=>

C ---.. :0 r......::l

I m c::x::> c=:>

* NOTE

4

5

. ve leather (8) In d idoes not hil . ment Earlier rno e . , ot a replace . This IS n

seal carfl~:se models Item on t 1

L

10

12

Fiywe 1

1 DUST SEAL 2: WIRE RING 3. SHIM 4 SEAL 5' HOUSING 6: SEAL CARRIER

7. ~~!~HER BACK UP * 8. SHAFT SEAL

9. THRUST BEARING 10. 11 SHAFT 12· DRIVE LINK 13' WEAR PLATE

14: ~~~~EI:I ST A TOR 15. t6 PIN 17· END COVEA 18: BOLT (4)

18

)

)

SERVICE PROCEDURE

Disassembly Procedure ...

Prior to removing roller stator motor from unit. clean off all dirt. Disconnect hydraulic connections and plug ports. Remove the motor from unit. After removal. wash the motor with solvent to remove all excess dirt from outside of the motor. Remove the woodruff key from shaft (11). place the motor In a vise as shown in Fig. 2 taking care to clamp at port area of housing (see Fig: 2). Place newspapers or a sheet of cardboard on top of bench to obtain a clean work area.

DISASSEMBLY OF ROLLER STATOR

(reference Fig. 1)

1. Remove four bolts (18) (9/16 socket or boxed end).

2. Shift wear plate to clear end of drive link and lift group [end cover (17). rotor assembly (15) and wear plate (13)] from housing assembly (5).

3. Remove shaft (11) and drive link (12) from housing by pushing up on shaft end with palm of one hand and lifting shaft with the other hand. Items 6, 7, 8, 9, 10, 11, 12 and 16 usually will come out from assembly.

4. Remove housing (5) from vise and place upside down on work bench. This allows thrust bearing (10) to fall free. Next place fingers through dust seal (1) of housing and push seal carrier (6) out the opposite end from the dust seal. Care should be taken to keep the seal carrier from maring the housing bore. This procedure will remove items 6, 7, 8, 9 and 10 from housing.

5. Mount housing assembly (5) in vise, using the grip end of a large screw driver, tap dust seal (1) until it falls free.

6. With sma" screw driver remove retaining ring (2), seal (4) and shim (3).

IMPORTANT

ASSEMBLY PROCEDURE

(reference Fig. 1)

Before assembling, wash all parts off in clean solvent. It is advisable to use a new seal kit containing items 1, 3, 4, 7, 8, 9 and 14 (3 seals).

1. Place housing with mounting flange end up on newspaper, install seal (4) in groove.

2. Install shim (3) into groove next to seal.

3. Push retaining ring (2) into position.

4. Place housing (5) in vise as shown in Fig. 4 with groove side up clamping at ports.

5. Assemble shim (7) in seal carrier (6) next push leather backup (8) into place followed by shaft seal (9) with lip side away from leather backup.

6. Place thrust bearing (10) on shaft (11) followed by the seal carrier assembly (6,7,8 and 9) with large diameter of seal carrier towards thrust bearing.

7. Assemble the drive link (12) into shaft (11). Care must be taken to align mark at root of drive line ~oo~h with mark on cupped end of shaft. If spline IS tight. assembly can be made by rapping the end of. the. drive link. with a ha m mer. See Fig. 3. Fill drive link end With grease. Note, if markings are indistinguishable the root of the drive link tooth should be placed with the angle drill slot of the output shaft to the right and 1/4" thru hole to the left. (Mark alignment as described on drive link end with soft pencil if no marks appear.)

8. Slide output shaft assembly (6, 7, 8,9, 10, 11 and 12) into housing Fig. 4. (Shaft must be flush or slightly below housing.)

9. Place lightly oiled seal (14) in groove of housing.

10. Place wear plate (13) on top of drilled end of housing, insuring alignment of seven feed holes. See Fig. 5. Note alignment groove of wear plate to be indirection of ports.

11. I nstall lightly oi led seal (14) into groove of roller stator (15). With seal side down place roller stator (15) over drive link with mark on drive link root in

ANGLE DRILLED

SLOT

Fig. 3

Fig. 5

.,--."-. ~, ,) I '/ 1 ';

Fig. 2

Fig. 4

line with rotor valley (min. diameter). See Fig. 6. Mark on stator must be in line with slot in wear plate. Note alignment of seven feed holes with wear plate and housing. See Fig. 6. Align four bolt holes with housing. Care must be taken to insure that seal stays in place. Note: Counterbore on rotor is away from housing.

12. Place lightly oiled seal (14) into end cover (17).

13. Place grease in recessed center of end cover face.

14.

15.

16.

Install pin (16) intogreased recess if recess is filled with oil, wipe clean before loading with grease.

Carefully invert end cover assembly (17, 16 and 14) and place into position on top of roller stator assembly. Take care not to dislodge seal or pin from end cover.

Check sides for seals that may be out of place.

Insert four bolts (18) and torque to 50 foot pounds.

- ~. T><A\J Z"""""TlNG HOL£S EOLotoL.LY

r1:f~~~r& ~i;~~o~'i.

-:,r,~\~,-_ ~ .' ..

17. Place assembly on side (ports up) in vise and rotate shaft with key in place and check to insure the suction port is in the same direction of rotation.

-~. .. ' ; t,

Fig.6 Fig.7

~'l- ~PROV'OEO"O"~5IQXI03 90 CResS SECTlCl'fo-RING

4!!,72 iMU.;. 2.76

t-16UNCX S20EEP ~ HOLES EQUAlLY SP.A.CEO AND LOCATED ON 1.3250 01 ... 8C

180 .-

-_. ~~~'~~9 0"---_

'1,01 ;)11. •. -t-2oUNC

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

. , ' ,"-', t::~ ---.' _ --~ . .!.---- --.---i-~~

,~: ~;

z ! " < :-s

~ Q~ i~

z: ~

0'" :5

;~ ~~ ~o: :;;Z

~:; ::!:!.

~~

70·

5

6-8 SPLINE (SAE J4991

I 680 I ~ 1

~ i 1 !

+~ ,If', I 'r L i\ -18 UNC ..so MIN DEEP

i4\ Moun""Q Hoi.>

MANIfOlD PORTING *' AVQllabMt w4th 2 Hoi. Of ~ Hoi. flanoe Hou""Q

WHITE HYDRAULICS, INC . P. O. BOX 2306

WEST LAFAYETTE, INDIANA 47906 ~

TELEPHONE (317) 742-0255 j'

TWX 232005 ASAS Attn: White Co,

DIMENSION "A u

MOTOR DISPLACEME NT 2 Hole Flange 4 Hole FlangE SERIES

Cu.ln./Rev. Cu.Cm./Rev. In. mm In. mm

RS-AA-1 3 49,2 5.41 137,41 5.41 137.41

RS-AB-' 4.5 73.8 5.41 137.41 5.41 137.41

RS-AC-1 6 98,3 5.41 137.41 5.41 137,41

RS-AE-1 10 163,9 6.12 155.45 '6.12 155.45

RS·AG-1 '2 196,7 6.12 155.45 6.12 155.45

RS-AK-1 14 268.6 6.66 169.16 6.66 169.16

RS-AM-1 '8 295 6.66 169,16 6.66 169.16

RS-AP-1 24 393.4 7.37 187.20 7.37 187.20

)

II

JULY 11, 1988

WHITE HYDRAULICS, INC. Bill Bryan Boulevard Box 1127, Hopkinsville, KY 42240 502-885-1110/ TWX 757176 FAX 502-886-8462

SERVICE BULLETIN

HS & RS SERIES SERVICE AND SEAL KIT INSTALLATION

THESE INSTRUCTIONS COVER BOTH THE HS & RS SERIES MOTORS. NOTE CAREFULLY THE DIFFERENT TIMING PROCEDURES FOR EACH SERIES ..

PRIOR TO DISASSEMBLY, CLEAN OFF THE EXTERIOR OF THE MOTOR IF NECESSARY AND MARK A VERTICAL LINE UP ONE SIDE OF THE MOTOR WITH A FELT MARKER FOR LOCATION REFERENCE WHEN REASSEMBLING.

HAVE A ClEAN WORK BENCH AVAILABLE.

DISASSEMBLY

1. PLACE MOTOR IN VISE AROUND PORT AREA.

2. REMOVE 4 BOLTS AND END COVER.

.~ 3. SUDE WEAR PLACE OFF CENTER AS NECESSARY TO CLEAR THE DRIVE UNK SPLINES AND REMOVE THE ROTOR SET AND WEAR PLATE AS ONE PIECE TO PREVENT ROLLS FROM FALLING OUT.

4. REMOVE DRIVE LINK AND PIN.

5. REMOVE SHAFT UP THROUGH HOUSING. BE CAREFUL NOT TO LOSE THE COOLING PLUG LOCATED INSIDE THE SHAFT.

6. REMOVE HOUSING FROM VISE AND PLACE WITH MOUNTING FLANGE UP ON WORK BENCH. THIS ALLOWS THRUST BEARING (AND THRUST WASHER IN MAY, 1988 AND NEWER MODELS) TO FALL FREE. CAREFULLY INSERT A SCREWDRIVER BET'NEEN DUST SEAL AND SEAL CARRIER AND PRY OUT DUST SEAL .

7. PRESS THE SEAL CARRIER BACK THROUGH THE HOUSING, BEING CAREFUL NOT TO SCORE THE HOUSING BORE.

8. REMOVE RETAINING RING, BACK UP SHIM AND LATHE CUT SEAL FROM GROOVE IN HOUSING WITH A SMALL SCREWDRIVER.

REASSEMBLY AND SEAL KIT ASSEMBLY

THIS COVERS REASSEMBLY USING SEAL KIT NUMBER PS222001, WITH VITON SEAL AND THRUST WASHER. PS222001 IS A UNIVERSAL KIT COVERING BOTH HS & RS SERIES MOTORS SO THERE WILL BE 2 EXTRA BODY SEALS LEFT WHEN REASSEMBLY IS FINISHED.

EACH PART SHOULD BE WASHED IN CLEAN SOLVENT PRIOR TO REASSEMBLY. INTERNAL WORKINGS OF ) MOTOR MUST BE TOTALLY FREE OF DIRT OR DEBRIS. ALL SEALS SHOULD BE LIGHTLY OILED PRIOR TO

_ INSTALLATION.

1. PLACE HOUSING IN VISE WITH MOUNTING FLANGE UP.

2. INSTALL 1.735" 1.0. LATHE CUT SEAL

3. INSTALL BACK-UP SHIM. THIS SHIM MUST BE FOLDED AND BENT SLIGHTLY AND THEN WORKED INTO PLACE WITH A SMALL SCREWDRIVER.

4. INSTALL WIRE RING AND TURN HOUSING OVER SO IT IS IN VISE WITH FLANGE DOWN.

5. SEE ATTACHED DRAWING C10014 FOR INSTALLATION OF SEAL CARRIER COMPONENTS.

6. CAREFULLY SLIDE SHAFT ASSEMBLY INTO HOUSING. BE SURE THE COOLING PLUG IS STILL PROPERLY PLACE IN HOLE IN BOTTOM OF THE SHAFT.

IMPORTANT - TIMING INSTRUCTIONS

(STEPS 7-10) FOR HS MOTOR

7. USE TIMING DOT ON DRIVE LINK END AS A REFERENCE OR MARK ANY SPLINE ROOT WITH A PENCIL CAREFULLY LOWER DRIVE LINK INTO SHAFT WITH

REFERENCE MARK DIRECTLY IN LINE WITH THE CENTER OF ANY OF FOUR THROUGH HOLES IN SHAFT. AS DRIVE LINK SPLINES CONTACT THE SHAFT SPUNES, SLOWLY TURN DRIVE LINKS, COUNTERCLOCKWISE UNTIL SPLINES ENGAGE IN SHAFT SPLINE. TAPLIGHTLY ON DRIVE LINK END TO SEAT THE SHAFT ASSEMBLY INTOTHE WIRE SNAP RING. SHAFT END SHOULD BE SLIGHTLY ABOVE FLUSH FLUSH WITH HOUSING SURFACE. (APPROXIMATELY .010"-.020") BUT WILL

SEAT AS MOTOR IS BOLTED ·TOGETHER.



10. PLACE WEAR PLATE ONTO SEAL SIDE OF ROTOR SET WITH THE CENTER HOLE OF WEAR PLATE DIRECTLY CENTERED ON ROTOR SPLINES. (BE SURE THE WEAR PLATE IS LOCATED SUCH THAT THE NOTCH ON ONE SIDE OF WEAR PLATE PERIMETER WILL LINE UP WITH TAB ON ROTOR SET PERIMETER WHEN BOLT HOLES ARE ALIGNED). LOCATE ANY ONE OF THE FOUR ROTOR SPLINES THAT ARE DIRECTLY ON A CENTER L1NEWITH THE HIGH (CONVEX) LOBE OR ROTOR. PLACE THE WEAR PLATE AND ROTOR SET ONTO DRIVE LINK SPLINE AS ONE PIECE WITH THE HIGH LOBE SPLINE ENGAGING THE PREVIOUSLY DETERMINED DRIVE SPLINE. WEAR PLATE SHOULD BE BETWEEN HOUSING AND ROTOR SET. ALIGN PLATE AND

ROTOR SET BOLT HOLES WITH HOUSING BOLT HOLES. THE WEAR PLATE NOTCH AND ROTOR SET TAB MUST BE IN LINE AND MUST BE LOCATED ON THE PORT SIDE OF THE HOUSING.

.. ~ )

IMPORTANT - RS SERIES TIMING INSTRUCTIONS

SEE STEPS 7-10 FOR HS SERIES TIMING

11. USE TIMING DOT ON DRIVE LINK END AS A REFERENCE OR MARK ANY SPLINE ROOT WITH A PENCIL CAREFULLY LOWER THE DRIVE LINK INTO THE SHAFT WITH REFERENCE MARK DIRECTLY IN LINE WITH THE CENTER OF ANY OF THE 6

THROUGH HOLES IN SHAFT. AS DRIVE LINK SPLINES CONTACT THE SHAFT SPLINES, SLOWLY ROTATE THE DRIVE LINK CLOCKWISE UNTIL SPLINES ENGAGE IN SHAFT SPLINES. (NOTE: THIS APPLIES TO TIMING PROCEDURE

FOR MOTORS WITH STANDARD CW ROTATION CODE '0'. FOR REVERSE CCW ROTATION CODE 'I' ROTATE THE DRIVE LINK CCW UNTIL SPLINE ENGAGES. ROTA

TION CODE IS SEVENTH DIGIT OF SPEC. NUMBER). TAP LIGHTLY ON DRIVE LINK END TO SEAT THE SHAFT ASSEMBLY INTO THE WIRE RING. SHAFT

END SHOULD BE SLIGHTLY ABOVE FLUSH WITH HOUSING SURFACE, BUT WILL SEAT AS MOTOR IS BOLTED TOGETHER.



14. PLACE WEAR PLATE ONTO SEAL SIDE OF ROTOR SET WITH THE CENTER HOLE OF WEAR PLATE DIRECTLY CENTERED ON ROTOR SPLINES. (BE SURE THE WEAR PLATE IS LOCATED SUCH THAT THE NOTCH ON ONE SIDE OF WEAR PLATE PERIMETER WILL LINE UP WITH TAP PROTRUDING ON ONE SIDE OF ROTOR SET PERIMETER WHEN BOLT HOLES ARE ALIGNED). LOCATE ANY ONE OF THE 6 ROTOR SPLINES THAT ARE DIRECTLY ON A CENTER LINE WITH ANY OF THE 6 ROTOR VALLEYS (MINOR DIAMETER OF ROTOR). PLACE THE WEAR PLATE AND ROTOR SET ONTO THE DRIVE LINK AS ONE PIECE WITH THE ROTOR VALLEY SPLINE ENGAGING THE PREVIOUSLY MARKED DRIVE LINK SPLINE. WEAR PLATE

MUST BE BET'NEEN HOUSING AND ROTOR SET. ALIGN WEAR PLATE AND ROTOR SET BOLT HOLES WITH HOUSING BOLT HOLES. THE WEAR PLATE NOTCH AND ROTOR SET TAB MUST BE IN LINE AND MUST BE LOCATED ON THE PORT SIDE OF THE HOUSING.

15. PLACE PIN IN DRIVE LINK NOTE THAT PIN HAS ONE CONVEX END AND ONE CONCAVE END. CONVEX END MUST GO INTO THE DRIVE LINK

16. INSTALL BODY SEAL INTO END COVER GROOVE AND PLACE THE END COVER ON THE MOTOR SO THAT CONCAVE END OF PIN ENGAGES INTO THE HOLE IN

CENTER OF END COVER. ALIGN BOLT HOLES.

17. INSTALL BOLTS AND TORQUE DOWN TO 50 FT. LBS.

18. CHECK TO SEE THAT REF. LINE YOU MARKED ON THE EXTERIOR OF THE MOTOR PRIOR TO DISASSEMBLY, MATCHES UP THROUGH ALL THE PARTS.

[10014 R

SERVICE PROCEDURE SUPPLEMENT FOR SERL KIT PS222001 W/VITON

SEAL AND THRUST WASHER.

SERVICE PROCEDURE SUPPLEMENT FOR SERL KIT PS222001 W/VITON SERL RNO THRUST WRSHER.

1. PLRCE THRUST BERRING ON SHRFT.

2. PLACE THRUST WASHER (5) ON SHAFT.

3. INSTRLL SHAFT SEAL (4) ONTO SHAFT AND DOWN AGAINST THRUST WRSHER (5) ORIENTED AS SHOWN. (NOTE: TRKE CRRE NOT TO ORMRGE SEAL WHEN SLIDING OVER SHAFT SLINES OR KEYSLOT.)

4. INSTALL TEFLON BRCK-UP (3) ONTO SHAFT ORIENTED AS SHOWN. THE LIP ON THE TEFLON BACK-UP (3) SHOULD ENGRGE WITH SHAFT

SERL 1.0. (4)

5. INSTALL BRCK-UP SHIM (2) ONTO SHAFT AND DOWN AGAINST TEFLON BACK-UP (3)

6. CRREFULLY PUSH THE SEAL CRRRIER (1) STRAIGHT DOWN OVER SliRFT SERL RSSEMBL Y ~ OR I ENTEO RS SHOWN, TRK I NG CARE NOT

TO COCK THE CRRRIER WHILE INSTRLLING.

7. RETURN TO STEP 6 OF REASSEMBLY SECTION OF SERVICE PROCEDURE.

8 G)

8 8 o

80

SEAL CRRRIER RS018991

BRCKUP SHIM - RS018D20

TEFLON BRCKUP RS0180S8

SHAfT SEAL - - - - - - - RS018053

THRUST WASHER - - - - - - RS0180S9

)

BRAKE TORQUE ADJUSTMENT FOR HYDRAULIC MOTOR

(Calavar Part #32762 - Braden Winch Co. Owg. #0-03016)

Due to manufacturing tolerances of the brake parts (including the springs), the number of brake plates may vary to obtain the required brake torque.

Nominally, this assembly will require:

5 friction plates 6 steel plates 3 brake plate spacers 5 springs

The brake should be assembled as shown on the cross-section Drawing 0-03016.

Using a torque wrench, the torque, where the brake starts to slip, should measure 106= 10-ft/lbs.

If less torque is desired, reassemble the brake with:


If more torque is desired, reassemble the brake with:


or


Please note that the number of brake 'springs could be adjusted to obtain the desired brake torque. However, this would change the fully released brake pressure and may be objectionable.

~0-.-,,_ 0~~---_,~~._.'" " 0(

"".

)

OESC~IPTION QTV/PER-

030}6 P32Q SUING DRIYE

GOI 25533 HOI/SING 1 002 25527 OUTPUT PINION 1 003 25582 OIL SEAL 1 004 __ """'2_5L-5u.8 ..... '.J--_________ ..u.B"-F ....... AAR..4.r~"Ll.JG~C.J..jlli.Lp~ __________ ..L 005 25584 aEARl NG CONE 1 006 25585 3EAR I NG CUP 1

_D...O..1_ 25586 Be AQ I NG CONE -__ ____ _ 1 OOB 25549 BEARING SPACER 1 009 2 55 8 1 S NAP R I N G 1 ~ ______ ~)_5~5~3~2~ ______________ ~O~IJ~T~p~t1~r~p.!~A~NuF~r~c~A~R~R~rF~R~ _________ -Ll

Oll 25546 OUTPUT PLANE T GEAR 3 o 12 2 5545 au T PU T P LAN E T G EAR S H AFT 3 ~- ----~Z~1~O~4~9~---------------~R~L~a=-uQ~1~5=-~R~a~!~f~p~I~N~--____________ ~3 014 24175 ROLLER BEARING 6 015 24167 THRUST BEARING 6 ~~ _____ ~2_5~5~4~8~ ___________ ..u.H_E_A.QR~r~N~G~S~P_A~C~F~R~ ____________ ~

011 25544 OUTPUT SUN GEAR 1 018 25588 S'4AP ~ING 1

_..a.l.3._ J 30 2 3 L 9 '+ 1 0 I) 6 S \I APR I N G l.. o 20 2 55 9 a T H R U S T RAe E 2 Olt 25531 PRIMARY PLANET CARRIER 1

_Q2L- 2 55 5 f P R. P-1 A a y P! AN E T G E A. R l 023 2554) PLANET GEAR SHAFT 3 02~· 12025 RIZ-OSO RGLLPIN 3

_Q25 __ ------~Z~4~q~1~5~--------------____ ~B~E~A~R~[~N~G~~Q~Q~'~'~E~RL_ _________________ ~ 026 249t4 bEARING ~ACE-THRUST 6 027 25547 PRIMARY SUN GEAR t ~~- ____ ~,"5~5~5~~~----------------__ ~I~N~p~l!ur~S~H~4~E~T~ _____________________ l

029 25589 SNAP RING I 030 25534 BRAKE CYLINDER l

-.0..1 L_ 1 04 5 Q 1 0 4 '; 0 0 R t N G .1 012 24~16 B~AKE SPRING 5 033 25593 r~RUSr BEARING t ~J~__ ,5552 SPRING PJ ATE l 0)3 25594 U-CUP SEAL 1

...!l.3b._ -----.'2~§~i~5~71------------ ~_AA--·COUP~L-+I~~~'-· ----------...... L a ~5';50 BRAKE PLATE SPACER J 033 25540 BRAKE DISC o 39 -e-c2~5~5"'t_4_i_l--------- ~~I"O~-_4Dr:J_,rL-.u.~----04) 10138 16262-249 a-RING 041 25535 MOTJR ADAPTER 042 2l4&e ~~15P~5 C&P~CQE~

843 tl107 SO)l-lOPH5 C~PSCREW 044 1 102 4 A 0 '3 t LaC x wAS HER

o 5

l 1 ~

i4 n45 ,- ----.:2~J~G~9~5i__-----------~~13~ PbUC; Z 046 22.314 EO 12A PIPE PLUG 2 a 4 1 1 00 7 4 2 5 '; 8 a () 1 R ELI E F V A L V E 1 0" 1:1 2 5 It 0 3 ---5).4 r P P I ~4 G P LUG H¥ G-+-,Lt~M l: 049 23108 23108 G~SKET-~CTCR 2 050 2195g MU1-502DG SHIELD OUST 1

-0.5.1.-- ---l--OOI4-,O~ql----------- ~C-')...Q-Q.-5t2r4'j G-u~~€-W--------·-----l_

052 11026 AOSO LOCKI-JASHER 2

CONDOR MODEL 46N

ELECTRICAL SLIP RING (Calavar Part No. 32559)

The electrical slip (collector) ring assembly is mounted at the center of rotation of the turret. Its purpose is to provide electrical current between the turret, which can rotate continuously, and the carriage, which is stationary. Without the slip ring, the wire harness from one to the other would twist off, and electrical current would be lost.

The slip ring assembly is designed for maximum efficiency with a minimum of maintenance. It is of a compact design, which allows for stacking many circuits in a small space. The brushes used are a self cleaning type, which in normal use will last the life of the machine. In circuits requiring up to 20 amp capacity, one pair is used per circuit. For circuits requiring up to 30 amp capacity, two pair are used per circuit. These ride on a 3/16" wide brass ring. For 40 amp capaCity, a 3/8" wide brass ring and a single pair of wider brushes is used, and on 60 amp capacity, two pair of wide brushes are used. The brushes are riveted to a nylon brush arm. The rivet concept allows the brush to pivot slightly on the arm. This assures complete contact at all times between the brush and the brass ring. This is especially important as the equipment ages, and an orbiting condition arises. The brushes are normally attached to the upper wire harness with knife disconnect terminals. This allows for quick disconnect of the terminals should removal of the ring be required. The terminal connection of this type is protected by a plastic sleeve. When installing the ring assembly, care should be taken to insure complete coverage of the terminals by this sleeve. Some rings use multiple circuit plugs. These should be removed and rep.laced carefully to avoid damaging the contacts.

The center harness is normally connected to the core leads on the ring by set screw type connectors. These connectors have proven to be superior to the twist on type, especially in field installations, because they are a positive type termination. The brass sleeve is slipped over the stripped wire endss, and the set screw tightened with a straight screwdriver. The nylon cover is then screwed down over the sleeve for protection. Care should be taken to keep the center leads as short as possible when connecting the center harness. This is to prevent the wires from catching on any portion of the upper.

Some slio rings are prewired during manufacture, and the center core leads are permanently fastened to the center harness with machine crimoed ~erminals. If it becomes necessary to remove these, the set screw type connectors should be used for reolacement.

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------------------.---.------------------------------------------a u

______ . --..",,-- .- r- --.)~- r--"\I··---(;------_· :-=-=--==:.::=x::..:r..-=:='~~&::lI::I::i:QI __ c.:I:I~

-D~':_= ___ LO

---- Hake centro harness connectlon5 a8 short AS poasl blo to prevent rubbing on tho sllp-ring cover •

. _________ ~ Hake bruah harnoacs connoctlona a lid lar ~ to the ·Christaa. troa' type a66ellhly ----==== ahown. Tha taralna} connectlon .uttt

_____ he cOllplotoly covered by tho slo6v6.

~ T}GIITU4 Sh.1'SCHl!lIS SEClJHEl. Y to tho ~ drivo tube

~ 1/2" drive plne rocoliPlonded to turn ~ baae. Do nol faalon Laue down llKhllY. 'J 1.500 I.D. nylon bearing accopts A

.ountlng tube of 1.'!2§ Dlaaolor. D'92 .

-----

EU:ClIU CAL SL I P In NG CALAVAR NO.

32659

In some conditions, the slip ring will have a tendency to collect fine silt, or a salt atmosphere will cause corrosion. If this happens, swing the upper several timess. This should clean the surfaces. If it does not, it may be necessary to use a standard non-residue solvent to clean the ring. Then lightly sand the brushes and rings with a fine grade of sandpaper. They can then be blown off with compressed air.

To replace a brush and arm assembly, remove the hex nut and washer at the top of the brush stud. This will allow the brush assemblies to be removed. Be sure when replacing the brush and ann assemblies that all assemblies are located on the corresponding circuit, which is identifiable by number. And be sure that all springs are hooked at the brush arms.

There is a nylon bearing in the base of the assembly, eliminating the need for lubrication of the ring base bearing.

If it should become necessary to remove the slip ring from the machine, do so by loosening the socket screws at the base of the ring. This will allow the ring to be lifted off the mounting tube. When replacing it, make sure these set screws are again tightened, as they hold the core in a stationary position. If the set screws are not tight, the core can turn, and twist off the wires. The mounting tube should be 1.492-1.496 inches, maximum outside diameter, and 14 gauge thickness. This allows for proper fit, al~g with maximum inside clearance, while maintaining necessd:y strength. Care should be taken to abide by these tolerances if mounting tube replacement is required.

ihe slip ring drive pins, which are located on the. rotating ~ernber, should be 1/8" smaller in diameter than the 3/4" diameter holes in the base bracket of the ring. This base bracket should not be bolted down tightly.

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SYNCHRO-START D.C. SOLENOIDS GENERAL INFORMATION

Because of the dual coil design, Synchro-Start D.C. Solenoids may be energized continuously without any duty cycle derating. This is an advantage over single coil solenoids. The dual coils, one low resistance. the other high resistance, permit safe operation even in high ambient temperatures.

The low resistance coil provides a high pulling force. Upon completion of the plunger stroke, the heavy duty double break self contained switch automatically disconnects the high current pull winding within .040 seconds of energization. This means that Synchro-Start D.C. Solenoids pack more power in a smal.ler space at lower co!St.

All D.C. solenoids using dual coils must be installed and adjusted so that the plunger always completes its stroke, ie., the plunger must bottom. disconnecting the low resistance coil. If this does not occur, excessive heat ensues, which in time (over 30 sec." does irreparable damage.

WARRANTY

THE DUAL COIL GIVES GREATER PULLING POWER AND PERMITS CONTINUOUS OPERATION AT HIGHER AMBIENT TEMPERATURES

HOLD

'_I I

c=::J

I Synchro-Start Heavy Dyty Solenoids are Rugged and Performanc~ Tested.

Proper installation is extremely important. Plunger must bottom properly to operate pull coil disconnect switch. If contacts fail to open and circuit is not protected against overload, the pull coil will burn out in 50 seconds. Damage of this type is due to faulty installation and is not covered by Synchro-Start's norma I warranty.

SYNCHRO-START D.C. SOLENOIDS

1. GENERAL

• Condor uses the Synchro-Start D.C. Solenoids for choke and throttle control on the gasoline engines, and for fuel on/off and throttle control on the diesel engines. (See Table ItAII for the list of Condor Models and the solenoids used.)

• The solenoids used have the dual coil design, and may be energized continuously without any duty cycle de-rating. They have an extremely high work output for their size, because of the high amperage IIpull ll winding and a separate low amperage 'Ihold ll winding. These dual coils (one low resistance, the other high resistance) permit safe operation even in high ambient temperatures.

• The low resistance coil provides a high pulling force . . Upon completion of the plunger stroke, the heavy duty double break self-contained switch automatically disconnects the high current pull winding within .040 seconds of energization.

• All D. C. solenoids using dual coils must be installed and adjusted so that the plunger always completes its stroke, i.e., the plunger must bottom, disconnecting the low resistance coil. If this does not occur, excessive heat ensues, which in time (over 30 sec.), does irreparable damage.

• -CAUTION:

Proper installation is extremely important. Plunger must IIbottom ll properly (i.e., complete its stroke) to actuate the pull-coil disconnect switch. If contacts fail to open and circuit ;s not protected against overload, the pull-coil' will burn out in 30 to 50 seconds. Damage of this type is due to faulty installation and is not covered by normal warranty.

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2. ELECTRICAL DATA: SYNCHRO-START D.C. SOLENOIDS

LENGTH OF RATED D.C. PULL HOLD SOLENOID PART NO. STROKE VOLTS AMPERES AMPERES

32111 1 IN. 12 24 0.5

40808 1 IN. 12 37 0.6

32239 It IN. 12 42 0.6

#32111 #40808 #32239

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__ - Contacts must Open with Plunger Bottomed

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SYNCHRO-START D.C. SOLENOIDS - continued:

3. TEST PROCEDURE TO DETERMINE PLUNGER HAS BOTTOMED

• On units with an auxiliary terminal, connect a voltmeter or appropriate light (voltage rating) between auxiliary and 11+" terminals. When the solenoid is energized and the plunger bottoms, the voltmeter will indicate the battery voltage or the light is energized.

• Visual Method - Push the plunger to the full bottomed position and measure the plunger extension length from the solenoid body before the linkage ;s connected. Connect linkage and energize the solenoid. If the plunger has fully bottomed, the plunger extension lengths should be the same.

4. TEST PROCEDURE TO DETERMINE ADEQUATE VOLTAGE

• Connect a D. C. Voltmeter across the solenoid terminals and manually hold the plunger so that it cannot bottom. Energize the solenoid just long enough to obtain a voltmeter reading, then connect the same voltmeter across the power source and manually hold the plunger so that it cannot pull in just long enough to obtain a voltmeter reading. The difference between the two voltmeter readings is the voltage reduction due to wiring which should normally be less than 7% of rated voltage.

5. CORRECTIVE ACTION

• If the power source voltage is low, check for partially discharged battery, etc. If the solenoid voltage is low, check for undersized hookup wire, high resistance connections and underrated control device contacts.

)

TABLE "A"

LIST OF CONDOR MODELS & SYNCHRO-START D.C. SOLENOIDS USED

CONDOR SOLENOID MODEL ENGINE CONTROL FUNCTION PART NO.

36N Wisconsin Ga.sol ine Choke 32111

I

I ! 46N Model VH40, Throttle 32111 i 30 HP : f

I

36N Deutz 46N Diesel Fue 1 S hut Off 32239

Model F2L511

;

I ) 1

60N Wisconsin Choke 32111 48 Gasoline

! 50 56 Model VG40, Throttle 40808

: 58 37 HP : 68

I : 76 ! 46Q8 I

I I

! 60N I

Deutz I 48 I 50 Diesel ! 56 - F2L912 Fuel On 40808 : 58 i 68

76 46Q8

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TABLE "S"

SYNCHRO-START SOLENOIDS USED ON CONDOR MODEL 86

CONDOR MODEL

86

86

86

ENGINE

Ford Gasoline

Wisconsin Emergency Gas Engine

Ford Diesel

. Deut% Diesel

- F4L912

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:

CONTROL SOLENOID FUNCTION PART NO.

Choke 32111

Throttle 32239

Choke 32111

Fuel Shut-OFf 32111

Throttle 32239

Fuel On ' 40808

Throttle 40808

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CORPORA TION

COUNTERBALANCE VALVE CARTRIDGE CALAVAR PART NO. 32585

• Low leakage load holding ( 0 to 5 drops per minute, max. )

• Built-in free-flow check valve; cracking pressure = 4 psi

• Manual emerge~cy load release

• Pilot ratio 3:1

• Seals: Buna-N

• Pressure adjustment range : 1000 - 4000 psi

• Standard setting: 2900 psi (stamped on cartridge hex)

• Installation torque: 40- 45 ft-lbs.

1.12 2.38

SCREW au T TO INCREASE ~ESSURE SEiTING.

SCREW IN TO RELEASE LOAD.

~--Locating shoulder

IN

FREE FLOW (VALVE)

I--~~- 300~----------,

vAL,YE , I I

! I ' 100

1.- __

LSYmbOl eYL.

10 G.P.M.

CALAVAR PART NO. 32585

COUNTERBALANCE VALVE CARTRIDGE

SERVICE INSTRUCTIONS

Calavar 432585 cartridges are basic service items in themselves. They are easily removed from their mounting for cleaning or replacement, but are not designed to be disassembled or repaired in the field.

It is not necessary to remove an entire holding valve from the circuit plumbing. Simply unscrew the cartridge from its body for troubleshooting (below) or replacement.

If, for any reason, a cartridge does not perform as required, the troubleshooting steps given below may be taken. Following this, if the cartridge still does not function, it should be replaced with a new factory-tested cartridge. The non-functioning cartridge may be returned to Calavar through your local dealer/distributor for evaluation if desired. A full report of our findinas will be issued on request. ~

TROUBLE SHOOTING

The most common cause of a cartridge failing to operate is dirt in the hydraulic fluid - dirt which lodges in the working parts and interferes with their operation. Cartridges can be cleaned without altering their pressure setting.

To check and clean a cartridge which is not functioning:

1) Remove the cartridge from the cavity. 2) Inspect for visible contaminants and carefully remove obvious

particles. 3) Through the nose of the cartr.idge, manually operate the inner

working parts several times. Use a wooden or plastic dowel to avoid damaging soft seats, sharp edges or finished surfaces. All parts should move freely. If possible, do this with the cartridge submerged in clean mineral spirits.

4) After IIflushing", b.low dry with clean filtered air. 5) Replace seals if indicated, using the appropriate service kit. 6) Reinstall cartridge, tighten to specified torque, and retest. 7) If this procedure does not eliminate the problem, replace with a

new factory-tested cartridge.

CARTRIDGE SEAL KIT: Calavar Part No. 93067

nstoll nose end ---_ 5EAL

!)OCK-UO r.ng ~ ",ese: ::~D & seat os ~ _9ACI<.-UP

snown. ~ RING

[ ---}:~

~--.r--_~I

-...J ~~-------....: 3:'~··_O ; .,.::

Kit contains quantity = 3 seals and quantity = 3 back-up rings.

When replacing spiral back-up rings, take special care that the SPIRAL IS WOUND LIKE A LEFT-HANDED THREAD, so that the back-up ring will follow the cartridge into the cavity properly when being assembled.

INSTALLATION TORQUE: 40 to 45 ft. lbs.

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WATERPROOF LIMIT SWITCHES

Calavar Part No. 40207 (All Boom Machines)

Calavar Part No. 40208 (Model 86 and Truck Mounts)

Condor self-propelled aerial work platforms use water?roof limit switches manufactured by Control Products, Inc. They are designed for rugged military and mobile equipment applications.

These switches are really WATER-PROOF. They are designed to operate reliably under exposure to water, oil, humidity, sand, dirt, vibration and shock. They do not rely on gaskets, O-rings, or diaphrams. The neoprene jacKet is bonded to the neoprene insulation on the leads, to withstand temperatures from -65°F to +165°F.

The cpr waterproof switches meet or exceed Military Specifications with exact ratings shown in Table I.

large area actuating button accurately locates actuation pOint on snap action spflng. __ -:::.~ ...... ~~ .. _

Plated steel switch -...,...----- case and cover.

Riveted snap action blade mounting points.

Eccentric adjustment ~~~~~.~~ for precise tensioning of blade.

Flexible waterproof neoprene jacket molded

J.EZ~--- to lead wires.

Sine blade. ----....:~~===;;;;r~ act - Carrying extension lever

r-REQUIREMENT

f---.-

ConstructIon

Material: Rubber Jacket Wire

Corrosion ResIstance

I Fungus Res;stance

: Water j Prcofness !

IExtrerne , Temp. Res.

Shock I ReslstJnce

Vibration Resistance

CPI MEETS OR EXCEEDS MIl. SPEC.

MS 39058

MS 39058. MiI·R-3055 MS 39058. Ord. :: 7722204

I Mil·Std.202 : Method lOLA I 200 hrs .. Salt Spray

I i Mil-F·13927 90 Days

; MiI·S-13~34 8 : 6 psi Internal pressure. 30 min. I 5 psi internal vacuum. 30 min. i Immersed In Salt Water SOlutl~

i Mi1S-13434 B I : 24 hrs. at - 55' - 5 F i 24 hrs. at 165' ;-S'F . : Operated 1000 cycles 28 V.D.C. ! IS arrp load

202A MI! "'·1 202A : 100 gra, ;nlts "g's" ! 28 V.D.C. ; 5 amp :resistive)

load during test

20lA MII·Std 202A 1 hr. of vibration 3 malor axes repeated in

I

REQUIREMENT

Mecha!llcal Actuation

Contact Voltage Drop

Overload

High Voltage

Ooen Circuit Resistance

Endur Jnc~

CPI MEETS OR EXCEEDS MIl. SPEC.

Actuating Force - 1 to 2 pounds Release Force - 6 oz. minimum Release Time - 1 f 4 sec.

maximum at -55'F Pretravef - .015 minimum Overtravel - .015 minimum Differential -005 maximum

MiI·S·13484 8 28 V.D.C. 15 amp 'resistive) load Voltage drop shalf not exceed

150 millivolts

MiI·S·134848 28 V.D.C. 22·1/2 amp (resistive) 100 "make" and "break"

I Mil·S·13484 8 ,. I 440 Volts 'R~AS) at 00 CPS ! I mm. between leads

I MiI·S·13484 B Open contacts not less than 1 megohm

I M:I-S-13484 B 28 V.D.C. 7·1/2 amp

(inductive) load 7·l!2 amp (lamp) load 25.000 "make" and "break" cycles

I I

i

I ! I

open position. (Not less than 5 hrs. in vibration.) .05 inch double amolitude fieQuency 10 and 55 CPS

115 V.A.C. 50 Hz I 1/ 3 H.P. motor load I'

Lead Connections

return to 10 CPS 28 V.D.C. 15 amp resistive load

during test.

Subjected to a tensile force of 25 pounds along axis of lead and perpendicular to axis of leads.

5 amp. lamp. lD amp. resistive

25.000 "make" and "break" cycles

115 V.A.C. 60 Hz 4 amp. inductive L! R = .049 8 amp. resIstive

100,000 "make" and "break" cycles

CPI Waterproof Switches

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Torque-Hub Final Drives

Service Manual

N3 3

JRI vE

Fairfield Manufacturing Company, Inc. South Concord Road. Lafayette. Indiana 47902. U.S.A. 317/474-3474

• •

Introduction This Service Manual is a step-bv-step guide designed for the customer or shop mechanic who is servicing or repairing a particular model of Torque-Hub Final Drive. (The model covered by this copy of the Manual is specified on the Manual cover.)

Included are -1. assembly and exploded view drawings 2. disassembly procedure 3. main assembly procedure (assuming

all sub-assemblies to be intact) 4. sub-assembly procedures.

At the time of printing, this Manual was complete for the specific Torque-H ub model designated. However, Fairfield Manufacturing Co., Inc., reserves the right to update and improve its products at any time. All specifications and procedures are therefore subject to change without notice.

Safety Standard safety practices should be followed during the disassembly and assembly procedures described. Safety glasses and safe~y shoes should be worn; heavy, heat resistant gloves should be used when heated components are handled. Be especially alert when you see a caution symbol C1~J. This symbol indicates that a particular operation could cause personal injury if not performed properly or if certain safety procedures are not followed.

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W3B-W3C Disassembly Procedure

1. Loosen all 12 Cover Bolts and drain the oil from the unit.

2. Remove the 12 Cover Bolts and lift off the Cover Sub-Assembly. Discard the '0' ring Seal from the Cover cou nterbore.

3. Lift out the Carrier Sub-Assembly and *Thrust Bearing Set. A Thrust Washer may stick inside the Cover.

4. Pry the Ring Gear loose and remove it. Discard the '0' ring Seal from the Hub counterbore.

5. Remove the Input Shaft, Input Gear, and the Thrust Spacers that are on the Input Shaft.

6. Lift out the Internal Gear and Thrust *Bearing Set. A Thrust Washer may stick to the bottom of the Carrier.

7. Remove the Retaining Ring from the Spindle and discard; then lift the hub off the Spindle.

Eye protection should be worn during Retaining Ring removal.

8. The inside Bearing Cone and the Bearing Shim can now be removed.

9. The Seal can be pried out of the Hub with a screw driver or pry bar. This will also allow the outside Bearing to be removed.

Note: If bearing replacement is necessary, the Bearing Cups can be removed with a "slide hammer puller" or driven out with a punch.

10.To remove the Cluster Gears from the Carrier, drive the anti-roll pin into the Planet Shaft of the Cluster Gear. After the Planet Shaft is removed the roll pin should be driven out of the Planet Shaft.

WARNING: When rebuilding the unit, the '0' rings and Retaining Rings should always be replaced.

Main Assembly Procedure

1. Using an arbor type press if available. (if

not, a hammer may be used\. install the wheel studs. The hub flange should be supported from the underside durl ng this operation.

Note: Wheel studs are optional.

2. Using an arbor type press if available. press Bearing Cups with large inside diameters facing out. into Hub counterbores. Cup #JM71661 0 will go Into sfT1ail end of Hub, and Cup #JM515610 will go into large end of Hub.

3. Place Bearing cone :tJM716649 into Bearing Cup in small end of Hub.

4. Press Seal into Hub counterbore with flat metal side facing in. Use a flat object to assure that Seal is pressed evenly and IS

flush with Hub face.

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5. Lower Hub onto Spindle with large open end up.

6. Place Bearing cone #JM515649 over end of Spindle and into Bearing Cone.

7. Place Bearing Shim over end of Spindle and against Bearing Cone.

8. Secure Retaining Ring completely into Spindle groove and against Bearing Shim. Be sure that Retaining Ring is entirely in groove.

6 Eye protection should be worn during Retaining Ring installation.

9. The pipe plugs are installed in the Hub. The use of lub-seal is recommended on the pipe plug.

10. The disengage spacer and spring are installed into the co'bore of the Spindle.

11. Another spacer and the correct Retaining Ring are installed into the Spindle co'bore and Retaining Ring groove provided.

& Eye protection should be worn during Retaining Ring installation.

12. The internal gear is installed matching the Bore Spline to the Spindle Spline.

13. The thrust washer Ithrust bearing set IS

installed on the portion of the Spindle which extends into the internal gear.

14. The O'Ring is placed into the counterbore provided in the Hub. Slight stretching may be necessary. Use sufficient grease or petroleum jelly to hold in place.

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position punchmarks at 12 o'clock

15.1nstall retaining ring into input shaft retaining ring groove.

16.The input shaft is installed into the spindle.

The action of the spring should be checked at this point.

17.The thrust spacer is installed on the input shaft.

18.Locating the four counter reamed holes in the face of the hub, mark them for later identification.

These holes are reamed to accept the shoulder bolts.

19.Place Carrier Assembly on a flat surface with the large gears up and positioned as shown. Fi nd the pu nch marked tooth on each large gear and locate at 1 2 o'clock (straight-up) from each planet pin. Marked tooth will be located just under the Carrier on upper two gears.

.. ~.-•. -. ......

20.With shoulder side of Ring Gear facing down, place Ring Gear over (into mesh with) large gears. Be sure that punch marks remain in correct location during Ring Gear installation. The side of the Ring Gear with an "X" s.tamped on it should be up.

21.While holding Ring Gear and Cluster Gears in mesh, place small side of Cluster Gears into mesh with the Internal Gear. On the Ring Gear locate the hole marked "X" over one of the marked counterbored holes in Hub.

Note: If gears do not mesh easily or Carrier Assembly does not rotate freely, then remove the Carrier and Ring Gear and check the Cluster Gear timing.

22.The Input Gear is installed into this assembly meshing with the larger diameter Cluster Gear. The counterbored side of the Input Gear is installed down or to the inside of the unit.

23.After inserting at least one Shoulder Bolt in the proper location, rotate the Carrier. This is to check freedom of rotation and recheck the timing.

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24.Another thrust washer.: thrust bea fI ng set is now installed into the counterboreln tf:e face of the carrier.

25.Place O'Ring into cover assembly counterbore. Slight stretching may be necessarv Use sufficient grease or petroleum Jelly to hold in place.

26.Place cover assembly on Ring Gear with 011 level, check plug in cover located approxImately 90° from oil fill plug in Hub.

27.Locate four shoulder bolts 90 e apart into counterbored hole in Hub which were marked in step 17. Torque each bolt to 47ft. Ibs.

28.lnstall grade eight 'bolts into the remaining eight holes and torque all bolts to 47 ft. Ibs. Use the 180e to 90 e method in torqueing all bolts.

29.Place Coupling Into the Spindle and onto the Input Shaft.

Note: W3C units must have one external \ and one internal Snap Ring Installed. All ) units with a "X" on the end of the model number must have two internal Snap Rings with a spacer between them installed in the Coupling.

This completes the assembly. The unit must be filled one-half full of EP 90 lubricant before operation.

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Carrier Sub-Assembly

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1. Apply a coat of grease or petroleum jelly to Cluster Gear bore.

2. Place fourteen Needle Rollers into Cluster Gear bore.

3. Place Spacer washer into opposite side of Cluster Gear and against Needle Rollers.

4. Place second set of fourteen Needle Rollers into Cluster Gear.

.... 5. Apply grease or petroleum Jelly to the

tang side of two Thrust Washers. Place Thrust Washers against bosses in Carrier with washer tang fitting into slot in Carrier outside diameter.

Note: Some old style Carriers will not have slots and tangs should be located inside boss relief.

6. While keeping Thrust Washers in place, slide Cluster Gear into Carrier with the larger gear on the side with the small pin hole.

7. Line up Cluster Gear and thrust Washers with hole in Carrier and slide Planet Shaft through. Line up chamfered side of hole in Planet Shaft with pi n hole in Carrier.

8. Drive Anti-Roll Pin flush into Carrier hole, thereby locki ng Pia net Shaft into place.

Repeat these steps for remaining two Cfuster Gears to complete Carrier Sub Assembly.

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Cover Sub-Assembly

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1. Screw Pipe Plug into Cover.

2. Place '0' Ring into Cover Cap internal groove. The Disconnect Rod may be used to push '0' Ring into groove. Rod will be held in place by friction from the '0' Ring.

3. Slip '0' Ring over Cover Cap and against face.

4. Place ·Cover Cap into Cover with large hole located over Pipe Plug.

5. Install two 1/4 x 20 x 3/4 bolts 180 0

apart and torque to 70 - 80 in. Ibs.

6. Place disconnect cap over cover cap with nipple facing out and align with two open holes. Secure disconnect cap to cover with

·two 1/4 x 20 x 3/4 and 70 - 80 in. Ibs.

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) CONDOR MODELS 58, 68 AND 76

TORQUE HUB, CALAVAR PART NO. 21492

ITEM PART NO. QTY. DESCRIPTION

1 W3B110 1 HUB-SPINDLE SUB-ASSEMBLY 1A 3400702 1 Spindle 1B 3501301 1 Seal 1e 3500803 1 Brg. Cup (JM716610) 10 "3500804 1 Brg. Cone (JM716649) IE 3500805 1 Brg. Cup (JM515610) 1F 3500806 1 Brg. Cone (JM515649) 1G 3500601 1 Hub 1H 3900904 1 Spacer

II 910002 1 Retaining Ring 1J 950003 2 Pipe Plug 1N 970001 10 Stud

) 2 3400081 1 INTERNAL GEAR 3 3200001 1 CARRIER ASSEMBLY

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10 910016 1 RETAINING RING 11 3100109 1 INPUT SHAFT 12 3901001 1 THRUST SPACER 13 3100023 1 INPUT GEAR 15 3200306 4 THRUST WASHER 16 3200307 2 THRUST BEARING 17 930102 8 BOLT 18 3930201 4 SHOULDER BOL T 19 3100205 1 COUPLING

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FOR MATERIAL HANDLING EQUIPMENT. FARM MACHINERY. ROAD EQUIPMENT. MINING MACHINERY. ETC.

Fairfield Manufacturing Company, Inc. South Concord Road, Lafayette, Indiana 47902. U.S.A. 317/474-3474

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CORPORA TIOH

GENERAL:

H.P.I. PROPORTIONAL CONTROL VALVE

INSTALLATION & MAINTENANCE

• Fluid Viscosity: 35 SSU to 1750 SSU

• Temperature: -40°F to +180°F

• Seals: Buna N standard.

• Return Line Pressure: 500 psi maximum

INSTALLATION:

• Tie Bolts: Care should be taken to prevent stressing the assembly by over-tightening the tie bolts. Always use a torque wrench to tighten. Torque to 225 inch-pounds~

• Mounting: When mounting a valve be sure that the mounting bolts or connection pipe-work do not overstress the assembly.

• Sealing Compounds: No sealing compounds are required as all ports are SAE straight thread o-ring ports.

• Port Preference: If one of the user ports (A or B) will be handling a higher return flow, it is preferable to connect the higher flow to the B port. This will provide a more direct path to the tank port.

• Solenoids: The voltage should be checked against the solenoid nameplate before wiring. (12 Volt D.C.)

START-UP:

• Bleeding: Air in the system will impair control and may cause dangerous movement of a load. At start-up the hydraulic system should be bled at as many points as possible.

OPERATION OF HPI PILOT VALVE

The pilot valve is not a conventional 4-way 3-position valve, but a double pressure regulator. When one solenoid is energized, the armature exerts a force on the pilot valve spool which is proportional to the solenoid current. This force is balanced by the output pressure, which is led to the opposite end of the pilot spool. A given solenoid current will therefore generate a certain secondary pressure (up to 200 psi approximately). It is this secondary pressure which is applied to one end of the spool of the main valve to displace the spool against an opposing (centering) spring, this displacement being proportional to the applied pressure. The net effect is that the user speed may be controlled by varying the solenoid current - independent of the load and any load fluctuations.

This pilot valve does not require special filtration and required flow rate is approximately 1 GPM.

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TROUBLE-SHOOTING HPI PROPORTIONAL CONTROL VALVE

1. System pressure too low:

• Pump compensator set too low; adjust pressure setting up.'

2. Function pressure too low:

• Pump compensator set too low; adjust pressure setting up.

• The functions compensator sticking or stuck; remove and clean or replace.

• Shuttle valve leaking; locate leaking valve and replace cut o-ring or complete assembly.

3. Load does not move:

• Pump compensator set too low; adjust pressure setting up.


• Stuck compensator; remove and clean or replace.

• Improper voltage; no voltage to solenoid or weak signal.

4. Funct10n does not attain speed:

• Improper voltage; weak or not high enough voltage signal.


• Wrong directional spool; replace with proper spool (correct flow rate).

• Wrong compensator; replace with proper compensator to attain correct flow rate.

5. Function speed too fast:

• Wrong directional spool; replace with proper spool (correct flow rate).

• Wrong compensator; replace with proper compensator to attain correct flow rate.

6. Load moves erratically:

• Air in system; bleed at as many points as is possible.

• Faulty signal to solenoids; check solenoid input current and correct if needed.

• Adjust compensator dampening screw to a position to throttle pulsations.

• Fluctuating inlet pressure to the manifold; measure pump outlet pressure and stabilize if fluctuating significantly.

• Excessive tank pressure; look for restriction in tank line downstream of the valve.

7. Poor control:

• Adjust compensator dampening screw to a position at which the function operates properly.

• Faulty signal to solenoids; check solenoid input voltage for a smooth steady proportional signal.

• Air in system; bleed at as many points as is possible.

• Sticky pilot spool; remove and clean pilot spool of contamination.

8. Interreaction between functions:

• Functions eompensator stuck open; remove and clean or replace compensator.

• Pump bias pressure too low; adjust bias pressure up.

9. Moving function no signal:

• Directional spool centering spring retainer has backed out; screw retainer back in and lock.

10. Moving function:

• Check for electrical signal on valve.

)

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MeV-ISO VALVE SYSTEMS

INSTALLATION

START-UP

&

TROUBLE-SHOOTING

GUIDE

5/9/86

MCV-ISO VALVE SYSTEMS

INSTALLATION & MAINTENANCE

General

Filtration: 25 micron, return line Fluid viscosity: 35 to 1750 SSU Temperature: -40 degrees F. to +180 degrees F. Seals: Buna N standard

Specify viton if required Pressure: 3000 PSI maximum Return Line Pressure: 500 PSI maximum Inlet Flow: 40 GPM maximum

Installation

Mounting: The MCV-ISO will function in any mounting position. However, for optimum/long life performance; mount so that the solenoids are horizontal. When mounting a valve, be sure mounting bolts or connecting pipe-work do not overstress the assembly.

Sealing Compounds: Sealing compounds are not recommended or required. All ports are SAE straight thread O-ring ports.

Solepoids: The voltage should be checked against the imprint on the coil prior to wiring (take care not to bend the terminals).

Handle Position: The handle position may be changed as follows: Remove four mounting screws from the handle cap assembly, lift handle cap upwards (disengaging pinion gear from rack), remove handle cap, and rotate handle. Replace the handle cap (engaging pinion gear onto rack), and replace the four mounting screws.

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Page 2

Start-up

Pressure Setting: Before starting the pump, the relief valve adjustment should be fully unscrewed. Then, with the pump running and one of the functions dead-headed, adjust the maximum system pressure by turning in the relief valve adjustment.

Note: For systems incorporating power beyond, the power beyond circuit must incorporate a maximum pressure relief valve.

Bleeding: Air in the system will impair control and may cause dangerous movement of a load. At start-up the hydraulic system should be bled at as many points as possible.

Dampening: (For systems incorporating the MUV inlet only) The dampening throttle is factory set. If adjustment is required, remove the protective screw cap and adjust the throttle screw slightly. Keep in mind that the dampening throttle will affect the response time of the compensator. If the throttle is completely closed, the compensator and the relief valve will be completely eliminated from the circuit.

Page 3

TROUBLE-SHOOTING

(1) System pressure too low

(2) Load does not move or moves at low speeds

(3) Load moves erratically (system is oscillating)

(4) Poor control

(5) Pump does not destroke

(6) Pump does not unload

(7) Manifold shuttle valve locations

(8) Manifold shuttle valve removal/installation instructions

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Page 4

1. SYSTEM PRESSURE TOO LOW

For systems incorporating MUV inlet:

*

*

*

Open dampening orifice, clean/replace as necessary.

With dead-headed load, check relief valve setting, adjust as necessary.

Remove relief valve, inspect for damage. Replace external o-rings or replace relief valve as necessary.

* Remove MUV inlet spool, inspect, deburr, clean. Replace MUV inlet as necessary.

For all systems:

* Isolate area of low pressure to all functions or a single function.

If all functions are at low pressure, check hydraulic circuit for additional relief valve(s), check pump compensator setting. Adjust, replace as necessary.

If a single function, check manifold shuttle valve. (1)

(1) See section 7 & 8

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Page 5

2. LOAD DOES NOT MOVE OR MOVES AT LOW SPEEDS

FOR SYSTEMS WITH MUV INLET:

* Open dampening orifice, clean or replace as necessary.

* Readjust relief valve using a pressure gauge.

For all systems:

* Check input signal electrical or hydraulic pilot.

* Return line flow may be restricted, check for correct plumbing.

* Manifold shuttle valve sticking/leaking. (1) Clean, replace as necessary.

* Stroke controls preventing four-way spool shift. Adjust as necessary.

* output flow requirements exceed pump supply. Make appropriate system design modifications.

* Load sense bias pressure too low. Shim or adjust per pump manufacturers recommendations (typical load sense bias: 200 to 400 PSI).

* Pilot valve spool, four~way spool, or solenoids sticking: Swap with "good" section(s) to verify problem. Clean, deburr, replace as necessary_

(1) See Section 7 & 8

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Page 6

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NILhUL~ r LUiu t-U~Vt;H

Special Considerations:

Electric valves with auxiliary lever:

If four-way spool is sticking, check rack for bending. Replace as necessary. Check for proper engagement of the rack and pinion. Adjust as necessary (refer to Page 8). Inspect seals on pinion. If swelling or wear is present, replace pinion/seal assembly. Do not use other manual levers than those supplied with valve. Heavy levers will cause the spool to drag during electric actuation.

Electric valves:

When replacing solenoid assembly onto pilot valve, care must be taken to prevent excessive distortion of the flux tube: Torque four mounting screws to 30 inch-pounds using a sequence of torquing opposite screws (during mounting, end plate distortion and subsequent effective torque increase is acceptable. Effective torque should not exceed 45 inch-pounds).

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Page 7

3. LOAD MOVES ERRATICALLY AND/OR SYSTEM IS OSCILLATING

* Air in system: Bleed at as many points as possible.

* Electric valve pilot pressure collapse. Caused by light loads, negative loads, or holding valves with high pilot ratios.

Artificially increase light loads with springloaded check valve. Eliminate negative loads with counter-balance valves, brake valves, or pilot operated check valves.

Employ counter-balance valve, etc. with pilot ratios of 3:1 or 4:1. High pilot ratios will cause instantaneous pilot pressure collapse, system oscillation, and associated noise.

Note: If load pressure of 200 PSI cannot be assured, employ external pilot pressure supply.

* If demand flow exceeds pump flow, pressure compensation is lost. System design modification is recommended.

Cartridge compensator (CDM) may sustain damage due to starvation. If suspected, remove CDM and inspect for spool breakage (if spool is broken CDM cartridge will be in two pieces. The spool may remain in the manifold when the CDM's removed) .

* Severe load pressure fluctuations causing oscillation/noise. Isolate and eliminate cause(s} of pressure spikes. Dampen load sense signal to MUV or load sense pump as necessary.

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Page 8

4. POOR CONTROL:

Electric Valves

* Faulty input signal. Check controller specifications. 55 to 70 Hertz pulse width modulation (PWM) recommended for best proportional control.

* Faulty solenoid. Swap with "good" solenoid to verify. Replace as necessary.

* Open pilot chokes (optional). Clean as necessary.

* Adjust controller threshold and/or maximum output adjustment for best control from cracking to full flow.

* Controller ramp adjustment should be set for desired response.

Pilot Operated Valve:

* Check pilot supply pressure. Recommended range: 50 to 200 PSI.

Manual (and auxiliary lever) Valves:

* Check proper engagement of rack and pinion. If stiff, loosen lever cap, lightly tap lever cap up, retighten screws. If sloppy, loosen lever cap, lightly tap down, retighten.

* Check Note:

rack for bending. Rack is bent when large downward forces are applied to lever. If necessary, high pressure caps (option-G) with rack support should be specified.

Page 9

All Valves:

*

*

*

Manifold shuttle valve sticking/leaking. Clean, replace as necessary. (1)

CDM cartridge compensator damaged. Inspect, replace seals, replace CDM as necessary.

Incorrect four-way spool (spool rated for higher flow than required). Replace spool with one of correct maximum flow (be sure CDM flow rating and four-way flow rating match).


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Page 10

5. PUMP DOES NOT DESTROKE: (Load sense/pressure compensated pumps)

* Four-way not in neutral position (verified by seeing pressure at "Y" port or "L.S." port when four-way is "in neutral").

*

Check rack and four-way centering spring assembly. Both items are loc-tited and threaded into four-way spool. If they work loose, four-way spool may not find its true neutral position. If necessary, place spool in soft vise, loc-tite loose item and tighten onto spool.

Note: Four-way spool is not symmetrical. Small load sense groove must be located on "A" side.

Load sense signal does not drain to tank.

Do not use auxiliary shuttle if "zft port is plugged. Remove auxiliary shuttle if necessary. (1)

Manifold shuttle sticking. Clean, replace as necessary. (1)


Page 11

6 . PUMP DOES NOT UNLOAD, PUMP UNLOADS AT HIGH PRESSURE DROP:

(with all four-ways in neutral, fixed displacement pumps will unload across the MUV at approximately 150 PSI).

Fixed Displacement Pump does not Unload:

* MUV spool sticking. Clean, deburr as necessary.

* Load sense signal does not drain to tank - see pump does not destroke.

Fixed Displacement Pump Unloads at High PSI Drop

* Return line flow restricted, high return line pressure. Check for correct plumbing.

* Four-way spool not in neutral - see pump does not destroke.

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Page 12

7. MANIFOLD SHUTTLE VALVE LOCATIONS (drawing attached)

A. Two-function manifold

E. Three-function manifold

C. Four-function manifold

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All drawings show optional auxiliary shuttle valve location.

NICHOLS FLUID POWER

Page 13

8. MANIFOLD SHUTTLE VALVE INSTALLATION INSTRUCTIONS (refer to attached drawing)

To Remove Shuttle Valve from Manifold:

(1) Remove appropriate construction plug from manifold (see shuttle valve locations).

(2) Screw threaded rod (4/40 NC-2B) into shuttle valve (maximum thread depth is .25").

(3) Pull rod and shuttle valve out with pliers.

(4) If left in manifold, remove back-up ring.

To Install Shuttle Valve into Manifold:

(If possible, disconnect tank line from valve to prevent back flow during assembly).

(1) Remove appropriate construction plug.

(2) . Using pencil (eraser end) or similar instrument, insert back-up ring (#1) into bore, being sure back-up ring bottoms in bore.

(3) Same as step 2, insert o-ring (#2).

(4) Pre-assemble o-ring (#3) onto shuttle valve.

(5) Insert shuttle valve into bore.

(6) Apply firm pressure until the o-ring and back-up ring slip onto shuttle valve.

(7) Reinstall construction plug.

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MANNESMAN~ REXROTH Hydromatik Brueninghaus Hydrauli

R -'. 37195 Reparaturanieitung Verstellpumpe A10VSC Baureihe 30

Repair Instructions Variable Displacement PumpA10VSO Series 3.0

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A10VSO BaureiheiSeries 30

ROE 92711-02-R 04.88

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Reparaturanleitung A1QV SO Repair Instructions

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ROE 92711-02-R

Repara~uranleitung A10V/SO Repair lristructions

01 Wellendichtring fUr Antriebswelle.

Sealing ring of drive shaft.

02 Kompletter Oichtsatz (Oichtsitze sind typenbe-zogen festgelegt, Foto z.8. A.OVSO 28 OFR, ohne Steuerventildichtungen).

Complete seal kit (Sealing kits are based on the type of the pump, picture shows for example A10VSO 28 OFR, without pilot valve seals).

81 Steuervetil: Oruck- FOrderstromregler.

Pilot valve: pressure- flow control.

82 Verstellteile.

Control device.

83 AnschluOglatte mit Verstellteilen und Verteilerplatte.

Port plate and parts of control device and distributor Rlate.

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I Oichtsa. \ Seal ki

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~iebswelle abdichten . ~n9 the drive shaft

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Repara~uranle1~unq

Repa~r Instruc~~ons

Sicherungsring ganz einrasten.

A1QV/SQ

Assemble the retaining ring in the correct position.

7 PaBfeder einbauen.

Assemble the key.

Hvdroma1:ik 1

ROE 92711-02-R

Oemontage der Pumoe Oisassemoling of the pump

8 Hydromatik 8rueninohaus Hvdraulik

Reparaturanleitung A1QV/SQ Repair Instructions

11 Abbau des Steuerventils.

Disassemble pilot valve.

12 Markieren del" AnschluBplatte und Losen del" Befestigungsschrauben.

Mark pOSition of the port plate and remove socket screws of port plate.

13 Abheben del" AnschluBplatte mit allen Verstellteilen.

Remove port plate together with all parts of the control device.

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14 Abheben des Kegelrollenlagers und Abstimmschei· ,,'J ben" (anschluBplattenseitig).

Disassemble taper roller bearing and shims (nearby port plate).

15 Triebwerk herausziehen.

Disassemble the rotary group.

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~ontage der Pum~e sassemoling o~ the pump

Reoaraturanleitung A10V/SO Repair Instructions

10 O-Ring entfernen.

Remove the O-ring.

17 Lagerschalen herausheben.

Disassemble bearing shells.

18 Kugellager Ab- und Auszieher (handelsUblich) fUr Kegelrollenlager-AuBenring (antriebswellenseitig).

Use bearing puller to remove outer bearing race of front bearing.

19 Steuerplatte abheben.

Remove the control plate.

20 Kugellager Ab- und AU5zieher (handelsublich) des Kegelrollenlager-AuBenririges (anschluBplattenseitig).

Use bearing puller to remove outer bearin~ race of rear bearing.

Hydromatik 9 Qr-.,.~ ..... ""'t,,C; .... vt1,.'t., 1 i \(

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ROE 92711-02-R

Demontage der Pumpe Disassembling Of the jLump

21 Q-Ringe entfernen.

Remove the a-rings.

Reparaturanleitung A1QV/SO Repair Instructions

22 Demontage der Hutmutter rur Gewindestift.

Disassemble the head nut of threaded pin.

~~~iI~~t:.:~~~o"~~.:~r:: 23 Demontage des Gewindestiftes. "'~~~;4}:o .. ~!,. : 1 \

". _ ...• - Disassemble the threaded pin.

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24 Kolbenfuhrung V ausbauen.

Disassemble the guide of control piston.

25 Kolbenfuhrung des Gegenkolbens ausbauen.

Disassemble the guide of opposite piston.

10 Hydromatik

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mon~age der Pumpe sassemcling of the pump

ROE92n1~-R

Reparaturanle1tunq A1QV/SQ

Repa1r !nstruct10ns

2~ Antriebswelle aus der Rotationsgruppe herausziehen.

Pullout drive-shaft.--

;~~ 27 Kolben und RUckzugplatte entfernen.

., Remove the piston and retaining plate.

28 Ruckzugkugel ent~ernen.

Remove the retaining ball.

29 Vorspannung der Feder fur Ausbau des Sicherung~ ringes erhohen.

Compress the center spring in order to disassemble the retaining ring.

30 Sicherungsring ausbauen.

Disassemble the retaining ring.

Hydromatik 11

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AOE 92711-02-R

Oemon~age der Pumoe Oisassemoling of the ~ump

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H I N WEI S

NOTE

See picture 34.

12 Hydromatik 0 __ .. __ "'; __ "-_ •• _ u ........ __ .... ,.: t...

Reparaturanle1tung A1QV/SO Repair Instructions

31 Restliche,Einzelteile des Zylinders: Zylinderstifte, Zylinder, Scheibe, Feder, Scheibe.

Remaining-parts-9.f cylinder: pins, cylinder, shim, spring, shim.

32 Beim Zusammenbau der Pumpe in umgekehrter Reihenfolge ist auf die folgenden Punkte (33-43) zu achten.

Assemble the pump in reverse order and note thE following (33-43).'

33 Im GrauguBgehause werden die Kegelrollenlager mit einer Vorspannung von 0 ••• 0,05 abgestimmt.

Taper roller bearing in the cast iron pumphousing must have a initial tension with 0 ••• 0,05 mm.

34 Vorbereiten der AnschluBplatte (Orehrichtung rechts). Fuhrung fur Verstell- und Gegenkolbet mit Loctite einkleben.

Lagerichtiges Verdrillen in Orehrichtung 40

(Steuerplatte). Befetten der a-Ringe.

Port plate (direction of rotatio~ clockwise): Both piston guides are glued with Loctite.

- Correct position of distributor plate (clockwise 4 0

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- Grease O-rings prior assembly.

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montage der Pumpe sassemoling of the pump

See picture 36

ROE 92711-0'2-R

Reoaraturanleltung A10V/SO Repa1r Instructlons

30 Vorbereiten der AnschluBplatte (Orenrichtung links). FUhrung fUr Verstell- und Gegenkolben mit Loctite einkleben.

- Lagerichtige~ Verd~illen in Orehrichtung 4° (Steuerplatte).

- Sefetten der O-Ringe.

1. Lage des Gegenkolbens.

Port plate (direction of rotation anti-clockwise): Both piston guides are glued with Loctite.

- Correct position of distributor plate (anticlockwise 4 0

).

- Grease O-rings prior to assembly.

1. Position of the counter piston.

38 Vorspannen der Feder fUr Gegenkolben (Montagehilf.) •

40

Retain the spring tension with a bolt (only for f1 tting) •

Lagerichtiger Einbau der Schwenkwiege mit groeer Schmiertasche auf der Hochdruckseite, Schwenkwiege fUr Orehrichtung rechts oder Schwenkwiege fUr Orehrichtung links verwenden.

Correct position of cradle (lubrification bore relief on the high pressure side), use cradle for clockwise rotation, if counter clockwise use cradle for counter clockwise rotation (two different sub-assemblies).

Nacn dem Anziehen der AnschluBdeckelschrauben (lagerichtiges Anbauen. der AnschluBplatte, ent sprechend Markierung) entfernen der Montagehilfe.

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After fitting the port plate in the correct position (see mark), remove the spring re- ) taining bolt. .

Hvdromatik 13

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ROE 92711-02-R

Demontage der Pumoe Disassembling of the Qymp

14 Hydromatik

Reparaturanle~tung A10V/SO Repair Instructions

41 Montage des VerschluBstopfens.

Install the plug.

42 U.U. Nacharbeit der Schwenkwiege im Laufbereich durch Lappen meglich, jedoch Auspressen der Anschlage (Kugelzapfen und Gleitschuh) nicht zulassig. (Riefenbildung beim Wiedereinbau.)

If it is possible to lap the cradle (ru'nning . " area of the piston shoes) it can be possible J to use the cradle again. Notice: It is no allowed to press out the piston connection parts of the cradle (~~oringS while fittinq!).

43 Kontaktstelle Steuerplatte/Zylinder durch Nachlappen qqf. wiederverwenden (Anqabe qilt nicht fur GuA-Zylinder).

Connection between control plate and cylinder: .~

,if lappinq is possible use it aqain, but it is not allowed if you use cast iron cylinders.

44 Uberprufung der Laufeigenschaft des Verstell- :J kolbens. ~

Check running condition of control piston.

45 Uberprufung.der Laufeigenschaft des Gegenkolbens.

Check running condition of opposite piston. L

Regler-5chnittbilder ',1 pilot valves (Sections)

Stopfen ., plug,

.astungSduse montiert :"ice

1erausfUhrung cial design

ROE 92111-m-R

Reparaturanleitung A10V/SO Repai~ Instructions

Hydromatik ____ ..: __ r._

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ROE 92711-02-R

Ze~legen und Reinigen des O~uCk- und Fo~de~st~omreg1ers Oisassemo1ing and c1~ing the pressure- and f10wcont~ol

Reparaturanleitu~g A10V/SO Repair Instructions

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16 Hydromatik 8rul!ninnnau!; Hvrl .. ,. .. lilr

Losen de~ Befestigungssch~auben.(siehe S. 15).

Loosen socket screws.(see page 1~).

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47 Ent~ernen der O-Ringe •

Remove the O-rings.

48 Entfernen der Hutmuttern. Die folgenden Arbeiten werden erst beim Druckregler, dann be-im

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FOrderstromregler durchgefUhrt. ,-

Remove the hexagon nuts. First disassemble pressure control, afterwards flow control.

Kontermutter losen und Gewindestift herausdrehen.

Loosen the lock nut and unscrew threaded pin.

50 VerschluBschraube demontieren.

Disassemble the plug.

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erlegen und Reinigen des Oruck- und Forders~romre91ers Repara~uranlei~ung A10V/SO ;sassemoling and cleaning the pressure- and flow- Repa1r Ins~ruc~ions

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51 Herausnehmen der Scheibe.

Remove ~he disc.

52 Herausnehmen der Feder (bei Forderstromregler 2 StUck).

Remove the spring (two of them are in the flowcontrol).

53 Herausnehmen des Federtellers.

Remove the spring cup.

1!54 VerschluBschraube entfernen.

Disassemble the plug.

55 Sorgfaltiger Ausbau des Kolbens.

8e careful while disassembling the piston.

Hvdromatik 17

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Roe 92711-02~

Zerlegen und Reinigen des Qruck- und Fijrderstromreglers Disassembling and cleaning the pressure- and Flowcontrol

Reoaraturanleitung A10V/SO Repair Instructions

HINWEIS

NOTE

18 Hvdroma:tik

56 Oemontage der Pulsationsblende (im OruckreglerFederraum) •

Disassem~l~ the ~rifice (spring area of pressure control).

57 Demontage des Stopfens bzw. der Entlastungsduse (1m Forderstromregler-Federraum).

Disassemble the plug or orifice (spring area of flow control). .

Auswaachen des Steuerventilgehauses und Einzelteile mit grundlichem Beseitigen des Waschmittels d~rch Ausblasen.

Clean housing and parts with clean fluid and dry with air carefully.

59 Zusammenbau des Steuerventils in umgekehrter Reihenfolge. Oabei ist auf folgende Punkte zu achten (60-63).

Assemble pilot valve in reverse order and note the following (60-63).

60 Kontrolle der OUsendurchlassigkeit.

Check the opening of orifice.

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ROE 92711-02·;,1

~rlegen und Reinigen des Oruck- und Forders~romreglers ;assemaling and cleaning the pressure- und flow-

Reparaturanle1tung A10V/SO Repa1r Instruc~10ns

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61 Einkleben der nUsen (auf ver5~opfte OUsen 1st beim Klebevorgang zu aChten).

Be careful when loctning the orif.ice.

62 Laufeigenschaft der Reglerkolben prUfen, keine Beschadigungen der Kolben und der Bohrungen.

CheCk the movement of the pilot valve spool, and drillings should not be damaged.

e3 Einstellen des Steuerventils siehe Einstellhinweise (s.S. 21).

For adjustment of the pilot valve see set up instructions (page 21 ) •

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ROE !32711-Q2-R

Tabelle List

Reparaturanleitung A10V/SO Repair Instructions

T A 8 ELL E

.J,.1ST

"mechanische Forderstrombegrenzung"

mechanical flow limiter

NG I Size 28

Volumenanderung (in ~, 1,~8 pro Gewindestiftumdrehung

Oi fferntial vol~me (em') if you are rotating the. threaded pin - each rotation.

MONTAGE-ABSTIMMUNG (Kegelrollenlager)

45

3,23

A10V SO 8R 30 u. A10VQ 8R 21 mit GuB-Pumpengehause

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71 100

0-0.05

Abstimmung der Triebwerkslagerung (Kegelrollenlaqer-Pumpengehiuse GG-30).

Die Vorspannung der Triebwerkslagerung von Obis 0,05 mm durch Abschleifen der Abstimmscheibe Pos. 12 hergestellt.

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Cast iron pumphousing must have initial tension of the bearings: 0 ••• 0,05 mm.

20 Hydroma1:ik

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ellhinweise ng and se~ up-ins~ruc~ions

ROE 92T1'~2-A

Repara~uranleitung A10V/SO Repa1r Instructions

OR: bei geschlossener Verbraucherleitung wird der Regler auf Sollwert einges~ellt (bei OFR einstellb. Orossel offen, FR-Feder vorgespannt)

OR: When pressure line is closed adjust the pressure of the controller (if it's OFR design then open th adjustable orifice and increase force of the spring - FR -).

FR: Oifferenzdruck 14 bar wird eingestellt bei halbem Schwenkwinkel der Pumpe (eins~ellbare

Orossel teilweise geschlossen).

FR: If swivel angle is in the mid position adjust differential pressure 14 bar (adjustable orifice is par~ly closed).

Mechanische Forderstrombegrenzung: Ourch Dreher .. Gewindestift kann der Forderstrom der Pumpe bis ~OX von Vg max reduziert werden. Einstellwerte siehe Tabelle Seite 20.

Mechanical flow limiter: While screwing in the threaded pin you will be able to reduce the flow from Vg max to SOX of Vg max. Set up instructions see "lists" on page 20 •

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ROE 92711-02-R

werkzeuge/Hilfswerkzeuge/Anziehdrenmomente Tools/auxiliary toolS/tightening-torques

ReQaraturanleitung A10V/SO ReQair Instructions

BRUENINGHAUS HYDRAUUK GmbH An den Ketterwiesen 14 0-7240 Horb 1 Postansduitt: Postfach 1440. 0-7240 Horb 1 Telefon (07451) 920 Telex 765321 Telefax (07451) 82 21

Verwendete Loctite-Sorten / take Loctite:

alIa AbR!iBstcpfen/ puiI-off pfugs sonstJ normaty

An%iehdrehmomenta lightening torques .

Festigkeitskfassen • • Stab. -dassificatiorl 8.8, 10.9, 12.9

Nt.S01 Nr.242

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ROL-SEAL® MOTOR ROLLING ABUTMENT TYPE

WASHINGTON SCIENTIFIC INDUSTRIES, INC. MODELS RSA,

POWER COMPONENTS DIVISION RSB 2605 West Wayzata Blvd. PO Box 340

Long Lake, Minnesota 55356 Telephone: (612) 473·1271 TWX: 910·576·2742

AND RSC

MAINTENANCE AND PARTS MANUAL

NOTE

ONLY FACTORY OR QUALIFIED DISTRIBUTORS ARE AUTHORIZED TO OVERHAUL AND REPAIR WSI EQUIPMENT. ALL FACTORY WARRANTY IS CANCELLED UPON DISASSEMBLY BY UNAUTHORIZED PERSONNEL.

FORM 201FM

ROL-SEAL MOTOR MODELS RSA, RSB AND RSC

TABLE OF CONTENTS

TITLE PAGE

INTRODUCTION ............. _ ............ - ............. " ..

HOW TO AVOID REPAIRS ............... _ ................... 1

TOOLS FOR DISASSEMBLY .................................. 1

DISASSEMBLY ........................................... 2

REASSEMBLY ............................................ 5 ) SEAL REPLACEMENT ...................................... 6

TROUBLE SHOOTING ...................................... 7

ROL-SEAL MOTOR EXPLODEq VIEW .......................... 8

REPLACEMENT PARTS LIST ................................. 9

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INSTRUCTION MANUAL

INTRODUCTION

The ROL-SEAL ® Motor was designed to give both high volumetric and high torque efficiencies. I t is manufactured with good quality workmanship and a design concept that allows it to be mass produced. Because of its low breakaway and low leakage characteristics it is understandable. why this motor is desired in this energy conservation time.

HOW TO AVOID REPAIRS

Maintain cleanliness in your system. Be careful when adding to the reservoir that clean oil is added and the container being used is clean. Proper filtration does not guarantee a contaminate-free system if the filters aren't serviced at regular intervals. Make sure that pro·per care is taken when installing the motor. If a flexible coupling is used, alignment must be within the coupling range. Do not exceed radial or t~rust load ratings of the shaft.

For hydraulic surge pressures applied to or by the motor, a close-coupled direct·acting relief valve must be provided in the circuit. The motor must be protected from any pressure surges that exceed twice the pressure rating of the motor.

DISASSEMBL Y

Cleanliness is extremely important when repalrmg the ROL·SEAL Motor. Before you remove the motor from the system, clean as much debris off of the exterior as possible. The area around the ports is most important. Upon disconnecting use something to plug the ends of the hydraulic lines to prevent contamination of the system.

Remove the key. Carefully remove all burrs from the shaft. Make sure there are no sharp corners around the keyway, to prevent the shaft seal from being cut upon removal of the end cap. If there is any rust present, remove using 180 grit emery cloth.

The tools that are recommended for a successful repair job are as follows:

"A" AND "B" FRAME MOTORS

1. Soft face hammer or mallet.

2. Torque wrench with at least 50 ft. Ibs. capacity.

3. 5/15" Allen wrench adaptable to torque wrench.

4. No. 03 internal snap ring pliers.

5. 3/ 15" Allen wrench for gear cover.

"c" FRAME MOTOR

1. Soft face hammer or mallet.

2. Torque wrench with at least 175 ft. lb. capacity.

3. 1/2" Allen wrench adaptable to torque wrench.

4. No. 06 external snap ring pliers.

5. No. 05 internal snap ring pliers.

6. 3/15" Allen wrench for gear cover.

A bench vise is very helpful in the disassembly and assembly of the ROL·SEAL Motor. Our instructions will be based on the assumption that this item is available.

PAGE 1


DISASSEMBL Y

FIGURE 1

1.) Place motor in vise as shown in Fig. 1, tightening vise enough to prevent motor from rocking out. Excessive clamping pressure could damage the inlet and outlet ports. Normally the standard jaws will not contact spotface of ports.

2.) Unfasten the nine cap screws holding the end caps and housing together. (Fig. 1.) Remove the cap screws completely "from the assembly.

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FIGURE 2

3.) Using the soft-faced hammer or mallet, tap upward on the ear of the SAE mounting flange. (Fig. 2.) By putting the heel of your hand over the output shaft and your fingers on the opposite ear you can keep the front end cap from falling back down after each successive rap.

When you get beyond the dowel pin engagement there should be no further requirement for the hammer. Simply lift the end cap off of the assembly.

FIGURE 3

4.) Removal of the displacement housing, (Fig. 3) the dark center portion of the assembly, is carried out similar to step 3_ There are two scallops in the rear end cap. I t is this area that you tap to remove the housing_ (Fig. 3.) Do not ever use any screwdriver or pinch bar to remove this part. It is extremely easy to damage the end cap faces. The dowel pins will remain in the displacement housing. Unless you are replacing the housing, leave them intact. The dowels are a press fit.

NOTE

The remaining steps can be performed on a bench.

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DISASSEMBL Y

FIGURE 4

5.) Remove seal plates (Fig. 4).

FIGURE 5

6.) Remove seal rollers (Fig. 5). The motors have two sizes. The seal rollers in the rotor tip are about 1/32nd dia. larger than those behind the seal plates.

7.) Unfasten the seven socket head cap screws which hold the Model Code and Serial No. plate on the rear end cap.

FIGURE 6

8.) The previous step exposed a set of tl mlng gears. Before removing these parts you must mark them (Fig. 6). The two small gears should also be marked left and right.

FIGURE 7

g.) Remove the snap rings that retain the gears, (Fig. 7) and remove the gears.

PAGE 3

ROL·SEAL MOTOR MODELS RSA, RSB AND RSC

DISASSEMBL Y

FIGURE 8

10.) By positioning the rotor as in Figure 8, you can lift one of the abutment valves out. Rotate the shaft and remaining abutment until the paddle of the rotor leaves the abutment cavity. You now can remove this abutment.

FIGURE 9

11.) Lift the rotor up, which will expose the drive key. Remove the drive key. (Fig. 9.)

PAGE 4

FIGURE 10

12.) Remove the snap ring which retains the shaft and thrust bearing. (Fig. 10.)

F1GURE 11

13.) Remove the shaft from the rear end cap. (Fig. 11.)

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ROl-SEAL MOTOR MODELS RSA, RSS AND RSC

DISASSEMBL Y

FIGURE 12

14.) The step bearing that remains in the front end cap should be taken out and inspected. There is an O-ring and Teflon back-up ring under this part. (Fig. 12.)

15.) Check all mating metal-to-metal parts for scratches or burrs which could cause leakage. Replace all parts on which excessive damage is found. Use the following procedure to be sure that all these surfaces are perfectly smooth:

Place a piece of 240 grit paper on a flat, smooth surface.

Place the part on the grit paper and stroke gently in a figure eight motion several times. Excessive removal of material should not be done as the. parts may not reassemble with proper clearances.

16.) Clean all parts in solvent and let them air-dry. All O-rings and shaft seals should be replaced. If conditions are such that you have to use the old seals they should be washed 'in a mild soap and water solution.

REASSEMBLY

1.) Install shaft with thrust bearing and races through the back of the rear end cap.

2.) I nstall snap ring to retain shaft.

3,) Put spacer over shaft end, and assemble the large ti ming gear to the shaft.

4.) Assemble snap ring to retain gear.

5.) Turning this subassembly and setting it on the rear cover face, you can install one abutment valve. Install new back-up ring and O-ring first. A light film of oil should be applied to all new seals.

6.) Reassemble the round drive key in the key seat and slip rotor over key.

7.) Set the subassembly on its side and proceed with the alignment and ti ming of the abutment and rotor. Either one of the abutments can be assembled.

8.) Rotate the shaft so the second abutment can be installed. Align the timing marks. If the shaft can be rotated one complete revolution, it is likely that the proper assembly has been carried out. NOTE: When properly timed, the rotor tip will pass directly through the center of the abutment cavity.

9.) Proceed to assemble the snap rings to retain the gears assembled in the previous step.

10.) Set the assembly back on the rear cover face. Install the seal plates and the seal pins in the rotor.

11.) Place the new O-ring in the groove of the end cap. A light film of gun grease will help keep the O-ring from slipping out of the groove.

12.) Install the housing. If binding occurs take a soft faced hammer and tap on the housing to free it.

13.) Install new O-rings and back-up rings in the front end cap. Put the step bearings in place. Apply a light film of gun grease to the large static seal, and place it in the groove.

14.) Install the front end cap by slipping it over the shaft and watChing the statiC seal to make sure it stays in place. Tapping lightly with a soft face hammer may be required to seat the front end cap.

15.) Set the body cap screws in place and tighten to recommended torque values using a crisscross pattern. Torque settings are for lubricated threads. (see chart on following page)

PAGE 5


REASSEMBLY

FRAME SIZE DISPLACEMENT

"A" and "8" 2

"A" and "8" 3

"A" and "8" 4

"C" 6

"C" 8

"cft 10

SERIAL COVER ALL PLATE

TORQUE

500 in # (56 N-M)

500 in # (56 N-M)

500 in # (56 N-M)

150 ft # (203 N-M)

150 ft # (203 N-M)

175 ft # (237 N·M)

125 in # (14 N-M)

16.) Assemble Model Code and Serial No. plate to back of the motor along with new static seal.

17.) 8efore installing new shaft seal, make sure that shaft turns. Then proceed to install new seal and replace snap ring. NOTE: Remove any burrs or raised edges from shaft keyway as not to damage seal lip.

18.) Replace motor in the system and run unit through normal operating cycle.

SEAL REPLACEMENT

1.) Clamp the motor in a vise. Remove the key and all

burrs or sharp edges which may have developed. Use 400 grit emery cloth to remove all rust from the shaft.

2.) Remove the snap ring.

3.) Remove front end cap as in steps '-3 of the disassem· bly procedure.

4.) Turn end cap with sealing face up. Use a large screwdriver blade inserted between the seal lip and shell. Proceed to pound out seal alternating from side to side so as not to damage the end cap bore.

5.) Replace end cap and torque body bolts to recommended torque, (see chart above.)

PAGE 6

6.) Apply a thin film of grease to the lip of the new seal. Slide over shaft to face of end cap.

7.) The seal must be installed without cocking it. The best procedure is to obtain a short piece of tubing or pipe which is square on the ends and will contact the outer shell of the seal. If the tubing is too small it will damage the seal.

8.) Press seal in just far enough so the snap ring will stay in the seat bore. Using the snap ring to seat the seal will prevent you from pressing the seal in too deep. When the snap ring pops into the groove the seal is properly seated.

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TROUBLE SHOOTING The following chart lists the possible troubles that may be encountered, the probable cause and the remedial action recommended.

TROUBLE-SHOOTING CHART

Trouble Probable Cause

No pressure 1.) Loose coupling.

2.) System relief open.

Noisy system 1.) Cavitation at pump.

. 2.) Reservoir low.

Motor wi II not 1.) System relief unloading. develop torque.

2_) Worn out.

3.) High temperature operation.

Blown rear cover 1.) Drain restriction.

2.) High case drain.

Leakage around shaft. 1.) Shaft seal worn out.

Motor turns in wrong 1.) Hose connection wrong. direction.

Remedy

1.) Repair or replace coupling.

2.) Clean, adjust, or replace if necessary.

1.) Check for inlet air leaks. Check pump inlet for restriction.

2.) Fill to recommended level.

1.) Disassemble, clean, adjust.

2.) Repair or replace.

3,) Change to fluid with higher viscosity index.

1.) Drain directly to tank.

. 2.) Repair motor .

1.) Replace.

1.) Reverse connections.

PAGE 7

ROL·SEAL MOTOR

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PAGE 8

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MODELS RSA, RSB AND RSC

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FIGURE 13. ROL-SEAL MOTOR EXPLODED VIEW

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ROL-SEAL MOTa R MODELS RSA, RSB AND RSC

PARTS LIST

REPLACEMENT PARTS LIST - ROL-SEAL@ MOTOR

NOTE

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When Ordering Replacement Parts, Give Model Number, Serial Number, Item Number, Description and Quantity.

Item Description Quantity

1 Key, Woodruff 3 2 Pin, Drive 1 3 Ring, Retaining 2

4 Gear, Drive 5 Spacer 6 Ring, Retaining

7 Race, Bearing Thrus~ 2 8 Bearing, Thrust 1 9 Bearing, Roller 2

10 Seal, O-Ring 3 11 Cap, Rear 1 12 Pin, Rotor Tip 3 12A Pin, Seal Plate 18 13 Rotor 1 14 Plate, Seal 3 15 Valve, Rotary Abutment 2

16 Beari ng, Needle 4 17 Bearing, Step 4 18 Seal, a-Ring 4

19 Ring, Teflon Backup 4 20 Pin, Dowel 2 21 Screw, Cap 9

23 Seal, Shaft 24 Cap, Front

25 Housing, Displacement 26 Ring, Retaining 4 27 Gear, Timing 2

28 Shaft, Power 29 Cover, Gear 30 ·Screw, Cap 7 31 Ring, Retaining 32 O-Ring, Front Cap Seal

PAGE 9

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PAGE 10 PRINTED IN U.S.A. FORM 201FM

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ROL·SEAL® BRAKE

REAR-MOUNTED, MULTI-DISC TYPE FOR RSA AND

RSC MOTORS WASHINGTON SCIENTIFIC INDUSTRIES, INC.

10/84

POWER COMPONENTS DIVISION

Long Lake, Minnesota 55356

Telephone: (612) 473·1271 TWX: 910·576·2742

MAINTENANCE AND PARTS MANUAL

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NOTE

ONLY FACTORY OR QUALIFIED DISTRIBUTORS ARE AUTHORIZED TO OVERHAUL AND REPAIR WSI EQUIPMENT. ALL FACTORY WARRANTY IS CANCELLED UPON DISASSEMBLY BY UNAUTHORIZED PERSONNEL.

FORM 304FP

304 FP 10/84 ROL·SEAL!> BRAKE

TABLE OF CONTENTS

PAGE

TITLE ...................................................... 1

INTRODUCTION ............................................. 1

HOW TO AVOID REPAIRS ..................................... 1

REAR MOUNTED BRAKE ASSEMBLY ........................... 2

TOOLS REQUiRED ........................................... 2

DISASSEMBLY .............................................. 2

REASSEMBLy .............................................. 3

PARTS LiST ........................ , ................ " ...... 4

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304 FP 10/84 ROL·SEAL~ BRAKE

INSTRUCTION MANUAL

INTRODUCTION

This Wet Disc Type Brake was designed to fit on the W.S.1. Rol-Seal®Motor to provide either dynamic braking, or as a mechanical means of locking the motor shaft to prevent motor drift due to overhanging loads. The number of disc brake sets provide for a higher static torque loading than the dynamic torque rating of the hydraulic motor.

HOW TO AVOID REPAIRS

Maintain cleanliness in your hydraulic system. Be careful when adding to the reservoir that clean oil is added and the container being used is clean. Proper filtration does not guarantee a contaminate-free system if the filters aren't serviced at regular intervals. Caution should be used when connecting the brake release pressure port to the brake housing inasmuch as the drain port is adjacent to the pressure port.

CASE DRAIN

These units are provided with a case drain connection. A line must be provided to return case drain flow to the reservoir at no more than 250 PSI surge pressure. Cross port check valves are optional for internal drain but should not be used where instantaneous shock pressures occur, such as in dynamic braking.

OTHER BRAKE SPECIFICATIONS

WK2 of brake ....................... 2.6 lb. in. 2

Volume of oil to release brake ........... 0.6 in.3 Torque holding

capacity ... " 2 in.3 3 in.3 4 in.3

940 lb. in. 1410 lb. in. 1880 lb. in.

PAGE 1

304 FP 10184 ROL·SEAL~ BRAKE

Pressure Port lip"

~--Return to Tank Port "T"

2 8

1

11 12 13

. FIGURE 1. SECTIONAL VIEW, ROL·SEAL® BRAKE

REAR MOUNTED BRAKE ASSEMBLY.

TOOLS REQUIRED: % allen wrench

NOTE: If it is necessary to remove adapter plate (8), a ~'6 allen wrench and centering fixture (avail· able from factory) will be required.

DISASSEMBLY (Figure 1)

1. Thoroughly clean the exterior of the assembly and hydraulic lines before attempting removal.

2. Disconnect hydraulic lines and cap them to prevent loss and contamination of fluid.

3: Remove the eight cap screws (13), and separate t~e brake housing (1) from the adapter plate (8). Discard a-ring (5).

PAGE 2

4. Remove remaining brake components.

(To remove brake piston (10), it', may be necessary to inject shop air (80 PSI max.) into pressure port "P". PLEASE NOTE: If air is used, precautions must be taken to retain piston so as to eliminate the possibility of injury!)

5. Remove the back-up rings (11" 15), and a-rings (12, 14) from the housing (1).

6. If it's necessary to remove the adapter plate (8) from·the motor, remove the seven cap screws (7).

7. Clean all components in solvent and dry.

8. Inspect all components for wear and damage. Replace compGnents unfit for service. Note quantities of friction discs (3) and drive plates (4) in parts lists on following pages.

Condor Lift Model 68

Documents

excessive

epoxy gray

high pulling

aerial work

master leveling

products previously

steering knuckle

lower control