3160 #92277

Transcription

3160 #92277

AERIAL WORK PLATFORM
MODEL 3160
(includes Models 2032,3146, and 3154)
OPERATOR'S, MAINTENANCE,
ILLUSTRATED PARTS, AND VENDOR
MANUAL
SHIPPING ADDRESS
CALAVAR CORPORATION
8300 IMPERIAL DRIVE
VVACO, TEXAS 76712
(817) 666-4545
MAILING ADDRESS
CALAVAR CORPORATION
P.O. Box 21447
VVACO, TEXAS 76702-1447
(817) 666-4545
MANUAL922n
SEPTEMBER 1993
MODEL 3160
(includes Models 2032, 3146, and 3154)
OPERATOR'S MANUAL
MAILING ADDRESS
SHIPPING ADDRESS
CALAVAR CORPORATION
P.O. Box 21447
VVACO, TExAs 76702-1447
(817) 666-4545
CALAVAR CORPORATION
8300 IMPERIAL DRIVE
VVAco,TExAs76712
(817) 666-4545
MANUAL 922n-001
SEPTEMBER 1993
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. F!imiliarize yourself with
the functions and operations of the upper and lower controls. A good understanding of the controls, their limitations, and their ~apabilities will maximize
operating efficiency. The various decals attached to this CONDOR® also
contain vital operational instructions. Read the decals before operating this
CONDOR®.
It is YOUR RESPONSIBILITY to follow procedures while operating the CONDOR®. The
manufacturer of this CONDOR® cannot control the wide range of applications that may be used
in carrying out a variety of jobs. Therefore, it is THE USER'S RESPONSIBILITY to consider all
personnel when making decisions regarding the CONDOR®'s intended use.
It is also YOUR RESPONSIBILITY to understand and obey all federal, state, and local regulations
regarding the operation and use of aerial work platforms. A copy of the ANSI/SIA Manual of
Responsibilities is attached for your use: ANSI/SIA A92.5-1992 is provided for BoomSupported Elevating Work Platforms, and ANSI/SIA A92.6-1990 is provided for Self-Propelled
Elevating Work Platforms.
Calavar Corporation 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 CALA VAR CORPORA TION
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 Calavar Corporation
in order to ensure the original integrity of the product. Repairs and adjustments should only
be made by trained and qualified personnel. Please refer to the maintenance and parts sections
of the Calavar Operation, Maintenance, & Parts Manual for information on service and
maintenance of the CONDOR®.
NOTE:
Please refer to the Calavar Parts section of the Operation, Maintenance, & Parts
Manual for information pertaining to your CONDOR®.
MANUAL 92277-0111
SEPTEMBER 1993
TABLE OF CONTENTS
INTRODUCTION .......••••...........•..........•••.....•....•..••......•..........•...........•............•........... i
TABLE OF CONTENTS ...............................•............................................................... ii
I. PREPARATION, INSPECTION, AND MAINTENANCE •.•...........•......•........................... 1
A.
B.
C.
D.
E.
OVERALL CONDITION.................................................................. •............•
LOWER CONTROL STATION .........•.•...•.•••........••...•..........••....•...................•
PLATFORM & UPPER CONTROL STATION ....................•...•.•..................••.•..
HYDRAULIC SYSTEM •..•...........•..•.•.........................•.................................
BATTERIES & CHARGER .•••...................................................•.............••.....
1
1
1
2
2
II. MACHINE OPERATION ...•..•...........•........•............•..........•..................................... 2
A. RATED WORK LOAD .•....•.....................••.•••..........•.....•.................•............ 2
B. LOWER CONTROLS •..•.........•.••..•••......•.......••............•....•..........••.......•....... 2
C. PLATFORM CONTROLS ....•......•...•............•....•.................................•..•..•... 3
III. OPTIONAL EaUIPMENT .•........•.•.•............•....••.•...•....••.•........................•....•.....•..•• 3
IV. EMERGENCY LOWERING ..•............•...........•...••..............................•.•.................... 4
V. MOVING FROM JOB SITE TO JOB SITE ....................................•............................. 4
A.
B.
C.
D.
LOADING AND UNLOADING ...........•...............•....•......•...............................
RAMP METHOD ..............•.••.••.•.....•....•••..................•................•.•..............
FORKLIFT LOADING/UNLOADING METHOD ....•............................................
TRANSPORTING ......................•.................•..•...•........................................
4
4
4
5
VI. FREEWHEEL OPERATION ....•....•.•..•.................•.............................................•....... 5
APPENDIX: ANSI/SIA 92.6 - 1992 MANUAL OF RESPONSIBILITIES
ii
MANUAL 922n-001
SEPTEMBER 1993
IMPORTANT: A COpy OF THE ANSI/SIA 92.6 - 1990 MANUAL OF RESPONSIBILITIES IS
ATTACHED TO THIS OPERATOR'S MANUAL. IT CONTAINS IMPORTANT OPERATING
INFORMATION FOR THIS 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 WALKAROUND 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 KEY SWITCH AND ANY
DISCREPANCIES SHOULD BE CORRECTED
BEFORE OPERATING THE CONDOR®.
KNOW THE UNIT AND ITS CAPABILITIES.
REPORT ANY UNUSUAL OPERATION, SUCH
AS ERRATIC SWAY OR MOTION OF THE
ARMS OR PLATFORM.
CAUTION: DEFECTIVE COMPONENTS,
STRUCTURAL DAMAGE, MISSING PARTS,
AND EQUIPMENT MALFUNCTION JEOPARDIZE THE SAFETY OFTHE 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. LOWER CONTROL STATION
CHECK ELECTRICAL WIRES AND CABLES
FOR LOOSE, BROKEN, OR FRAYED WIRES.
ALL FUNCTIONS OPERATE PROPERLY,
CONTROL RETURNS FREELYTO NEUTRAL,
CENTER POSITION. DO NOT OPERATE THE
UNIT WITH STICKING CONTROLS.
C. PLATFORM AND UPPER
CONTROL STATION
CHECK ELECTRICAL WIRES AND CABLES
FOR LOOSE, BROKEN, OR FRAYED WIRES.
A. OVERALL MACHINE CONDITION.
TIRES AND WHEELS: CHECK FOR CRACKS,
TEARS, CUTS, OR MISSING OR LOOSE LUG
NUTS (A RUST LINE RUNNING DOWN THE
RIM FROM THE LUG NUT INDICATES A
LOOSE LUG Nun.
MISSING, BROKEN, OR DAMAGED PARTS:
CHECK CYLINDER MOUNTING PINS, PIVOT
PINS, PIN RETAINERS, BOLTS, AND NUTS.
STRUCTURAL: CHECK FOR DAMAGED OR
CRACKED WELDS ON STRUCTURAL COMPONENTS-ARMS, PLATFORM, CHASSIS.
STEERING: CHECK TIE ROD ENDS AND
STEERING CYLINDER FOR PROPER AND
SECURE MOUNTING.
DECALS:ALLDECALSANDWARNINGSIGNS
ARE IN PLACE AND ARE CLEARLY LEGIBLE.
ENTRY POINT BARS AND CHAINS ARE FUNCTIONAL AND SECURE, FOOTSWITCH OPERATES PROPERLY, GUARD IS IN PLACE.
RE-CHECK THE STRUCTURAL CONDITION
OF THE PLATFORM-PINS, RAILINGS,
FLOOR.
CHECK RED BUTTON: DISCONNECTS
POWER TO THE CONTROLS AND STOPS
THE OPERATION OF ALL FUNCTIONS.
CHECK THAT ALL CONTROL LEVERS RETURN FREELY TO THEIR NEUTRAL POSITIONS.
CHECK AUXILIARY LOWERING VALVES ON
ARM LIFT CYLINDERS.
1
MANUAL 92277·001
SEPTEMBER 1993
D. HYDRAULIC SYSTEM
B.
CHECK THE HYDRAULIC TANK FLUID LEVEL
WITHTHEARMS LOWERED. MAINTAIN FULL
FLUID LEVEL-DEPENDING ON THE UNIT,
THIS WILL BE TO THE MARK ON THE SIGHT
GLASS, TO THE MARK ON THE DIPSTICK,
OR TO WITHIN ONE INCH FROM THETOPOF
THE TANK. ADD SHELL TELLUS T32 HYDRAULIC OIL TO THE SYSTEM. ENSURE
THE BREATHER CAP IS CLEAN AND INPLACE
ON THE TANK.
MODEL 2032
CHECK FOR HYDRAULIC LEAKS AT FITTINGS, VALVES, AND CONTROLS.
CHECK ALL HYDRAULIC HOSES AND TUBES
FOR DAMAGE, KINKS, AND PROPER ROUTING TO AVOID PINCH POINTS.
E. BATTERIES & CHARGER
LOWER CONTROLS
AT THE LOWER CONTROL STATION THERE
ISASELECTOR SWITCH, A TOGGLE SWITCH,
AND CONTROL LEVER.
TO OPERATE THE LOWER CONTROLS,
TURN THE SELECTOR SWITCH TO THE
LOWER POSITION.
TO RAISE THE PLATFORM, PUSH THE
TOGGLE SWITCH TO THE UP POSITION.
THEN MOVE THE CONTROL LEVER IN THE
UP POSITION.
TO LOWER THE PLATFORM, PUSH THE
TOGGLE SWITCH TO THE DOWN POSITION.
THEN MOVE THE CONTROL LEVER IN THE
DOWN DIRECTION.
CHECK BATTERY ELECTROLYTE LEVEL
AND ENSURE THAT ALL CAPS ARE PRESENT
AND TIGHT ON THE BATTERIES. ALL BATTERY CABLE CONNECTIONS SHOULD BE
TIGHT AND CLEAN.
MODEL 3160
MAKE SURE THE BATTERY CHARGER IS IN
GOOD CONDITION AND THE ELECTRICAL
PLUG AND METER ARE NOT DAMAGED.
THE MAIN KEY SWITCH IS ALSO LOCATED
AT THE LOWER CONTROL STATION. WITH
THE KEY IN THE CENTER (STRAIGHT UP)
POSITION, THE UNIT IS OFF AND POWER IS
DISCONNECTED. WITH THE KEY IN THE
FAR RIGHT POSITION, THE CONTROL CIRCUIT IS ENERGIZED FOR OPERATION.
II. MACHINE OPERATION
A. RATED WORK LOAD
THESE PLATFORMS WILLSUPPORT A COMBINED WEIGHT EQUAL TO THE UNIT'S
RATED WORK LOAD-INCLUDING PERSONNEL, TOOLS, AND EQUIPMENT-THROUGHOUT THE WORKING ENVELOPE OFTHE MACHINE.
ATTHE LOWER CONTROL STATION, THERE
IS A "PUMP" SWITCH, A "PUSH TO LOWER"
SWITCH, AND CONTROL LEVER.
MODELS 3146 AND 3154
AT THE LOWER CONTROL STATION THERE
IS AN OPERATOR'S SELECTOR SWITCH
WHICH SHIFTS THE OPERATIONAL CONTROLS BETWEEN "PLATFORM" AND
"GROUND" MODES. NEXT TO THIS SWITCH
IS A TOGGLE SWITCH LABELED "UP" AND
"DOWN". FOR OPERATION OF LOWER CONTROLS, THE OPERATOR SWITCH SHOULD
BE SWITCHED TO GROUND. THE TOGGLE
SWITCH MAY BE HELD EITHER IN THE UP
OR DOWN POSITION WHILE HOLDING CONTROL LEVER IN POSITION DESIRED.
MANUAL 92277-001
SEPTEMBER 1993
2
TO OPERATE THE UNIT FROM EITHER CONTROL STATION, TURN THE KEY SELECTOR
SWITCH ON.
TO RAISE THE PLATFORM, DEPRESS THE
"PUMP" SWITCH, THEN MOVE THE CONTROL LEVER IN THE UP DIRECTION. TO
LOWER THE PLATFORM, DEPRESS THE
"PUSH TO LOWER" SWITCH, THEN MOVE
THE CONTROL LEVER IN THE DOWN DIRECTION.
C. PLATFORM CONTROLS
NOTE: AT LOWER CONTROL STATION, THE
OPERATOR SELECTOR SWITCH MUST BE
SWITCHED TO THE PLATFORM TO ENERGIZE THE UPPER CONTROLS.
EMERGENCY POWER BUTTON
PULL TO TURN ON AND PUSH TO TURN
OFF. NOTE: THIS IS ALSO AN EMERGENCY
STOP SWITCH. PUSH TO CEASE ALL FUNCTIONS.
THE CONTROLS ARE ENERGIZED ONLY
WHEN THE FOOTSWITCH IS DEPRESSED.
THE PLATFORM CONTROL BOX CONTAINS
THE FOLLOWING CONTROLS:
DRIVE/STEER CONTROL
THIS FOUR-WAY CONTROL LEVER OPERATES THE DRIVE AND STEER FUNCTIONS.
DRIVE "FORWARD" MOTION IS DETERMINED
WITH THE STEERING WHEELS LEADING THE
WAY, AND "REVERSE" MOTION IS DETERMINED WITH THE DRIVE WHEELS LEADING
THEWAY. MOVING THE DRIVE/STEER CONTROL LEVER TO THE FORWARD OR REVERSE DIRECTION WILL CAUSE THE UNIT
TO DRIVE IN THOSE RESPECTIVE DIRECTIONS. MOVING THE SAME CONTROL LEVER TO THE RIGHT OR LEFT WILL CAUSE
THE UNIT TO STEER RIGHT OR LEFT RESPECTIVELY. THE FOOTSWITCH MUST BE
DEPRESSED WHILE OPERATING THESE
FUNCTIONS. THE CONDOR® SCISSOR
LIFTS HAVETHREE (3) DRIVE SPEEDS: LOW,
HIGH, AND CREEP. LOW SPEED IS ACCOM-
PLISHED WITH THE SCISSOR ARMS COMPLETELY LOWERED. THIS ALLOWS THE
GREATEST POSSIBLE TORQUE FOR DRIVING UP MAXIMUM INCLINES. HIGH SPEED
IS AVAILABLE WITH THE PLATFORM RAISED
JUST A FEW INCHES SO THE ARMS JUST
CLEAR THE TRANSMISSION VALVE ACTUATOR. THIS ALLOWS THE FASTEST DRIVE
SPEED, BUT HAS REDUCED TORQUE.
CREEP SPEED IS ACCOMPLISHED BY RAISING THE SCISSOR ARMS FURTHER, APPROXIMATELY 12 INCHES, TO CLEAR THE
CREEP VALVE ACTUATOR. THIS ALLOWS
THE MINIMUM DRIVE SPEED AND GREATLY
REDUCED TORQUE WHILE DRIVING AT INCREASED PLATFORM HEIGHTS.
LIFT UP/DOWN CONTROL LEVER
TO RAISE THE UNIT, MOVE THE CONTROL
LEVER TO THE "UP" POSITION. TO LOWER
THE UNIT, MOVE THE CONTROL LEVER TO
THE "DOWN" POSITION. THE FOOTSWITCH
MUST BE DEPRESSED FOR BOTH "UP" AND
"DOWN" OPERATIONS; HOWEVER, THE
HYDRAULIC PUMP WILL NOT BE OPERATINGDURINGTHEHDOWN" FUNCTION. GRAVITY LOWERING IS ACCOMPLISHED.
III. OPTIONAL EQUIPMENT
THE FOLLOWING OPTIONSAREAVAILABLE
ON THE CONDOR® AERIAL WORK PLATFORM:
-DECK EXTENSION
-TRAVEL WARNING HORN
_5° MULTI-AXIS SLOPE SENSOR
-110V LINE TO PLATFORM
-SELF-CLOSING GATE
-HOUR METER
-3154 OPTION
3
MANUAL 92277-001
SEPTEMBER 1993
IV. EMERGENCY LOWERING
THE CONDOR® IS EQUIPPED WITH EMERGENCY LOWERING VALVE(S) LOCATED AT
THE HOLDING VALVE ON THE LIFT
CYLINDER(S). TO OPERATE THE EMERGENCY LOWERING VALVE(S), DEPRESS
THE RED-KNURLED KNOB AND TURN COUNTERCLOCKWISE UNTIL IT POPS OUT
SLIGHTLY (1/8" - 1/4"). THE LIFT/LOWER
CONTROL LEVER AT THE LOWER CONTOL
STATION CAN NOW BE MOVED TO THE
"LOWER" POSITION AND THE PLATFORM
WILL LOWER. (NO ELECTRICAL ACTIVATION IS NECESSARY)
V. MOVING FROM JOBSITE TO JOBSITE
THE RAMP SHOULD BE SET AT AN ANGLE
NO STEEPER THAN THE MACHINE'S RATED
GRADE-ABILITY. MODELS 2032 AND 3146:
11° OR 21%, OR A RISE OF 25 INCHES IN 10
FEET. MODELS3154AND3160: 15°0R26%,
OR A RISE OF 32 INCHES IN 10 FEET.
BEFORE DRIVING THE UNIT ON THE RAMP,
LOWER THE PLATFORM COMPLETELY,
TEST THE DRIVE/STEER CONTROLS AND
THE BRAKE SYSTEM, AND BEWARE OF
FREEWHEELING CONDITIONS.
DRIVE UP OR DOWN THE RAMP SLOWLY,
ALLOWING FOR STEERING CORRECTIONS
TO BE MADE. KEEP UNIT IN ALIGNMENT
WITH THE CARRIER AND RAMP DURING
LOADING AND UNLOADING PROCEDURES.
A. LOADING AND UNLOADING
ALTHOUGH THE CONDOR® IS SOMEWHAT
SMALL COMPARED WITH LARGER CONSTRUCTION EQUIPMENT,ITREQUIRESTHE
SAME CARE AND ATTENTION IN LOADING,
TRANSPORTING, AND UNLOADING AS DOES
LARGER EQUIPMENT. AT NO TIME SHOULD
ITS SIZE BE UNDERESTIMATED. BEFORE
LOADING OR UNLOADING, INSPECT THE
UNIT FOR ANY PHYSICAL DAMAGE OR DEFECTS.
THE MEANS BY WHICH YOU LOAD OR UNLOAD THE UNIT SHOULD BE OF SUFFICIENT
STRENGTH TO WITHSTAND THE WEIGHT
OF THE CONDOR®.
MODEL WEIGHT(#) WEIGHT (KG)
962
2032
2,120
2,105
3146
4,640
2,622
5,780
3154
2,250
4,960
3160
C. FORKLIFT LOADING AND UNLOADING
METHOD
ENSURE THAT THE FORKLIFT HAS SUFFICIENT CAPACITY TO HANDLE THE WEIGHT
OF THE CONDOR®.
(SEE PAGE 4)
MODELS 2032, 3146, AND 3154 SHOULD
ONLY BE LIFTED FROM THE SIDE, POSITIONING THE FORKS UNDERNEATH THE
CHASSIS. FORKS SHOULD BE LONG
ENOUGH TO GO ACROSS THE WIDTH OF
THE FRAME AND SHOULD BE POSITIONED
AS CLOSE TO THE INSIDE OF THE TIRES AS
POSSIBLE. NOTE: DO NOT ATTEMPT TO
LIFT THESE MODELS FROM EITHER END.
MODEL 3160 SHOULD ONLY BE LIFTED
FROM THE FRONT OR REAR, USING THE
FORKLIFT BOOTS PROVIDED.
B. RAMP METHOD
THE CONDOR® SHOULD ONLY BE RAISED
TO A HEIGHT SUFFICIENT TO CLEAR ANY
OBSTRUCTIONS.
ENSURE THAT THE RAMP BEING USED IS
SUFFICIENTLY STRONG TO HANDLE THE
WEIGHT OF THE UNIT.
KEEP FORKLIFT TRAVEL TO A MINIMUM,
AND SET GENTLY DOWN TO GROUND
LEVEL.
4
MANUAl 92277-001
SEPTEMBER 1993
D. TRANSPORTING
THE CONDOR®CAN BE EASILY AND SAFELY
TRANSPORTED FROM THE JOBSITE IF THE
FOLLOWING RULES AND PROCEDURES
ARE FOLLOWED:
BLOCK ALL WHEELS TO PREVENT FORWARD AND REVERSE MOTION.
TIE DOWNTHECONDOR®WITH CHAINS OR
CABLES, RUNNING THEM THROUGH THE
TIE-DOWN BRACKETS ONLY. DO NOTCHAIN
OR STRAP OVER THE GUARD RAILS. SEVERE DAMAGE TO THE SCISSOR ARMS
MAY RESULT FROM SECURING THE UNIT
OVERTHETOPOFTHEPLATFORM,DUETO
EXCESS PRESSURE.
ALWAYS TURN THE POWER OFF AT THE
GROUND CONTROL STATION.
VI. FREEWHEEL OPERATION
CAUTION: WHEN USING THE FREEWHEEL
VALVE, THECONDOR®MUSTBEONLEVEL
GROUND. TURN VALVE KNOB CLOCKWISE
UNTIL CLOSED AND DRIVE THE CONDOR®
APPROXIMATELY 3 FEET. THIS WILL DISABLE THE BRAKE, ALLOWING THE CONDOR® TO BE MOVED.
THE VALVE KNOB MUST BE TURNED FULLY
COUNTERCLOCKWISE (OPEN) FOR NORMAL OPERATION.
NEVER EXCEED 5MPH WHEN MOVING THE
CONDOR® IN THE FREEWHEEL MODE.
5
MANUAL 922n-001
SEPTEMBER 1993
A div. of TIME Manufacturing Company
SELF-PROPELLED
ELEVATING WORK PLATFORM
MODEL 3160
MAINTENANCE MANUAL
MAILING ADDRESS
SHIPPING ADDRESS
CONDOR®
CONDOR®
A DIV. OF TIME MFG. CO.
A DIV. OF TIME MFG. CO.
8300 IMPERIAL DRIVE
VVAco,TEXAS76712
(817) 666-4545
P.O. Box 21447
VVAco,TEXAS76702-1447
(817) 666-4545
MANUAL 92277-002
JUNE 1996
I
INTRODUCTION
The primary purpose ofthis manual is to provide the user with a thorough understanding ofthe proper
operating procedures necessary to comply with the intended use ofthe CONDOR®, and to provide the
information necessary to maintain and service the CONDOR®.
THE OPERATOR'S MANUAL MUST BE RETAINED ON THE CONDOR®AT ALL TIMES.
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
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.
regarding the operation and use of aerial work platforms. A copy of the ANSIISIA Manual of
Responsibilities is attached for your use: ANSIISIA A92.5-1992 is provided for Boom-Supported
Elevating Work Platforms, and ANSIISIA A92.6-1990 is provided for Self-Propelled Elevating Work
Platforms.
Calavar Corporation 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.
FROM THE MANAGEMENT OF CALA VAR CORPORATION
manufacturer recommends that replacement parts be purchased through Calavar Corporation in order to
ensure the original integrity ofthe product. Repairs and adjustments should only be made by trained and
qualified personnel. Please refer to the maintenance and parts sections of the Calavar Operation,
Maintenance, & Parts Manual for information on service and maintenance of the CONDOR®.
NOTE:
Please refer to the Calavar Parts section of the Operation, Maintenance, & Parts Manual for
information pertaining to your CONDOR®.
CONDOR® SERVICE INFORMATION
1. If you need assistance or have any service or maintenance questions, Condor service and
parts personnel are always available by phone or fax. The telephone numbers are:
(817) 666-4545 Telephone
(817) 666-5125 Voice Mail
(800) 443-5803 FAX
2. There are numerous written Maintenance Procedures available for this CONDOR®.
These procedures are available through the Condor Service Department to anyone
who requests them.
3. Service and maintenance are not a substitute for trained, qualified service technicians.
Condor conducts service schools on a continuing basis. Call any of our service or sales
persons for a schedule. Remember, training of mechanics is the responsibility of their
employer, but Condor Service Schools help you provide this training.
4. Condor Service School Training Manuals are available for purchase through the parts
department. The part numbers for these manuals are: #92333 for self-propelled models;
and #92334 for truck-mounted models.
8300IMPERIALDRIVE,P.O. Box21447, WACO, TEXAS 76702-1447 817-666-4545, 817-666-4544 FAX
0
iii
Condor® Self-Propelled Booms and Scissors
WARRANTY
Calavar Corporation (" Calavar") warrants to the purchaser that each new aerial work platform
made by Calavar is free from defects in material and workmanship arising under normal use
and service-in the case of major weldments, (chassis, turret, and booms), for a period of five
(5) years after the original shipment of the aerial work platform from Calavar'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 Calavar' s
plant, whichever comes first.
The obligation and liability under this Warranty is expressly limited to repairing or, at Calavar's
option, replacing free of charge at its factory in Waco, Texas or at an authorized repair facility
designated by Calavar, the defective part. In no event shall Calavar 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 Calavar, 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 Calavar'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 Calavar or alteration or repair of the
equipment by any person not authorized by Calavar shall, at Calavar's option, void this
Warranty. Calavar shall have no liability or responsibility for damages resulting from accident
or the malfunction of equipment and components not supplied by Calavar.
No agent, employee, distributor, dealer, or other representative of Calavar 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 Calavar and
should not be relied upon as limited warranties of Calavar, and no attempt, effort, or promise
to repair equipment by Calavar 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 Calavar. This
Warranty covers only new and unused aerial work platforms manufactured by Calavar.
Products or parts manufactured by others are covered only by such warranties as are extended
to the purchaser by Calavar's suppliers.
This Warranty is in lieu of all other warranties, expressed or implied, including but not limited
to warranties of merchantability and fitness for a particular purpose. Any applicable implied
warranty shall be limited in duration to the warranty period.
8300 Imperial Drive, P.O. 80x 21447, Waco, Texas 76702-1447 0 817-666-4545,817-666-4544 FAX
Form NO.513·3M-392
Effective Date 911/90
Printed in U.S.A.
Effective January 1, 1993
WARRANTY PROGRAM
Warranty is a function of a manufacturing company to back up the product it manufactures. It is a
guarantee against defects in design and workmanship ofcomponents utilized in the product, and is offered
for a fixed period of time following the purchase of the product by a customer.
Calavar Warranty states, in general, that Calavar 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 Calavar. These will be outlined in subsequent paragraphs.
A.
WARRANTY PERIOD
1.
The Self-Propelled Boom and Scissor Warranty is one (1) year from placing the
CONDOR® in service or two (2) years following shipment from Calavar, whichever
comes first. In the case of major weldments (chassis, turret, and booms), the Warranty
Period is five (5) years following shipment from Calavar.
2.
The Truck-Mounted CONDOR® Warranty Period is one (1) year from shipment of the
CONDOR® from Calavar's plant.
3.
F or parts so ld 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 Calavar, whichever comes first, unless the part is furnished to correct a
defective part on the original shipment still under Warranty.
4.
Replacement parts provided under the terms ofthe Warranty are for the Warranty Period
applicable to the unit in which they were installed as if such parts were original
components of the aerial work platform.
5.
During the Warranty Period, in addition to covering the parts replaced under Warranty,
Calavar will pay a Dealer Warranty Labor Rate which is based on a percentage of your
standard shop labor rate.
NOTE:
The term "IN SERVICE" means that the Warranty starts at the time the CONDOR® is
first used for any purpose. An example: The dealer may have purchased a CONDOR®
to have in stock, but may not use it. After three months, the CONDOR® is sold or the
dealer decides to putthe CONDOR® into its rental fleet. In this situation, the Warranty
Period begins the day the dealer puts the CONDOR® into the fleet or when the
CONDOR® is delivered to the end user.
The submittal of a warranty claim against a stock machine constitutes it as being "in
service," initiating the warranty period.
B.
PRE-DELIVERY INSPECTION SHEET (P.D.I.)
1.
Each Self-Propelled Boom or Scissor CONDOR® shipped from Calavar's facility will
have a Pre-Delivery Inspection (P.D.I.) sheet enclosed in the Safety Manual holder tube.
2.
It will be the responsibility ofthe original recipient ofthe CONDOR® from Calavar,
whether it will be the dealer orthe end user, to complete this form and return itto Calavar's
facility within 45 days from the date of receipt to set up the Warranty Account.
3.
Failure to complete the P.D.1. sheet and return it to Calavarwithin the time frame given
will result in voiding the Warranty on the CONDOR® .
NOTE:
The form must be filled out completely, giving the name of the dealer, address, model
number, serial number, person inspecting the CONDOR® 's, signature, and date of
inspection. (The date of inspection does not constitute the "In Service" date.)
C.
ITEMS NOT COVERED UNDER WARRANTY
Some components are used on the CONDOR® which are not warranted by Calavar. 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. Calavar can advise you who
the dealer is if unknown to you.
2.
Tires and Batteries: These are normal wear items and are considered normal
maintenance items. However, ifthey are found to be defective, contact can be made with
the manufacturer's local dealer.
3.
Hvdraulic 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 Calavar by its suppliers.
5.
Freight and Charges: The warranty does not include any transportation, other charges,
or the cost of installation or any liability for direct, indirect, or consequential damages or
delay resulting from the defect.
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, Calavar
Warranty will cover reasonable labor charges for the removal and replacement of
defective components.
D.
PROCESSING OF WARRANTY CLAIM
During the Warranty Period, should a component failure be encountered within the guidelines of
the Calavar Warranty Policy, the following procedure is to be followed:
1.
Upon identifying the defective component, the replacement can be obtained by:
a.
Issuing an order to our Parts Department through normal channels, which
entails your being invoiced.
b.
You may have previously purchased the part from Calavar for your stock
and will utilize it for this replacement.
The above two methods will enable you to indicate on the claim the Calavar invoice
number to substantiate the parts purchase and the amount to be credited.
2.
c.
Although not recommended, you may purchase the part locally. When this is
done, a copy of the purchase order or receipt MUST accompany the claim.
Calavar has the option to ship a replacement part at no charge if the local cost
would be greater, in lieu of issuing credit for locally purchased parts.
d.
When parts are purchased from Calavar, 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 Calavar to thoroughly evaluate the
claim and process it in the shortest amount of time possible.
NOTE:
WARRANTY CLAIMS NOT RECEIVED BY CALAVAR WITHIN 45 DAYS OF
FAILURE WILL BE DENIED
3.
E.
Provided no return parts are required and all the information has been verified, the claim
will be processed and credit will be issued against your account.
RETURN AUTHORIZATION
1.
If a component is found to be defective within the normal guidelines of the Warranty, a
Warranty Claim Form must be completed.
2.
It will be necessary for you to call the Calavar Service Department and ask to be issued
a Return Authorization (R/A) number. You will be asked for a Dealer Claim Number.
As noted in Section 2, Item A, ofthe Warranty Claim Procedure, this is a number assigned
by the dealer for the purpose of tracking the claim, as there may be more than one claim
for the same CONDOR®. The R/A number issued must be logged in the appropriate
section ofthe claim form, and the gold copy (R/A) ofthe form must be returned with the
parts being returned.
NOTE:
DO NOT SHIP ANY RETURN PARTS WITHOUT
A RETURN AUTHORIZATION (RIA) NUMBER
Doing so may result in parts getting lost in the system and may delay processing the claim,
or may cause denial due to the time element ofthe claim.
3.
All RIA parts must be received at Calavar within 45 days from the date the RIA number
was issued. Failure to do so will cause the claim to be denied.
4.
All parts claimed under Warranty will be required to be shipped back to Calavar
FREIGHT PREPAID. No freight collect shipments will be accepted.
CONDOR® Model 3160
MAINTENANCE MANUAL
TABLE OF CONTENTS
INTRODUCTION ..................................................................................................................... i
CONDOR® SERVICE INFORMATION .............................................................................. ii
SELF-PROPELLED WARRANTY ........................................................................................ iii
Table of Contents ...................................................................................................................... 1
Specifications ............................................................................................................................ 3
Recommended Tool List ........................................................................................................... 4
Serial Number Location ............................................................................................................ 5
Hydraulic System Description .................................................................................................. 7
Electrical System Description ................................................................................................. 17
Battery Service ........................................................................................................................ 27
Preventive Maintenance .......................................................................................................... 31
Hydraulic Oil Specifications .................................................................................................. 41
Bolt Torque Chart ................................................................................................................... 43
REVISEDJULY1996
MANUAL 92277-002
JUNE 1996
•
•
NOTES
MANUAL 92277-002
JUNE 19%
•
SPECIFICATIONS
SPECIFICATIONS
3160
Maximum Working Height
Platform Height
Stowed Platform Height
Overall Length
Overall Width
Overall Height
Platform Size
Platform Capacity
Gross Weight
Power System
Battery Capacity
Number of Batteries
Battery Voltage
Battery Charger
WheelBase
Tires
31 ft.
25 ft.
51"
120"
60"
93"
116" x 56.5"
15001bs.
4,960Ibs.
36 volt DC
250 amp hour
6
6 volt
35 amp
7'-6"
600x9
(Solid Rubber)
8'-6"
0-2.4 mph
25%/14°
35/24 sec
Inside Turning Radius
Drive Speed
Gradeability
LiftlLower Time
OPTIONS
*
*
*
*
*
*
Battery Condition Indicator
Strobe Light
Non-Marking Tires
Hour Meter
Travel Alarm
Charging Cut-Out Relay
*
*
*
*
*
MotionIMovement Alarm
Descend Alarm
5° Slope Alarm
Low Volt Warning/Interrupt Battery
Protection System
110 volt Line to Platform
The CONDOR® Model 3160 is designed and built to conform to Calavar's understanding and
interpretation of all applicable OSHA rules and regulations as well as ANSI standards:
ANSI Standard A92.6 - 1990 ................... Self Propelled Elevating Work Platform
CAUTION
It is imperative that all owners and operators of the CONDOR® read, understand and conform to
these regulations. Ultimate compliance to prevailing OSHA regulations is the RESPONSIBILITY
of the employer utilizing the equipment.
MANUAL 92277-002
JUNE 1996
•
RECOMMENDED TOOL LIST
The following is a list oftools that you will find helpful when performing service, maintenance
or troubleshooting the CONDOR® equipment.
1 each
1 each
1 each
1 each
1 each
1 each
1 each
1 each
1 each
1 each
1 each
1 each
1 each
1 each
1 each
1 each
1 each
1 each
1 pair
1 pair
1 pair
1 pair
2 pair
Volt/Ohm Test Meter
Hydraulic FlowMeter, 0-10 GPM
Hydraulic Flow Meter, 0-50 GPM
Hydraulic Quad Meter Pressure Gauge
Battery Hydrometer
Battery Load Tester
1/2" Drive Torque Wrench, 0-250 ftIlbs
Pry Bar
Strap Type Filter Wrench
Grease Gun
Hammer, 24 oz.
Vice Grip Pliers
Combination Wrench Set, 1/4" to 1-1/2"
3/8" Drive Socket Set, 114" to 3/4"
112" Drive Socket Set, 3/8" to 1-112"
Hex Key (allen wrench) Set, up to 1/2"
Screwdriver Set, Phillips Tip & Slot Tip
Punch Set; Drift, Lineup and Straight
Wire Stripping Pliers
Wire Crimping Pliers
Wire Cutting Pliers
Needle Nose Pliers
Jumper Wires with Alligator Clips
NOTE: This list is notintended to be all inclusive ofthetools required to perform every maintenance
function that may be required on this specific CONDOR® model. However, these tools will greatly
assist in troubleshooting problems and conducting routine maintenance on the equipment.
MANUAL 92277-002
JUNE 1996
SERIAL NUMBER LOCATION
2
The CONDOR® Model 3160 Serial Number is stamped in two locations on the machine.
1.
The first place to find the serial number is on the data plate affixed to the
chassis rail, near the lower control valve.
2.
The second place to find the serial number is at the rear of the right side
armstack pivot, near the footsteps.
MANUAL 92277-002
JUNE 1996
•
o
NOTES
MANUAL 92277-002
JUNE 1996
•
HYDRAULIC SYSTEM DESCRIPTION
The following is a detailed description of the hydraulic system used on the CONDOR® model 3160
scissor, and how it is designed to operate. To assist in understanding the system, this description should
be used in conjunction with the hydraulic schematics found at the end of this section.
GENERAL
The hydraulic system on the CONDOR® model 3160 consists of a single gear pump and two
control valves, one located at each control station, and is ofthe open-center valve type, meaning that the
hydraulic fluid circulates back to the tank when the pump is running and no functions are being operated.
Additionally, because this is an open-center system, the valve nearest the pump will have priority over
the other valves. At the upper controls, the steering and drive have priority. For example, if steering or
drive were commanded while lifting the platform, the platform would slow down or even stop lifting.
The system is designed to operate at a maximum of2400 psi, with all lift and drive functions operational
from the platform controls and only lift functions available from the ground controls.
HYDRAULIC TANK
The hydraulic tank (See FIG. 1) is a
rectangular weldment having a fluid capacity of
5 US gallons, and is located next to the batteries
in the belly pan, nearest the fixed axle end ofthe
unit. A filler cap, and a level sight glass are
provided for checking and maintaining the fluid
level. Filtration of the hydraulic fluid is provided through a 10 micron spin-on return filter,
located at the end of the tank nearest the lower
control valve. A ball valve, or shut-off valve, is
located in the suction line leading to the pump,
and when closed, will prevent the hydraulic tank
from draining during repairs to the hydraulic
system. The cylinder vent fitting indicated in
FIG. 1 is provided to connect the rod end of the
lift cylinders to the hydraulic tank. This effectively vents the cylinders and allows any fluid
that may leak past the cylinder packing, to have
a path back to the hydraulic tank.
Cylinder Vent
Fitting
Filler Cap
Level Sight Glass
Ball
Valve
FIG. 1
NOTE: Only check the tank fluid level when the unit is in its stowed position to ensure the level will
be at its highest. The hydraulic fluid used is Shell Tellus T-32 and only this fluid, or its equivalent should
be used.
DO NOT MIX HYDRAULIC FLUIDS.
MANUAL 92277-002
JUNE 1996
•
PUMP/MOTOR
The pump and motor assembly is located in the right side of the belly pan, between
the tank and the battery charger (See FIG. 2). A
36 volt DC motor drives a gear pump, which
draws fluid through the ball valve, from the
hydraulic tank, and discharges this oil at a fixed,
constant flow rate of 4.26 gallons per minute
(GPM) throughout the hydraulic system and
back to the tank.
Battery Charger
(reference)
Hydraulic Tank
FIG. 2
LOWER CONTROL VALVE
Located in the left rear comer of the belly pan, nearest the fixed axle is the lower control valve,
which allows operation of the lift function only (See FIG. 3). This valve is of the closed-center working
port, open-center pressure port, manually-operated directional control type. The valve also contains a
system relief cartridge which is adjusted to 2400 psi. Function speed (raising/lowering) is controlled by
the amount of handle movement.
Chassis Cover
Pump Switch and Control Selector Switch
o
o
e
ll~PE~
O~
,,~
Valve Handle
SEl..ECTORSWlTCH
Lower Control Valve
Pump Solenoid
System Relief
Cartridge
Terminal Strip
J.l:C----
Free-wheel Valve
with thumbwheel
Shuttle Valve
FIG. 3
UPPER CONTROL VALVE
The upper control valve is located at the forward right hand side of the platform inside an
enclosure, and it allows operation oflift, steer, and drive (See FIG. 4 on following page). The lift and
steer sections, like the lower control valve, have closed-center working ports, which means that each
function port is "blocked" when the spool is in its center position. The drive section uses a motor spool,
which provides the drive function ports with a path back to tank. This effectively reduces dynamic shock
to the drive motors. A guard protects the lift lever from falling objects or accidental activation. The steer/
drive control handle, or joystick, protrudes directly from the top side of the control valve.
Inside the box assembly is a microswitch for activation ofthe pump solenoid and holding valves.
The microswitch is located near the lift valve handle on early model machines (as illustrated in FIG. 4),
and for late model machines the microswitch is mounted to the valve itself, to the lower end of the lift
spool.
MANUAL 92277-002
JUNE 1996
~
____________________________________~41)
Emergency Stop Button
Lift Handle
I~==::~=/::::J
____
Drive/Steer Handle
Speed Selector Switch
(late models)
Control Lever Guard
Emergency Stop
Button
~
Microswitch
mounted inside box
assembly (early
models)
Lift Handle
o
Lower end of Lift Spool (location of
microswitch on late models)
/
Control Lever Guard
FIG. 4
STEERING SYSTEM
When the footswitch is depressed, the pump motor turns on, thus pumping fluid through the lower
control valve to the upper control valve and then returning tothe hydraulic tank. While the pump is
running, the drive/steer control handle can be moved to the left or right from its vertical position to direct
fluid to the steering cylinder base end for left, or fluid to the rod end for right steering. Once the control
handle is released to its vertical position, the steering cylinder becomes "locked" by the closed-center
working ports of the upper control valve. Steering cannot be accomplished at the lower control valve.
LIFT SYSTEM
To raise the platform from the lower controls, press the lift toggle switch upward to tum the pump
on then move the valve handle upward. To lower the platform, press the toggle switch downward to
energize the holding valve on the lift cylinders (note: the pump will not run while the holding valves are
energized), then move the valve handle downward to begin lowering the platform.
The lift system functions the same from the upper controls. Here, the toggle switch is replaced
by a footswitch which must be depressed before any functions can be operated. For lowering, the
footswitch is depressed, then the lift handle is pushed downward, and as the handle is moved, a
microswitch will be activated by the handle lever. Activation of this microswitch will tum the pump off
and energize the holding valves. At this point, the handle can be moved further downward to begin
lowering the platform. At either control valve, the speed of movement is dependent on the amount of
handle travel from its center position.
MANUAL 92277-002
JUNE 1996
•
LIFT CYLINDERS
The 3160 armstack consists of a grouping of tubing weldments assembled in such a manner that,
when the arms are separated from one another, the stack raises upward. The process of separating the arms
from a collapsed, or stowed, position is accomplished through the use of two lift cylinders that work
together simultaneously. The primary means of
maintaining the platform in any position other
than stowed is employed by the use of a solenoid
operated manual-control valve, or holding valve,
Rod End of Lift
- I located at the base port of each lift cy linder (See
Cylinder
~
FIG. 5). This valve allows fluid to flow unrestricted to the cylinder, and blocks the flow of
fluid from the cylinder. Lowering of the platVent Port - Routed
back to Tank
~
form requires fluid to escape the lift cylinders,
therefore both holding valves must be opened
by applying 24 volts to the solenoids by pushing
Lift Cylinder
the upper control valve lever downward while
depressing the footswitch, or by pressing the
toggle switch at the lower controls to the downHydraulic Hose
ward position, then pressing the valve control
lever downward to lower the platform. In either
Holding Valve
at Base Port
situation (upper or lower controls), the holding
valves become energized but the platform will
not start to lower until the valve handle is moved
from its center position to allow the fluid to flow
past the spool and return to tank from the
cylinders.
The platform can be lowered if the solenoid or electrical system becomes inoperative.
To manually lower the platform, depress and
Manual Release Knob
at tip of Cartridge
tum the small red knob counterclockwise 1800
(on both holding valves), then push the lower
control valve handle downward to begin lowering the platform. To reset the holding valve for
normal operation, push the red knob "in" and
tum clockwise. This method of activation
"manually" opens the holding valve cartridge
rather than electrically, however, it must also be
"manually" reset.
.106" Orifice Located
in this Fitting
As shown in Figure 5, each cylinder has
a vent port at the rod end which is routed back to
the hydraulic tank. This port allows any fluid
that may leak past the cylinder packing to be
FIG. 5
returned to the hydraulic tank and also "vents"
the cylinder to prevent any pressure or vacuum
from building up within the cylinder.
MANUAL 92277-002
JUNE 1996
DRIVE SYSTEM
The CONDOR® model 3160 scissor drive system utilizes two hydraulic drive motors located at
the fixed axle of the chassis. Both drive motors have a 29.1 cubic inch per revolution (CIPR), but both
motors are not identical and are not interchangeable. The right side motor has a keyed, tapered shaft for
direct wheel hub mounting, and the left side motor has a splined shaft which mates to a brake assembly
which has the same size keyed, tapered shaft for direct wheel hub mounting identical to the right side
wheel/motor. A more detailed description ofthe brake system and how it operates can be found following
this drive system description.
The drive function is only available from the upper controls, and the drive function lever also
activates steering. Movement ofthe lever in the left or right side ofits centerline operates steering, while
movement in the forward or reverse side of its left to right centerline operates drive. Both steer and drive
can be manipulated simultaneously by moving the lever in an angled fashion from its forward/reverse and
left/right centerlines.
There are three travel speeds available when operating the drive function; high, low, and creep
speed. However, from serial number 3900 and up, the methods which these speeds are produced or
achieved by are different from earlier models. The drive speeds and how they operated will be discussed
in more detail following the brake system description.
BRAKE SYSTEM
The 3160 brake system consists of a
Left Rear Axle Tube
single, spring-applied/hydraulicaUy-released,
Brake Assembly
dry friction-disc brake, which is located at the
Drive Motor
left rear wheel of the drive axle (See FIG. 6).
Ports
Refer to paragraph one under "Drive System"
Output Shaft
for a description of the mounting configuration.
Figure 7 illustrates a partial cutaway
Brake Port
view of the brake assembly and itemizes the
following components: (1) brake springs which
FIG. 6
apply holding pressure, (2) friction discs which
lock the output shaft when compressed by springs,
(3) keyed, tapered output shaft for mounting of
(1)
(6)
the wheel hub, (4) drive motor mounting/input
/
(2)
end, (5) brake piston which transfers spring
pressure to the friction discs, and (6) brake
pressure port.
The brake assembly releases when approximately 200 psi or more is applied at the
(4)
pressure port (6). This fluid pressure overcomes
the static pressure being applied on the piston by
the twelve brake springs (1), and therefore pushes
the piston (5) away from the friction discs (2)
and thus compressing the springs and allowing
the output shaft (3) to rotate. Pressure for
FIG. 7
operating the brake assembly comes from a
shuttle valve in the drive circuit which allows fluid to be directed to the brake assembly regardless of the
direction of travel activated. Free-wheeling of the unit can be accomplished by turning the thumbwheel
on the free-wheeling valve (located next to the lower control valve - See FIG. 3) fully clockwise, then
MANUAL 92277-002
JUNE 1996
CD
BRAKE SYSTEM (cont'd)
energizing travel for about 3 feet. This will allow drive pressure to build up to above 200 psi and unlock
the brakes. Since the free-wheeling valve (which is simply an adjustable check/choke valve) is closed,
it will not allow fluid to pass back through from the brake and therefore the brake is maintained in its
released state and the unit can be moved. WARNING! -- In this condition the unit may begin to roll if
it is resting on an incline. To return the brake system to normal operation open the free-wheeling valve
by turning the thumbwheel counterclockwise.
The free-wheeling valve, in addition to free-wheel operation, can control the rate at which the
brakes apply which can be beneficial by helping to provide smoother braking action. The brake applies
as the hydraulic pressure is reduced to below that of the brake spring pressure. Ifthe hydraulic pressure
is restricted in such a manner that the hydraulic pressure reduces at a slower rate, then the rate at which
the brake applies will also be slower. The free-wheeling valve in its fully open (counterclockwise)
position will allow the hydraulic fluid to escape the brake housing at a faster rate when the drive function
is released. In this situation the brake may apply quickly while the unit is still rolling under momentum
and result in a jerky stop. On the other hand, if the free-wheeling valve were adjusted to nearly closed
(almost full clockwise), the unit would have time to stop or almost stop on its own as the brake applies.
CAUTION! -- Do not adjust the free-wheeling valve in such a manner that the brake does not apply at
a rate which will effectively stop the unit on an incline.
DRIVE SPEEDS
The 3160 utilized two methods for achieving the three available drive speeds which are: high,
low, and creep. High speed is a condition where fluid flows through the two drive motors in series, thus
providing a faster speed from the available flow rate. Low speed allows fluid to pass through the drive
motors in parallel, providing more drive torque but reduced speed since the available flow is split in half.
Creep speed is utilized for travelling at platform heights above 7 feet were movement of the unit while
on flat, level ground can be achieved without repeatedly lowering the platform. Drive torque and speed
are both dramatically reduced when in this condition by directing some ofthe fluid from the drive circuit
back to tank and effectively reducing pressure and flow.
Current production models (serial # 3900 and up) use an electromechanical system whereas each
speed is controlled by some electrical means. Older production models (serial #'s up to 3899) use strictly
a mechanical system meaning that there are no electrical circuits used for controlling the drive speed of
the unit. In both systems the primary means of speed control is hydraulic, however, it's the secondary
activation method where the differences lie.
Electromechanical system models utiSeries/Parallel Valves with Coils
lize a 3-position rotary switch at the upper controls for controlling the transmission valve (See
FIG. 8) which is located on the chassis at the
fixed end of the armstack, and the creep valve
which is located near the lower control valve.
Flow Divider/Combiner
This configuration allows selection of any ofthe
three speeds in any platform position below 7
feet. At heights of7 feet or above, a limit switch
mounted to the chassis becomes activated by the
Series/Parallel Valve
lower arm ofthe armstack and thus energizes the
creep valve. This activation is automatically
controlled by the position of the platform and
FIG. 8
will override the speed selected by the rotary
switch at the upper controls.
MANUAL 92277-002
JUNE 1996
DRIVE SPEEDS (cont'd)
Mechanical system models rely on
strictly platform position for controlling drive
speeds. There are no electrical circuits in the
drive speed system on the previous 3160 model
scissors (serial #'s up to 3899). A transmission
valve (See FIG. 9) is mounted to the chassis near
the fixed end of the armstack and contains a 2position 5-way cartridge which has a plunger
protruding from the top of the cartridge. This
plunger is depressed by the armstack when the
platform is stowed, and is fully released when
the platform is raised approximately 6 inches
from its stowed position. These two positions of
the platform yield two drive speeds - low and
high, with the armstack fully stowed (plunger
depressed) being low speed, and platform raised
slightly (plunger released) being high speed.
A creep valve is also activated by
armstack position (See FIG. 10). The armstack
depresses a spool in the same manner as that of
the transmission valve. However, due to the
positioning ofthe valve in relation to the armstack
pivot, the valve plunger moves at a much slower
rate. This means that when the platform is fully
stowed, the valve's spool is depressed and the
valve is closed. As the platform is raised the
creep valve spool gradually moves until at a
certain point (platform at approximately 7 feet)
the ports inside the valve become open to one
another since the spool has eventually uncovered the ports. When the ports are uncovered,
fluid is allowed to pass between the forward and
reverse drive circuits which will diminish drive
speed and torque. Inside one of the creep valve
hydraulic fittings is an orifice to control the
amount of fluid bypass when operating in the
creep speed mode. When the creep valve spool
is fully released, or opened, the drive circuit will
operate in creep speed.
Malfunctioning of the mechanical system could possibly be due to a benttransmission
valve plunger, spools sticking or binding, or
insufficient depression of a plunger or spool due
to armstack geometry and valve mounting locations. Contamination of the hydraulic system
can cause problems with any hydraulic circuit's
operation and should not be overlooked when
troubleshooting hydraulic systems.
MANUAL 92277-002
JUNE 1996
Armstack Movement
Operates Plunger
Plunger
2-Position 5-Way Cartridge
Flow Divider/Combiner
Transmission Valve
FIG. 9
Armstack Movement
Operates Spool
Manually Operated
Spool
Creep Valve
FIG. 10
UPPER CONTROL VALVE
315-00034-00
BRAKE, ESKRIDGE
J
126-10005-00
~
SEE NOTE 1
FLOW CONOROL
______________
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__________________
k+~~*-~~~~~-~~
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BRAKE, ESKRIDGE
126-10005-00
MDLJ146 & MDU154
OIA
STROKE: 21.75
106
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M
OIA
j94
2500 RPM
~
106
PUMP 017BR1 A
ADAPTER 735298
54286-394
~--~.
STROKE: 20.56
NOTES:
WACO,
PRESSURE SWITCH USED ONLY WITH TRAVEL ALARM OPTION.
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1
0606 M4
0606
Ml
I
S703
MJ
0606 M2
0606
0606
PB
J
~~L,
~
~
PA
"J
21479-SEE
NOTE :3
~
0606
~
I
I
in
~N
0606
~
S704
0606
v
MOTOR
322-00015-00
2500 RPM
"
HYO. FILTER
33430
0606
PUMP
54286-394
I
I~
Ip
.39.7
MOTOR
321-00002-00
HYDRAULIC TANK
02D-R0060-00
DIA
.106
UFT CYL 2 PL
55116
BORE:4.0
ROO:2.0
smOKE: 20.56
I
HOLDING
VALVE 2 PL
527.l3
~
~
--
I
fJ-
S704
9
0606
TRANSMISSION VALVE
315-00027-00
~
STEER CYL.
162-96440-00
BORE;1.5
ROO:.75
STROKE: 5.25
S703
P
A1
~fJ:
~I~
S704
~N
0606
S704
9
DIA
.106
~
-
DI
L4DD~SI_ ~
LOWER
CONTROL
VALVE
315- 00m6- 00
S704
II
WACO, TEXAS
NOTES;
1. THIS SCHEMATIC SUPER CEDES 54284.
2. THIS SCHEMATIC REFLECTS IMPROVED "CREEP" PERFORMANCE
3. ADJUST CREEP SPEED TO 80-100 SEC/88 FEET, ON FIRM, LEVEL GROUND (REF .. 75/6 MPH).
4. LINE SIZES SHOWN ARE MIN I.D. FOR HYD HOSE.
A.HITTLE 04/05/95
4/25/95
B
RAK CHECKEO
APPR. "'PPROVED
RAK 04/07/9 SCI\LE NONE
c
55057
1 OF 1
NOTES
MANUAL 92277-002
JUNE 1996
•
ELECTRICAL SYSTEM DESCRIPTION
The following is a detailed description of the electrical system used on the CONDOR® model 3160
scissor, and how it is designed to operate. To assist in understanding the system, this description should
be used in conjunction with the electrical schematics found at the end of this section.
GENERAL
The electrical system of the CONDOR® model 3160 is a 36 volt DC (direct current) negative
ground system, which is made up of six, 6 volt Deep Cycle batteries connected in series to each other.
The pump motor, optional low volt interrupt (LVI), and the optional battery condition indicator are the
only circuits operating on the full 36 volt battery source while all other electrical circuits use only 24 volts
and are isolated from the batteries by a 20 amp fuse or circuit breaker. The 24 volt supply is achieved
by using the same negative ground and by making the positive lead connection at the positive terminal
of the fourth battery's positive terminal. This separate "grouping" of batteries, although they are still in
the 36 volt "total" system, yields the necessary 24 volts to power other machine functions which have
a 24 volt maximum capacity.
BATTERIES
To ease in battery maintenance, there is a pull-out battery tray weldment on each side ofthe belly
pan, in front ofthe hydraulic tank, nearest the steer axle. Each tray contains three 250 amp hour batteries,
which are connected in series combining their voltage to make up the 36 volt DC system. The batteries
are ofthe wet-cell type, and when filled with electrolyte, each battery weighs 781bs. Iffilling is needed
during routine maintenance, distilled water can be used to bring the level up to the indicator in each cell.
DO NOT OVERFILL ANY CELL. More information on batteries in general can be found in the
Battery Service Section beginning on page 23.
BATTERY CHARGER
The battery charger has a 40 amp @ 36
volt DC nominal output, and operates off of aIlS
volt AC (alternating current), 160 Hz, 8 amp
input. The charger is located on the right side of
the belly pan, between the hydraulic pump/motor
and the fixed axle (See FIG. 11).
Electric Motor
Battery Charger
(reference)
\l"",
[~2J
"-,_, i
0
Ref,
Hydraulic Tank
,,/
FIG. 11
MACHINE FUNCTIONS
The 3160 pump motor is rated at 6 HP @ 2500 RPM with a 160 amp current draw and utilizes
the 36 volt system described in the General Description. The motor is turned on by means of a 24 volt
solenoid, mountednextto the lower control valve, whereas the solenoid contacts handle the 36 volt motor
circuit and the solenoid coil is activated by a 24 volt signal. The solenoid receives a signal whenever the
footswitch is depressed or the lower control pump switch is pushed upward.
MANUAL 92277-002
JUNE 1996
MACHINE FUNCTIONS (cont'd)
When the solenoid is energized the contacts close completing the 36 volt pump motor circuit. In
any situation, the red Emergency Stop Buttons must be pulled out to allow operation of the UPPER!
LOWER selector switch which must be set for the intended control station. Since lift, drive, and steer
are hydraulic functions, the pump motor must be running to obtain the hydraulic pressure to perform these
functions.
Lowering ofthe lift is accomplished by energizing the holding valves on the lift cylinders. When
operating from the lower controls this can be accomplished by pressing the pump switch downward to
energize the holding valves, then move the lift valve handle downward to begin lowering the platform.
When operating from the upper controls, lowering is achieved by depressing the footswitch to energize
the electrical circuits, then simply moving the lift valve handle (at the upper controls) downward to begin
lowering. The upper lift handle controls a microswitch. This switch completes a circuit, from its normally
closed contacts, from the footswitch to the pump solenoid in all situations except lowering. When the
footswitch is depressed the pump motor turns on, then as the lift control handle is moved downward, the
pump will tum off as the contacts are opened. Likewise, the normally open contacts close as the handle
is moved downward, which then completes a circuit from the footswitch (common terminal of
microswitch) to the holding valves. When lowering the platform from either control station, once the
holding valves are energized, the fluid is still being held in the lift cylinders by the control valve spools
and can be released by downward movement of either control valve handle. When the holding valves
are energized, the pump motor does not run because the unit utilizes a gravity lowering system whereas
the fluid is allowed to escape from the cylinders at a controlled rate. This rate is proportional to the amount
of handle travel.
Drive and steer functions can only be operated from the upper controls. When the footswitch is
depressed and the pump turns on, movement of the vertical joystick (on top of the upper control valve)
will operate drive, steer, or both simultaneously depending on the direction of handle movement. Handle
movement in the forward or reverse direction of the unit itself produces drive in that direction, while
movement to the left or right ofthe handle centerline produces steering in that direction. NOTE: The
steering wheels will remain in their position as the handle is released and will not return to center or
straight-line travel. The wheels must be returned to the straight forward position by operation of the
joystick in the opposite direction until the wheels are in the proper or intended position.
CHARGING CUT -OUT RELAY (OPTION)
A charging cut-out relay (R3) can be utilized to prohibit machine operation during charging. This
is accomplished by a 115 volt AC relay which is energized when the battery charger is plugged in. The
R3 relay uses two sets of contacts, R3-A and R3-B. Contacts R3-A are normally closed and they open
when relay R3 is energized (batteries charging). The R3-A contacts are wired into the 24 volt DC tap
circuit and the opening of these contacts disables all machine functions from either control station.
Simultaneously, the R3-B contacts close (since they are normally open) and energize a green charging
light through the 24 volt DC tap circuit.
BEACON/STROBE (OPTION)
Power is supplied to the beacon/strobe light from either position of the "UPPERILOWER
SELECTOR SWITCH", and functions as long as the lower Emergency Stop Button is pulled out.
Although the current draw is relatively small, the batteries could become discharged ifthe beacon/strobe
were left on for a substantial period of time.
MANUAL 92277-002
JUNE 1996
LOW VOLT INTERRUPT (OPTION)
The Low Volt Interrupt Module (L VI) is used to shut down all functions at the upper controls
should the battery voltage drop to 31.5 volts while under a load for 21 seconds. This will protect the
electrical system from damage due to high amp draw from a low battery voltage condition. The interrupt
system can be overridden by a momentary push button switch at the upper controls to allow the operator
to lower the unit and connect the battery charger to a suitable power source for charging. The override
should only be used when absolutely necessary and will only allow three, repeated by-pass cycles of 2
minutes 30 seconds each. Once the unit is re-charging, the battery voltage must reach 38.25 volts to reset
the LVI module and allow normal operation ofthe CONDOR®. When the unit is in the "interrupt" mode,
an amber light will be illuminated at the upper controls, next to the override button. The interrupt system
is only operational when the upper controls are selected, and the operation ofthe lift can still be performed
from the lower controls, although the usage time should be kept to a minimum during an interrupt
condition.
TRAVEL ALARM (OPTION)
The travel alarm signals forward or reverse movement ofthe CONDOR®. This is accomplished
by a pressure switch located in the brake line and senses brake pressure (brake released), thus closing the
switch and energizing the alarm.
HOUR METER (OPTION)
The hour meter is used to monitor the "run time" of the unit, which is reflected by the actual
running of the pump motor itself. The hour meter is powered by the circuit which controls the pump
solenoid when operated from either the upper, or lower controls, therefore the meter only runs when the
pump motor runs. The meter does not run during lowering of the platform.
MOTION ALARM (OPTION)
The motion alarm signals both raising and lowering of the platform. This is accomplished
through the use oftwo diodes, one for the pump solenoid circuit (similar to the hour meter circuit) and
another diode for the holding valve circuit.
DESCEND ALARM (OPTION)
The descend alarm signals descent of the platform only, and does not require the use of any
diodes. The alarm is powered by the holding valve circuit and will sound as long as the holding valves
are energized, even though the platform may not actually be lowering (valve spool barely shifted resulting
in microswitch activation but no fluid flow past the spool).
110 VOLT LINE TO PLATFORM (OPTION)
The CONDO R® 3160 can be equipped with a 110 vo lt AC receptacle at the upper contro Is, next
to the lift valve lever, and an extension cord pigtail in the belly pan, which would allow small electric tools
or lights to be operated from within the platform. The male pigtail should be connected to a suitable AC
power source such as that which the battery charger is connected to. While the platform can be raised
or lowered when using the 110 volt outlet, it is not recommended that the machine be driven while the
supply cord is connected to the pigtail to prevent any damage to, or accidental disconnecting of the cord.
MANVAL 92277-002
JUNE 1996
•
5° SLOPE SENSOR/ALARM (OPTION)
The optional slope sensor system consists of a multi -axis level sensor, a slope alarm, and a limit
switch (for early 3160 models). The purpose ofthe system is to notify the operator when an out-of-Ievel
condition exists, by sounding an alarm. The functions are not inhibited when in this condition to allow
the operator to reverse the direction of travel to bring the unit back to a level condition. The sensor is
mounted to the base ofthe belly pan and is adjusted to "level" when the chassis is on a level surface. The
alarm is mounted at the upper controls. The sensor is supplied 24 volts when the upper/lower selector
switch is placed in the upper position. When the CONDOR® is driven to an out-of-Ievel condition of
5° or more, the sensor turns on, thus grounding the alarm which has 24 volts supplied to it. Essentially,
the sensor completes the ground circuit for the alarm when positioned 5° or more out-of-Ievel. The early
3160 models which also incorporate a limit switch will not be active until the platform is raised
approximately 6 feet. The 24 volt circuit to the alarm is connected to the normally closed contacts of the
limit switch and therefore breaks the circuit when the platform is stowed or raised up to approximately
6 feet. Once the limit switch closes, the supply circuit to the alarm is complete and the system is ready
to notify an out-of-Ievel condition. Regardless of model, both systems will energize the sensor when in
the upper control mode, but the later models alarm may sound regardless of platform position when an
out-of-Ievel condition exists.
BATTERY CONDITION INDICATOR (OPTION)
The optional battery condition indicator, located at the upper controls, measures the voltage of
the 36 volt system and provides a "state of charge" reading for the operator. This indicator is connected
directly to the batteries through a 3 amp circuit breaker, and is not switchable so it will remain on at all
times, however its amp draw is relatively low and not a concern for battery drain.
MANUAL 92277-002
JUNE 1996
BEACON/STROBE OPTION
GROUND
NEG
36 VDC
BATTERY
HYD PUMP
'"w~
"uP"
PLATFORM RAISING
L.::.LO::.:W.:.:E",R---<>-__
RED
<r.c"D'"""O'"""W"'N'""---f--.---------<;>-'1r<>---4 PLATFORM LOWERING
BLK
BA TTERY
CHARGER
&-1,-0---.... SEE NOTE 3
3A CIRCUIT BREAKER
f-------+ MOTION ALARM OPTION
~--------4'FLJEL'
EMERGENCY
f----4
~
OPTIONAL BATTERY
GAGE
DESCEND ALARM OPTION
JL~-~-~Y
R2
CONDITION INDICATOR
SEE NOTE 4
6
I
SEE NOTE 5
~------------------~RE~D~ S"
BLK
SEE NOTE 4
o
SLOPE ALARM OPTION
LOW VOLT SENSOR
R-.
\..V
LOW VOLT OVERRIDE
SLOPE SENSOR OPTION
SEE NOTE 4
} - - - - - - + LOW VOLT WARNING
R2
SEE NOTE 6
L-_ _ _~"'- ,'---------------1 HORN f - - - - . TRAVEL ALARM OPTION
= GROUND
NOTES:
1. THIS SCHEMATIC IS STANDARD FOR MDL3146, MDL3154,
AND MDL3160 SCISSOR LIFTS. REFER TO DIAGRAM 54356.
2. SWITCH ACTIVATED BY VALVE LEVER IN PLATFORM.
3. SECOND HOLDING VALVE, ON MDL3160 ONLY.
4.
THRU (j) REPRESENT TERMINALS OF OPTIONAL LOW
VOLTAGE WARNING/INTERRUPT SENSOR/SWITCH.
5. LIFT LIMIT SWITCH IS SHOWN W1TH PLATFORM ALL THE WAY DOWN.
6. PRESSURE SWITCH SENSES BRAKE RELEASE PRESSURE.
CD
WACO, TEXAS
6846
ttjj7~88~8tJ/~2B'Z/9~5~~;.:;.~;;~;;~~
>-",+,,-",,'
,,'+6;c1;;15!,:19~4+:2'RA:::K~
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5547
7/9/9] RAK
SCHEMATIC, 3146/60 ELECTRICAL
F"+"::='.=-I--"'=-"""-E':"-I==-_---"J·--'C"'A"RM""C"A"l-+"'I"''''''iO''1'
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TOlERANCES ON:
.1998
7/6/9~
RAK
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X:::'~D
*1/18
SiZE
DRAWING NO.
54.3 5 5
D
CHEQ<;W
RAK
7/6/9;:; SCALE 1/1.5
1 OF 1
SEE NOTE 5
---O~TI:l
LOW VOLT
WARNING/
I
INTERRUPT
I
i
I
r+-1
OPTION
L
SEE NOTE 4
BLK--o---').,-o-~T
OVERRIDE
LOW VOLT
FOOT
HOLD
VALVE
~
»
~~
I
~
"UP"
---11'
[/)
tn
t:l
'~IS
" , N c::::
0
0
N
-'"'"
-<:
BEACON\STROBE
OPTION
~l_
-----O--LoWER'Q I
00.
O'\~ t""'
UPPER
j
~
---------c~-
---~
~~OR
EMERGENCY
'--+l------f-------<:!: STOP
lOA
CIRCUIT
BREAKER
0-,
RED
6V
115 VAC
NOTES;
2
3
SWITCH ACTIVATED BY VALVE LEVER.
LIFT LIMIT SWITCH SHOWN WITH PLATFORM ALL THE WAY DOWN.
THIS DIAGRAM IS STANDARD FOR MODELS 3146, 3154 & 3160
REFER TO SCHEMA TIC 54355
4. ONE VALVE COIL SHOWN FOR MDL3146 & MDL3154;
MDL3160 HAS TWO HOLDING VALVES.
6V
6V
0+_B_LK_ _ _ _ _ _ _ _ _ _._ _ _ _ _ _ _ _ _ _ _ _ _ _- - '
PUMP
REC
l'H
:0
EMERGENCY
R3-A
24C 24C 24C
~-f--I
24A
20A
0\.9
B_=-:24"'D'----_ __ i ; STOP
•
CHARGING LIGHT OPTION
HOUR METER OPTION
8A
POS
PLATFORM RAISING
8A
-'
_"l~J~P_"
GROUND
+24VOL T TAP
24
FUSE
____~__.__i
111111111111111111111111111111111111
R1
8B
18
8A
7A
.,.STOP
:\
&-
MOTOR
HYD PUMP
BLK
BATTERY
CHARGER
tTl
G
(")
PLATFORM LOWERING
"DOWN"
EMERGENCY
36 VDC
BATTERY
NEG
(")
::T'
(I)
DESCEND ALARM OPTION
8
2J
9-~;>-----'-~ SERIES/PARALLEL VALVES
WHT
OPTIONAL BATTERY
CONDITION INDICATOR
"FUEL'
GAGE
f, :
CREEP SPEED VALVE
SLOPE ALARM OPTION
Be
~3--------------------------------------~R~E~D~5·~B~LK~~ SLOPE SENSOR OPTION
~
11
LOW VOLT SENSOR
3
}---~
5C~--------------1~O~----------_i
.....
-Z
115 VAC PLUG
RELAY FOR 36V OPTIONS
LOW VOLT ALARM OPTION
1.0
0
0
OPTIONAL CHARGING
CUT-OUT RELAY
?,o
~
TRAVEL ALARM OPTION
GROUND
0
14=WHT=NEUTRAL
10 01
)-------------------------------------------------------~ STROBE LIGHT OPTION
NOTES:
1. THIS SCHEMATIC SUPERCEDES 54996.
2. SWITCH ACTIVATED BY VALVE LEVER IN PLATFORM.
3. LIMIT SWITCH SHOWN WITH PLATFORM BELOW 7'
4.
THRU (j) REPRESENT TERMINALS OF OPTIONAL LOW VOLTAGE WARNING/INTERRUPT SENSOR/SIIHCH.
0
UJ
SEE NOTE 5
=
[/)
(I)
SIGNAL HORN OPTION
3D
~
'"I
II)
SEE NOTE 4
LOW VOLT OVERRIDE
SEE NOTE 4
} -_ _ _-'-1.<c
2 _ _ _ _ _ _ __iB
.....
(")
GRN
~-------------------_iR2f___--~
3
II)
SEE NOTE 4
FAST/SLOW DRIVE SPEED
2 -__________________________________________-o-'~~
+-"3____--1 HOR N
(")
II)
3A CIRCUIT BREAKER
3 ~~o-",5-!-!--<~_-J---,7~I:__l---l
SEE NOTE 3
::t
.....
[ /)
,-- -----,
LSE~NOTE
RED
MOTION ALARM OPTION
0=
15=BLK=UVE
16=GRN=GROUND
~
WACO,
SCHEMATIC,
"'"'"-E
TEXAS
3146/60
ELECTRICAL
.........,......",-..
~1/r ~::i:gj'o
CD
110 VOLT EXTENSION
TO PLATFORM OPTION
tIll"
A.HITTLE 04/11}9&
5315
RAK 04/17/95
B
SCALE
DRAWING NO.
55060
NONE
1 OF 1
-<
(I)
CABLE
#
GRN
HORN
2
OPTION
3
WHT
RED
4
BLK
5
ORN
BLU
I
3
J:
18
0 DO
r---J~
tm
~
EMERGENCY STOP
SWITCH
fIr--
0 0
0
i<-
SEE NOTE 2
1
,--0
LOWERING
SWITCH
;\
SEE NOTE 2
~
r
~
6=8LU
12-BLK WHT
SA WHT
l=GRN
9
GRN BLK
ORN/BlK
11
-.@--'-
BLU BlK
BlK WHT
13
J
~
SA HERY CONDITION
~
"
~
HORN
SA-ORN
2
WHT
"j
"B
WHT
REO
ORN
RED BLK
GRN BLK
ORN BlK
BLU
0
CONTROL CABLE TO TERMINAL BOARD ON CHASSIS
CONTINUED ON SHEET 2
LK
BlK WHT
6
+
7
To
F=ff
F,t
FIT
Fit
~
ttl!
r!Fit
8lK
GRN
STROBE LIGHT OPTION
POWER TO LOWER CONTROLS
154247-042.00
55
"
,
Ii!
i'i
1.00
EA
1,00_
EA
~
CABL
ASSY.
CABL
ASSY. 15
CABL
ASS'
~
62-,",,'~
154247-0075.5
154247-0047.5
1.00
154247-00.".5
CABL
.00
CABL
1.00
CABL
CABL
CABL
1.00
154247-0047.5
52 154247-005.75
51 154247-007.25
1.00
5.00
5.00
41
RE
REI
21 155062
155062-002
20 155062-001
1.00
1.00
1.00
1.00
19 166751
18 134552-016
1.00
1.00
7295-0."
16 150089
15
123-001
1.41
ASSY.
1/2" BATTERY
" BAnERY
ASSY."
ASSY, 5 1/4" BATTERY
ASSY,
1/4' BATTEI
1110 VC
EX
OPTION
BLK
ORN
5
Bll)
WHT BLK
NEUTRAL
LIVE HOT
GROUND
~
54
OPTION
OPTION ..
RED
~
4
~
WHT
BLK
GRN
ROT swnCH
GRN
WHT
2
14
15
SLOW/FAST
'IT ,"'" {
OPTION ..
OPTION
OPTION
NOT USED
rJ
IB
1
lOW VOLT ALARM
3
56
[.![2
SLOPE ALARM
SIGNAL HORN SWITCH
LOW VOLT a'RIDE
:;?
4::::BLK
PUMP "ON"
HOLD VALVES
SPARE, OR GAGE
OOWN
10=ORN/SLK
5A=WHT
GRN
WHT/BlK
RED/BlK
17
18
SLOPE
ALARM
OPTION
SWITCH
UP
7
16
INDICATOR OPTION
CONTROLS
POWER TO UPPER CONTROLS
CREEP SWITCH/VALVE)
10
9=GRN/BLK
FOOT
7=WHT/BLK
8-REO/BLK
LOWER
SPEED LIMIT SWITCH
8
12
&
UPPER
DESCRIPTION OF CIRCUIT
SPARE, OR GROUND FOR OPTIONS ..
FAST 5 P VALVES
I,
"~J
6
LOW VOLT
O'RIDE
11=BllJ/BLK
BETWEEN
COLOR
1
SIGNAL
BLU
WHT BLK
RED BLK
GRN BLK
ORN BlK
BLU BLK
BLK WHT
WHT
BLK
OPTIDNAL 110 VOLT
EXTENSION CORD
GRN1
TERMINAL
STRIP ON
TO[BOARD
OF PL TFRM
15=LlVE=BLK
16-GROUND-GRN
, 4-NEUTRAL-WHT
~
SEE NOTE 3
\
~
.00
lEA
CABL' Kr 3160
TTERY
CABL' Kr 3146 BATTE
lOT S,"TeH W/GUARO • CABL
.00
.00
lEA
.00
.00
lEA I FUSE HOLDER
lEA 15TRIP, TER"INAL
CABL
16GAGE/B CONDUCTOR SJC
CONNEC~'E
lEA ISEAL
I
~
037
1.'
11
0'"
10 134552-01:
B
Z
1.088c
150075
I 322-00015-OC
.). ITEM 20 CONSISTS OF ITEMS 51-56.
""
1-
""
7/M'
lEA 15WITCH LI"'T BODY ONL
lEA 'TRIP, TERMINAL
lEA ;oARC TOGGl: ,,"T,," "'CRO
.00
1.00
lEA I'''TCH (REF PIN 7760)
lEA IMOTOR ELECTRI~
I
1.00
lEA 10PERATOR, 'POS ROT KEY ZBZ-BG.'
lEA I BATTERY. 6 VOL
CABLE, 16GA/B CONDl CTOR
I GABl , 16GA/B CONDUGTOR
6.00
65.00
6C.00
.00
OT
I~M~" .~:;,~"~
I~=w
.00
.00
.00
.00
6.0C
RAK
lEA I OFFSE r HEAD LI"IT SWITCH
1.00
1.00
I
I
.00
.00
.00
152671
'''' ,
1. THIS DIAGRAM SUPER CEDES 54356.
2. LOWERING SWITCH AND EMERGENCY STOP SWITCH ARE PART OF UPPER CONTROL BOX ASSY.
.00
150046
167295-02.'
167295-023
I.""
lITEM IPART NU"BE
NOTES:
.00
1.00
lEA CHARGER, BATTERY ,""'C/4DA
IUM I DESCRIPTION
~
;:;~RINe
owe,
WACO,
TEXAS
3146/60
CI~'-'"' 55062
ELECTRICAL
11
CONTROL CABLE TO TERMINAL STRIP ON PLATFORM
CONTINUED ON SHEET 1
NOTE 2
2
REF
TERMINAL
BOARD
9=GRN/BLK
3=RED
6=BLU
7A
B=RED/BLK
7A
7=WHT BLK
5=ORN
~
NC
CREEP
SPEED
VALVE
1=GRN
DRIVE SPEED VALVE
2=WHT
:~
6 PL
10=ORN BLK
HOLDING
VALVE
ON CYLS
SEE NOTE 1
NOTES:
PRIlPI'IETAIIYINFQIOIoIAl1ON
1. MOL .3146 HAS ONLY ONE HOLDING VALVE. MDU160 HAS TWO.
.3.
THRU (j) REPRESENT TERMINALS ON OPTIONAL LOW VOLT SENSOR/SWITCH.
CD
~
~~:i~iir~";! T'll~~
~
~O"~
A.HITTLE 04/21,"
WACO, TEXAS
WIRING DWG, 3146/60 ELECTRICAL
C
ORAMNC NO.
55062
E
~_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _'''_~'"_'~_''OO_E_ _ _ _ _'~_'_ _~ED
•
NOTES
MANUAL <XI.277-002
JUNE 1996
BATTERY SERVICE
•
BATTERY SERVICING TOOLS
Use proper tools when performing battery service to prevent damage to battery, cables, terminals and
hold-downs, and to save time and energy.
Suggested battery tools and their use are described below.
FILLING DEVICES
One of the most important routine battery service for conventional batteries is to maintain the
correct electrolyte level. Two devices are available for this purpose, a self-leveling filler which fills the
battery to a predetermined level automatically, and the syringe type. Battery cells should never be filled
above the level indicator. Do not squeeze the syringe so hard that the water splashes acid from the cell
opening.
SCRAPER AND WIRE BRUSH
The scraper and wire brush can be used for removing dirt, corrosion and rust from various parts
such as the battery posts, battery tray, the hold-down and the hold-down bolts.
BATTERY CARRIER
A battery carrier should not place any undue strain on the battery terminals or the container. An
excellent carrier for plastic cased batteries is a clamp ("ice tong") type carrier with rubber pads which grip
the SIDE WALLS ofthe container just below the lip of the cover. It is used on the side walls rather than
the end walls, since the side walls have additional strength from the inner cell partitions. Gripping the
flexible end walls of plastic containers could cause electrolyte to spew from some of the cells.
DANGER
,
Lead acid batteries generate highly explosive hydrogen gas especially during the
charging cycle. To AVOID the possibility of an explosion, charge batteries ONLY
in a well VENTILATED AREA. Keep fire, sparks, and burning material away from
the charging area. Do Not smoke near a battery, and always shield the eyes when
working near a battery.
MANUAL 92277-002
JUNE 1996
SERVICE PROCEDURES
The user should realize that the battery is a perishable item and requires periodic attention. With a
reasonable amount of care, the life of the battery can be appreciably extended. Neglect and abuse will
invariably cause shorter life.
Routine servicing of the battery should proceed as follows:
First, make a visual inspection for defective cables, loose connections, corrosion, cracked cases
or covers, loose hold-downs and deformed or loose terminal posts. Ifany parts such as cables, hold-downs
or the battery appear to be unserviceable, it is recommended that they be replaced.
When there is corrosion on the terminal posts or hold-down, the tray or hold-down parts are rusty,
or the battery is very dirty, it is recommended that time be taken to clean the parts. A wire brush can be
used to remove dirt, corrosion or rust from parts. Clean dirt from the battery top with a cloth wetted with
ammonia or baking soda in water.
Next, wipe with a cloth with clearwater. After rust is removed from a part with a wire brush, rinse
with clear water, dry and paint with an acid-resistant paint.
If corrosion is found on the terminal posts, remove the cable terminals from the battery (ground
cable first), using the proper end wrench. A wire cleaning brush can be used to clean the posts and the
mating surfaces ofthe cable clamps. Connect the cables to the terminal posts (ground cable last). Coat
the terminal connections with a spray corrosion inhibitor or high temperature grease.
The second item in routine servicing of conventional batteries is to check the electrolyte level in
all cells. If necessary, add clear, odorless, mineral free water to bring the liquid level to the level indicator
in all cells. If the battery does not have a level indicator, bring the level to 112" (13mm) above the tops
ofthe separators. Do not overfill any cell. When a cell is overfilled, the excess electrolyte may be forced
from the cell by the gas formed in the battery. This will cause excessive corrosion of adj acent metal parts,
reduced performance and shorter life.
MANUAL 92277-002
JUNE 1996
BATTERY TESTING
•
Battery testing should be considered an integral part of periodic equipment maintenance and should be
performed whether or not a starting problem has occurred. Servicing the battery in the equipment as
described will help prevent premature battery failure from external causes and periodic battery failure
from both external and internal causes or merely from the battery reaching the end of its useful life.
STEP 1 - VISUAL INSPECTION
F or protection, wear a face shield. First, visually inspect the battery. Check for container, cover
or terminal damage that might cause leakage ofelectrolyte or internal damage. If serious damage is found,
replace the battery. Check the electrolyte level in each cell. Ifbelow the tops ofthe plates in any cells,
fill all cells with water to just above the tops of the separators and charge for 15 minutes at 15-25 amps
to mix the water with the electrolyte. If electrolyte levels are above the tops ofthe plates, continue to Step
2.
STEP 2 - HYDROMETER TEST
Using the hydrometer, measure and record the specific gravity (sp. gr.), corrected to 80 degrees
F (26.7 C) ofthe electrolyte in each cell. Ifthe range (highest-lowest) is 50 points (0.050 sp. gr.) or greater
orthe lowest is less than 1.225 sp.gr., charge the battery atthe recommended rate or until all cells are 1.225
sp.gr. or greater and the range is less than 50 points. If no amount of charging will achieve these
conditions, replace the battery. Ifthese conditions are achieved, apply a 150 amp load for 15 seconds to
remove the surface charge on the battery and continue to Step 3.
The average state ofcharge ofthe cells in a battery can be determined by measuring the stabilized
voltage ofthe battery. The voltage is stabilized ifthe battery has been on open circuit overnight or for
a period of several hours. A voltage reading of 12.4 (6.2 on a 6 volt battery) is equivalent to a specific
gravity of 1.225. The disadvantage of measuring the open circuit voltage is that a lower voltage cell can
be masked by the remaining cells. Ifthe cell connectors are accessible for voltage measurements, a range
of 0 .05 volts between the highest and lowest cells corresponds to a 50 point variation in specific gravity.
A cell voltage of2.07 is equivalent to a specific gravity of 1.225.
MANUAL 92277·002
JUNE 1996
•
NOTES
MANUAL 92277-002
JUNE 1996
PREVENTIVE MAINTENANCE
In conjunction with the pre-operation inspection, a good preventive maintenance program will ensure
a properly operating CONDOR®. This section is directed toward those items of maintenance which
the operator should be aware of, and which may be accomplished prior to the operation of the equipment. Refer to the "Preventive Maintenance Daily Inspection" and the "Preventive Maintenance 50
Hour Inspection" for detailed inspection procedures. Included in this section are checklists, for the
Daily and 50 Hour Inspections, to assist in maintaining the CONDOR®. Please note that on the 50
Hour Inspection, some items may be stated as 500 Hours, where applicable.
LUBRICATION
NOTE:
Recommended lubrication intervals are based on normal use in
normal environmental conditions. The operator is cautioned to
adjust the lubricating interval accordingly to meet each individual
condition and usage. The recommended lubricants are generally
the best choice. Should these lubricants be unavailable in your area,
consult your local supplier for an equivalent.
Under NO circumstances should lubricant
containing "Lithium" be used.
1.
Wheel Bearings
Lubricant:
Wheel bearing grease.
Time Interval:
Every 500 hours of operation or yearly, whichever comes first
--or upon disassembly.
Procedure:
Raise chassis and support. Remove fixed axle wheels. Remove
outer dust cap, spindle nut, and washer. Remove outer cone
bearing, hub, dust seal and inner cone bearing. Clean cone
bearings and races, and inspect both for physical damage
(pitting, etc). Inspect spindle for bending, cracked welds, or
other physical damage.
IMPORTANT: If damage is evident, remove the CONDOR®
from service until the spindle assembly is replaced, and contact
the Condor Service Department to report the damage.
Repack cone bearings using fresh wheel bearing grease, install
new dust seal, then reassemble components in reverse order of
disassembly. Tighten spindle nut until hub will not tum, tum
spindle nut counterclockwise one castellation, or until cotter
pin will pass through spindle and spindle nut. Secure cotter
pin, ensure that hub will rotate. Reinstall wheel assembly;
torque wheel nuts to 120 ft lbs.
MANUAL 92277-002
JUNE 1996
•
2.
Hydraulic System
Fluid Level:
Check level daily. Maintain fluid level at full mark on sight
glass with platform in stowed position.
Return Filter:
Replace factory-installed filter element after first 50 hours of
operation. Thereafter, replace filter every 500 hours of
operation.
Tank BreatherlInlet Screen:
If equipped, clean every 50 hours of operation. Remove from
tank and clean with solvent; air blow-dry.
Hydraulic Tank:
Drain oil from tank and replace annually. Add oil to required
level using only Shell Tellus T-32 or equivalent.
Suction Strainer:
Drain oil from tank and replace strainer annually. If operating
in dusty or harsh conditions, inspect filter more frequently and
replace if necessary.
DO NOT MIX HYDRAULIC OIL
3.
Battery Servicing
FOR PROTECTION WHEN SERVICING BATTERIES,
AL WAYS WEAR A FACE SHIELD.
Visual Inspection:
Inspect for defective cables, loose connections, corrosion,
cracked or swelling cases or covers, loose hold downs, and loose
or deformed terminal posts.
Cleaning:
When needed, a wire brush can be used to remove rust, corrosion, or dirt from terminal ends or posts. The battery top can be
cleaned with a cloth wetted with ammonia, or baking soda with
water, then wiped with a cloth and clear water.
Electrolyte Level:
Check electrolyte level daily. Ifnecessary, add electrolyte or
clear, odorless, mineral free water to bring the level to 112" above
the top ofthe separators, or to the level indicator (if equipped),
in each cell.
MANUAL 92277-002
JUNE 1996
PREVENTIVE MAINTENANCE INSPECTION
•
This field inspection list provides for a systematic inspection of the CONDOR®. The items listed to be
inspected or checked daily will ensure proper unit performance prior to operation. By following the
daily inspection procedure on a regular basis, any potential malfunction will be identified before it can
become a major problem. The 50 Hour Inspection will detect any defective, damaged, or improperly
secured part. The 50 hour Inspection also includes items requiring attention at 500 hours or yearly
which, are indicated where applicable.
The time interval of 50 hours applies to normal operation under normal conditions. Should the
unit be subjected to extensive use or abnormal environmental conditions, the inspections should be
made more frequently. Condor recommends that a maintenance log be maintained, and that abnormal
conditions of any kind be recorded. To help assist in starting a maintenance log, there are inspection
checklists included after each inspection list. These are intended to be used with the field inspection
lists to help gain familiarity with the repetitive tasks.
DAILY INSPECTION
A.
B.
VISUAL INSPECTION
Overall Condition:
Inspect platform, armstack, and carriage to make certain that
no physical damage is evident. Look for missing components
and hardware, loose components, etc.
Tire Condition:
Inspect tires for wear, cuts, and abrasions.
Battery Cable Connections:
For protection, wear a faceshield. Inspect for swelling of
battery sides, tightness and corrosion of terminals. If corrosion
is present, remove cables from the battery (ground cable first).
Clean terminals and posts with a wire brush and reconnect to
battery (ground cable last). Coat the terminal connections with
a spray corrosion inhibitor, or high temperature grease.
Hydraulic Fluid Leaks:
Inspect to ensure that there is no evidence of leaking hoses or
fittings.
Decals and Placards:
Verify that all decals and placards are in place and are legible.
It is recommended that any decals or placards which are tom,
damaged, missing, or painted over, be replaced.
FLUID LEVEL CHECK
Hydraulic Tank Level:
Iflow, add hydraulic oil as required to maintain level at full
mark on sight glass, with platform in stowed position.
Battery Electrolyte Level:
For protection, wear a faceshield. Check electrolyte level and
add electrolyte or clear, odorless, mineral free water as required
to bring the level to 112" above the tops of the separators in
each cell.
MANUAL 92277-002
JUNE 1996
--
C.
OPERATIONAL TEST
Instrument Check
Hour Meter:
(Option)
Ensure that meter is recording properly.
Battery Condition Indicator:
(Option)
Ensure that indicator is monitoring the batteries state-ofcharge properly.
Ground Control
Operation Check
Emergency Stop Button:
Ensure that machine will not operate with button pushed in.
Check that button maintains its in or out position.
Control Selector Switch:
Ensure that switch controls the selection of "UPPER or
LOWER" properly. Make certain that machine will not
operate with switch in its center position.
Lift Control Function:
Check that switch, and valve lever both return to their normal
position when released, and that lift/lower function is working
properly.
Platform Control
Operation Check
Emergency Stop Button:
Ensure that machine will not operate from upper controls with
upper emergency stop button pushed in. Check that button
maintains its in or out position.
Lift Control Function:
Check that lever returns to its normal position when released,
and that the lift/lowering of the platform functions properly.
Make certain that lift/lower function does not operate unless
footswitch is depressed.
Drive/Steer Functions:
Depress footswitch and operate drive and steer functions.
Drive Speed Selection:
Ensure that each speed selection (either by electrical switch at
platform [late models], or by platform position [early models])
is functioning properly.
Slope Sensor:
Tilt sensor more than 5° (located in belly pan), and check for
audible alarm at platform controls. Controls must be in
"UPPER" mode.
MANUAL 92277-002
JUNE 1996
•
DAILY INSPECTION
MON
ITEM
~V
I
HOURS
VISUAL INSPECTION
TUES
WED
THURS
FRI
SAT
SUN
VVVVVV
Overall Condition
Tire Condition
Battery Cable Connections
Hydraulic Fluid Leaks
Battery Electrolyte Level
Verify Legibility of Decals & Placards
OPERATIONAL TEST
Hour Meter (Option)
Battery Condition Indicator (Option)
GROUND CONTROLS
Control Selector Switch
Lift Control Function
PLATFORM CONTROLS
Lift Control Function
Drive/Steer Functions
Drive Speed Selection
Slope Sensor
MANUAL 92277-002
JUNE 1996
PREVENTIVE MAINTENANCE INSPECTION
50 HOUR INSPECTION
A.
CHASSIS
Visual Inspection:
Inspect for cracks in welds, dents or bends in material.
Steering Cylinder:
Check cylinder, pins, and cotter pins holding cylinder in place
for proper installation.
Steering Tie Rod:
Check clevis bolts and jam nuts for proper installation. Check
for bends in tie rod. Check tie rod clevis' for any abnormal or
exceSSIve wear.
Steering Knuckles:
Inspect thrust bearings and pivot bushings for excessive wear.
Inspect welds for cracks in knuckle weldments and chassis yokes.
Ensure there is no binding throughout range of travel.
Wheels:
Check for loose or missing lug nuts, loose hub assemblies (fixed
axle), and damaged or cracked rims.
Drive Motors:
Check motor hydraulic lines for leakage. Check wheel hub
retaining nut and cotter pin for proper installation.
Brake Assembly:
Check hydraulic lines for leakage and mounting bolts for tightness. Check for proper brake release/apply operation.
Hydraulic Hoses
and Fittings:
Inspect for leaks, cuts, and abrasions. Check fittings for tightness.
Tires:
Inspect for excessive or abnormal wear, cuts and abrasions.
Belly Pan:
Check belly pan for damage, and welds to chassis for cracks.
Check for security of components.
Battery Charger:
Inspect for damage. Verify proper charging operation.
Wiring and Electrical
Connections:
Electric Motor and Pump:
Inspect for damage, fraying or cracked insulation, tightness of
terminal ends, and proper routing.
Inspect motor and pump mounting hardware for tightness, cable
connections for tightness, corrosion, fraying, or damage.
MANUAL 92277-002
JUNE 1996
B.
ARMSTACK
Visual Inspection:
Lift Cylinder Hoses
and Fittings:
Inspect for leaks, cuts, and abrasions. Check for tightness and
proper routing.
Electrical Cable:
Inspect for fraying or cracked insulation. Check for proper
slack throughout range of movement.
Lift Cylinders:
Inspect for damage to chrome on lift cylinder rod, damage
to cylinder body, and all welds for cracks. Inspect holding
valve fittings for tightness, and valve coil and wiring for
security.
Lift Cylinder Pins and
Retaining Bolts:
Limit Switch:
Lower Electrical
Connections:
Armstack Bearing Pads
(chassis):
C.
•
Inspect cylinder pins and retaining bolts for security.
Inspect for damage to switch housing, orto arm lever. Inspect
for security of internal wiring, proper strain relief sealing, and
security of switch mounting.
Inspect wiring connections at chassis end of armstack
electrical cable for corrosion and tightness. If rust or corrosion
are present, clean with a wire brush and coat terminal connections with a spray corrosion inhibitor or high temperature grease.
Inspect for binding, cracking, pitting, or abnormal wear. Clean
any dirt or debris from pad slide area. If binding or chatter is
present during movement, lubricate sliding surfaces with antiseize compound.
PLATFORM
Visual Inspection:
Platform Pivot Shafts and
Retaining Bolts:
Inspect security of retaining bolts and pin.
Platform Bearing Pads:
Inspect for binding, cracking, pitting, or abnormal wear. Clean
any dirt or debris from pad slide area. If binding or chatter is
present during movement, lubricate sliding surfaces with antiseize compound.
Platform Entrance Chain:
Inspect for damage.
MANUAL 92277-002
JUNE 1996
C.
PLATFORM (cont'd)
Footswitch:
Inspect for damage. Ensure that pump turns on when depressed
(must be in "upper" mode).
Electrical Cable Connections: Inspect for damage, fraying or cracked insulation, and proper
routing.
Manual Storage Tube:
D.
Inspect for damage and security. Ensure that cover or end caps
provide a watertight seal and that operator's manual is inside.
GROUND CONTROLS
Visual Inspection
E.
External:
Inspect for damage to any guards/covers. Ensure that all applicable decals are in place and are legible.
Internal:
Inspect for tightness of mounting of all related components.
Inspect for any visible damage.
PLATFORM CONTROLS
Visual Inspection
External:
Inspect for damage to enclosure or controls. Ensure that all
applicable decals are in place and are legible, and that lift lever
guard is in place and secure.
Internal:
Inspect for tightness of wire ends at all locations. Ensure that
valve and electrical components are securely mounted.
MANUAL 92277-002
JUNE 1996
•
50 HOUR INSPECTION
MON
ITEM
I
rz /
HOURS
CHASSIS
TUES
WED
THURS
FRI
SAT
/ / / / / /
Visual Inspection
Steering Cylinder
Steering Tie Rod
,
Steering Knuckles
Wheels
Drive Motors
Brake Assembly
Hydraulic Hoses and Fittings
Tires
Belly Pan
Battery Charger
Wiring and Electrical Connections
Electric Motor and Pump
ARMSTACK
Visual Inspection
Lift Cylinder Hoses and Fitting
Electrical Cable
Lift Cylinders
Lift Cylinder Pins and Retaining Bolts
Limit Switch
Lower Electrical Connections
Armstack Bearing Pads (chassis)
PLATFORM
Visual Inspection
MANUAL 92277-002
JUNE 1996
SUN
50 HOUR INSPECTION
(cont'd)
MON
ITEM
TUBS
WED
THURS
FRJ
SAT
SUN
Z / / / / 1/!//
I
HOURS
PLATFORM (cont'd)
Platform Pivot ShaftslRetaining Bolts
Platform Bearing Pads
Platform Entrance Chain
Footswitch
Electrical Cable Connections
Manual Storage Tube
GROUND CONTROLS
Visual Inspection--External
Visual· Inspection--Internal
PLATFORM CONTROLS
Visual Inspection--External
Visual Inspection--Internal
MANUAL 92277-002
JUNE 1996
HYDRAULIC OIL SPECIFICATIONS
FOR
CONDOR® AERIAL WORK PLATFORMS
Tellus - T32 Hydraulic Oil
Viscosity
SUS@ 100°F
SUS@2100F
155
47
Viscosity Index
Typical
154
Flash Point of
325°
Pour Point of
-54°
COLD TEMPERATURE OPERATION
For continuous operation in subzero temperatures, an oil change is required. We recommend the
following oils.
A)
Conoco DN-600 Antiwear Hydraulic Oil
Manufacturer: Continental Oil Co., Houston, Texas
B)
Sun Low Temperature No.3 Hydraulic Oil
Manufacturer: Sunoco, Inc., Toronto, Ontario, M5S 2S4, Canada
C)
Oil Conforming to MIL-H-5606C Specifications.
Examples: Chevron Aviation Hydraulic Fluid-C
Shell L.O. Hydraulic #23
MANUAL 92277-002
JUNE 19%
•
NOTES
MANUAL 92277-002
JUNE 1996
APPENDIX A
BOLT TORQUE CHART
NOMINAL
THREADS
BASIC STRESS
TENSILE STRENGTH (T) MIN
MAJOR AREA
SQ. IN
INCH
PROOF LOAD (P)
SAE GRADE (1957)
GRADES
liRADE8
DIA
T
p
T
SAE GRADE 5
LAMP
LOAD
LBS.
P
ASSEMBLY TORQUE
R-.ZOODRY
-.ISOLUB
SAEGRADE8
CLAMP
LOAD
LBS.
ASSEMBLY TORQUE
R-.ZOODRY
-.ISOLUB
4-40
.IIZO
.00604
IZOKS]
8SKS]
ISOKS]
IZOKS]
380
8LB-IN
6LB-IN
S40
IZLB-IN
9LB-IN
4-4/S
o-J1.
0-4U
.l1Z0
.00661
IZOKS]
8SKS]
ISOKS]
IZOKS]
4Z0
9LB-IN
7LB-IN
600
13LB-IN
10LB-IN
.1380
.00909
IZOKS]
8SKS]
ISOKS]
IZOKS]
S80
16LB-IN
IZLB-IN
8Z0
Z3LB-IN
17LB-IN
.1380
.0101S
IZOKS]
8SKS]
ISOKS]
IZOKS]
640
18LB-IN
I3LB-IN
920
ZSLB-IN
19LB-IN
8-32
.1640
.01400
IZOKS]
8SKS]
ISOKS]
IZOKS]
900
30LB-IN
ZZLB-IN
IZ60
4ILB-IN
3ILB-IN
IS-Jo
IU-1.4
IU-J1.
.1640
.01474
IZOKS]
8SKS]
ISOKS]
IZOKS]
940
3ILB-IN
Z3LB-IN
13Z0
43LB-IN
3ZLB-IN
.1900
.017S0
IZOKS]
8SKS]
ISOKS]
IZOKS]
IIZO
43LB-IN
3ZLB-IN
IS80
60LB-IN
4SLB-IN
.1900
.OZOO
IZOKS]
8SKS]
ISOKS]
IZOKS]
IZ8S
49LB-IN
36LB-IN
1800
68LB-IN
SILB-IN
l/4~1.U
ZSOO
.03180
IZOKS]
8SKS]
ISOKS]
IZOKS]
ZOZO
8LB-FT
7SLB-IN
Z860
IZLB-FT
9LB-FT
IOLB-FT
l/4~1./s
ZSOO
.03640
IZOKS]
8SKS]
ISOKS]
IZOKS]
Z3Z0
10LB-FT
86LB-IN
3Z80
14LB-FT
~/10-1/s
.3IZS
.OSZ40
IZOKS]
8SKS]
ISOKS]
IZOKS]
3340
17LB-FT
13LB-FT
4720
ZSLB-FT
18LB-FT
~/ 10-1.4
.3IZS
.OS800
IZOKS]
8SKS]
ISOKS]
IZOKS]
3700
19LB-FT
14LB-FT
SZZO
ZSLB-FT
ZOLB-FT
J//S-l0
J//s-1.4
//1/-14
.37S0
.077S0
IZOKS]
8SKS]
ISOKS]
IZOKS]
4940
30LB-FT
Z3LB-FT
7000
4SLB-FT
3SLB-FT
.37S0
.08780
IZOKS]
8SKS]
ISOKS]
IZOKS]
S600
3SLB-FT
ZSLB-FT
7900
SOLB-FT
3SLB-FT
.437S
.10630
1Z0KS]
8SKS]
ISOKS]
IZOKS]
6800
SOLB-FT
3SLB-FT
9SS0
70LB-FT
SSLB-FT
.437S
.11670
IZOKS]
8SKS]
ISOKS]
IZOKS]
7SS0
SSLB-FT
40LB-FT
10700
80LB-FT
60LB-FT
.SOOO
.14190
IZOKS]
8SKS]
ISOKS]
lZOKS]
90S0
7SLB-FT
SSLB-FT
IZ7S0
110LB-FT
80LB-FT
.sooo
.IS990
IZOKS]
8SKS]
ISOKS]
1Z0KS]
10700
90LB-FT
6SLB-FT
14400
IZOLB-FT
90LB-FT
.S6ZS
.18Z00
IZOKS]
8SKS]
ISOKS]
IZOKS]
11600
lIOLB-FT
80LB-FT
16400
ISOLB-FT
IIOLB-FT
.S6ZS
.Z0300
IZOKS]
8SKS]
ISOKS]
IZOKS]
IZ9S0
IZOLB-FT
90LB-FT
18ZS0
170LB-FT
I30LB-FT
::>11\-11
.6ZS0
.ZZ600
IZOKS]
8SKS]
ISOKS]
IZOKS]
14400
ISOLB-FT
1l0LB-FT
Z03S0
ZZOLB-FT
170LB-FT
5/1S-11S
.6ZS0
.ZS600
IZOKS]
8SKS]
ISOKS]
IZOKS]
169S0
180LB-FT
I30LB-FT
Z3000
Z40LB-FT
180LB-FT
3/4-IU
3/4-10
.7SOO
.33400
IZOKS]
8SKS]
ISOKS]
IZOKS]
Z1300
Z60LB-FT
ZooLB-FT
30100
380LB-FT
Z80LB-FT
.7S00
7116-20
1/2-13
1/2-20
9116-12
9/16-18
.37300
IZOKS]
8SKS]
ISOKS]
IZOKS]
Z3800
300LB-FT
ZZOLB-FT
33600
4Z0LB-FT
3Z0LB-FT
7/8-9
7/8-14
.87S0
.46Z00
IZOKS]
8SKS]
ISOKS]
IZOKS]
Z9S00
SZOLB-FT
390LB-FT
41600
600LB-FT
460LB-FT
.87S0
.S0900
IZOKS]
8SKS]
ISOKS]
IZOKS]
3Z400
S70LB-FT
430LB-FT
4S800
660LB-FT
SOOLB-FT
I-IS
1.000
.60600
IZOKS]
8SKS]
ISOKS]
IZOKS]
38600
770LB-FT
S80LB-FT
S4S00
900LB-FT
680LB-FT
1-12
1 118-7
1.000
.66300
IZOKS]
8SKS]
ISOKS]
IZOKS]
4Z300
8S0LB-FT
630LB-FT
S9700
1000LB-FT
740LB-FT
1.1ZS0
.76300
10SKS]
74KS]
ISOKS]
IZOKS]
4Z300
8ooLB-FT
600LB-FT
68700
IZ80LB-FT
960LB-FT
I InS-I1.
1.1ZS0
.8S600
IOSKS]
74KS]
ISOKS]
IZOKS]
47S00
880LB-FT
660LB-FT
77000
1440LB-FT
1080LB-FT
1 114-7
1114-12
I.ZS00
.96900
10SKS]
74KS]
ISOKS]
IZOKS]
S3800
lIZOLB-FT
840LB-FT
87200
18Z0LB-FT
1360LB-FT
I.ZS00
1.0730
10SKS]
74KS]
ISOKS]
IZOKS]
S9600
IZ48LB-FT
9Z0LB-FT
96600
ZOOOLB-FT
OOLB-FT
I J//S-O
1.37S0
1.1SS0
IOSKS]
74KS]
ISOKS]
IZOKS]
64100
1468LB-FT
lIOOLB-FT
104000
Z380LB-FT
80LB-FT
13/8-12
1.37S0
1.31S0
IOSKS]
74KS]
ISOKS]
IZOKS]
73000
I 680LB-FT
IZ60LB-FT
118400
Z7Z0LB-FT
Z040LB-FT
I 111.-0
1.5000
1.4OS0
10SKS]
74KS]
ISOKS]
IZOKS]
78000
I 940LB-FT
1460LB-FT
IZ6S00
3160LB-FT
Z360LB-FT
1112-12
1.5000
1.5800
10SKS]
74KS]
ISOKS]
IZOKS]
87700
ZZOOLB-FT
I 640LB-FT
14ZZ00
3S60LB-FT
Z660LB-FT
NOTES:
1. THIS CHART SHOWS RECOMMENDED BOLT TORQUES.
2. TORQUE = R X D X T
R = .150 FOR LUB CONDITIONS
R = .200 FOR DRY CONDITIONS
TO ASSURE CONSISTENCY IN TORQUE, LUBRICATE FASTENERS WITH ENGINE OIL
(MAY BE USED OIL)
D = NOMINAL DIAMETER IN INCHES
T = DESIRED CLAMP LOAD IN POUNDS = 75% PROOFLOAD X STRESS AREA
MANUAL 9ZZ77-00Z
JUNE 1996
~
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
DRY
LUBRICAJED
DRY
LUBRICAJED
DRY
THREADS THREADS
THREADS
THREADS
THREADS
THREADS
THREADS
THREADS
M4
27.5*
17*
30*
18*
38.5*
24*
53*
32.5*
M5
56.5*
33.5*
61*
37*
78*
47*
107*
65*
M6
95*
57.5*
103*
61*
132*
79*
180*
109*
M8
19
12
21
13
27
16
37
22
MIO
39
23
42
25
53
32
73
44
M12
67
40
73
44
92
55
127
76
M14
107
64
116
69
146
89
203
122
M16
167
100
181
108
230
138
316
190
M20
325
195
352
211
449
269
617
370
M24
562
337
609
386
775
465
1066
640
M30
1117
670
1210
726
1540
924
2188
1271
DIAMETER
LUBRICAJED
MANUAL 92277-002
JUNE 1996
LUBRICAJED
MODEL 3160
(includes Models 2032,3146, and 3154)
ILLUSTRATED PARTS MANUAL
SHIPPING ADDRESS
MAILING ADDRESS
CALAVAR CORPORATION
CALAVAR CORPORATION
8300 IMPERIAL DRIVE
VVAco,TExAs76712
(817) 666-4545
P.O. Box 21447
VVACO, TEXAS 76702-1447
(817) 666-4545
MANUAL 92277-003
SEPTEMBER 1993
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® A TALL TIMES.
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
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.
regarding the operation and use of aerial work platforms. A copy of the ANSI/SIA Manual of
Responsibilities is attached for your use: ANSI/SIA A92.5-1992 is provided for BoomSupported Elevating Work Platforms, and ANSI/SIA A92.6-1990 is provided for Self-Propelled
Elevating Work Platforms.
Calavar Corporation 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.
FROM THE MANAGEMENT OF CALA VAR CORPORA TION
manufacturer recommends that replacement parts be purchased through Calavar Corporation
in order to ensure the original integrity of the product. Repairs and adjustments should only
be made by trained and qualified personnel. Please refer to the maintenance and parts sections
of the Calavar Operation, Maintenance, & Parts Manual for information on service and
maintenance of the CONDOR®.
NOTE:
Please refer to the Calavar Parts section of the Operation, Maintenance, & Parts
Manual for information pertaining to your CONDOR®.
CONDOR® SERVICE INFORMATION
1. If you need assistance or have any service or maintenance questions, Calavar 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 Calavar Service Department to anyone who requests
them.
3. Service and maintenance are not a substitute for trained, qualified service technicians.
Calavar conducts service schools on a continuing basis. Call any of our service or sales
persons for a schedule. Remember, training of mechanics is the responsibility of their
employer, but Calavar Service Schools help you provide this training.
4. Calavar 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.
CALAVAR CORPORAnON
8300 IMPmuAL DRIVE, P.o. Box 21447, WACO, TEXAS 76702-1447.817-666-4545,817-666-4544 FAX
(
Self - Propelled Booms and Scissors
WARRANTY
Calavar Corporation ("Calavar") warrants to the purchaser that each new aerial work platform made by
Calavar is free from defects in material and workmanship arising under normal use and service, in the case
of major weldments (chassis, turret and booms), for a period of 5 years after the original shipment of the
aerial work platform from Calavar's plant; and in the case of all other parts, for a period of 1 year after the
aerial work platform is first placed in service or two years after the original shipment of the aerial work
platform from Calavar's plant, whichever occurs first.
(
The obligation and liability under this Warranty is expressly limited to repairing or, at Calavar's option,
replacing free of charge, at its factory in Waco, Texas or at an authorized repair facility designated by
Calavar, the defective part. In no event shall Calavar 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 damages or loss even if
Calavar, 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 Calavar'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 Calavar or alteration or repair of the equipment by any person
not authorized by Calavar shall, at Calavars option, void this Warranty. Calavar shall have no liability or
responsibility for damages resulting from accident or the malfunction of equipment and components not
supplied by Calavar.
No agent, employee, distributor, dealer or other representative of Calavar 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 Calavar and should not be relied upon as limited
warranties of Calavar, and no attempt, effort or promise to repair equipment by Calavar 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 purchaser's form will be honored by
Calavar. This Warranty covers only new and unused aerial work platforms manufactured by Calavar.
Products or parts manufactured by others are covered only by such warranties as are extended to the
purchaser by Calavar's suppliers.
This Warranty is in lieu of all other warranties, expressed or implied, including but not limited to
warranties of merchantability 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
Form No. 513-1 M-495
Printed in U.S.A.
How to Order Parts
1.
When ordering parts for your CONDOR®, ensure that you are able to give the
model and serial numbers of all units for which parts are needed. The serial
number(s) will assist the Calavar Parts Department in providing the correct
parts for your machine(s). Please refer to FIGURE A for Serial Number Location on this model.
2.
If known, please specify the Calavar part number(s) for the part(s) you require, and always provide a complete description of all parts.
3.
Fax orders are preferable, though parts may also be ordered by mail and
telephone. A sample parts order (with fax number) follows this page.
4.
Parts needed for a warranty repair must be purchased through the Calavar
Parts Department. Credit will be authorized through the Service Department
after a Warranty Claim has been submitted to Calavar. A Warranty Claim is
to be filed for any part received as defective ".
II
5.
Calavar 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.
Calavar 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.
Stock
Order to be shipped within (1) week.
7.
Calavar 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 Calavar 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.
CALAVAR PARTS DEPARTMENT
FAX ORDER FORM
(
IPURCHASER
ACCOUNT #
C
U
S
T
I
N
F
FAX NO. 800-443-5803
SALES ORDER #
NAME
NAME
ADDRESS
0
R
M
0
CITY
A
M
T
E
I
R
PHONE
0
)
(
N
CUST. PURCHASE ORDER NO.
STATE
S
H
I
P
ZIP
FAX
(
)
I ORDER DATE
I
I
I
T
ADDRESS
0
CITY
STATE
PHONE
FAX
(
(
)
REQUEST DATE
ZIP
)
SPECIAL MARKS & NUMBERS
SHIPPING INSTRUCTIONS
PART NUMBER
QTY.
DESCRIPTION
(
"(
FOR ORDER STATUS PLEASE CHECK
APPROPRIATE BOX BELOW
EMERGENCY
STOCK
NOTES
TABLE OF CONTENTS
3160
FIGURa
10
21
22
30
31
50
51
52
70
71
72
73
74
75
76
77
TI'rLB
Final Installation
Electrical Diagram
Hydraulic Schematic
Platform Installation
Platform Control Box Assembly
Lift Installation
Lift Cylinder Assembly
Arm Stand Assembly
Chassis Installation
Drive and Brake Installation
Brake Assembly
Hydraulic Tank Assembly
steering Installation
Battery Installation
Pump Asseably
Ground Control Assembly
FIGURE 10 FINAL INSTALLATION
!
1 REF
,:
~
3
'~45
:
~~
~
®
6
FIGURE 10 FINAL INSTALlATION
I
T
E
..
1
2
3
4
5
6
-7
-8
9
10
11
12
CALAVAR
PART
. NUMBER
34354
92272
67793
BOW31444
BOW36725
BOW31201
FIGURE 21
FIGURE 22
001-04000-1A
030-A4000-00
001-04000-2A
001-A4000-3B
~13 58276
10014 67470-001
1-15 287-96491-00
DESCRIPTION
QUANllTY
1 2345
Holder, safety MaJllual
Manual, OperatiQR and Safety
Clamp
Washer, Flat
, Washer, SPL Lock
Nut., Hex
Diagram, Electrical (See Fig. 21)
Schematic, Hydraulic (See Fig. 22)
Installation, Platform (See Fig. 30)
Kit., 3160 Decal
Installation, Lift (See Fig. 50)
Installation, Chassis (See Fig 70)
Paint Yellow
Oil, Hydraulic
Kit, Hose
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
SOLENOID
~------r-----~
+
MOTOR
I
+
I
o
KEY SWIl CH
PUSH
BUTTON
+
-
MASTER DISCONNECT SWITCH
r--
')
+
Jl=1
==>-+W::.!H!il..!...!TE~
'-
EMERGENCY
STOP
+
+
r---e
L----e
BATTERIES
,--",B=LA..;.;:C=K--c==l
FOOT
S~Jl TC H
BATTERY
CHARGER
BRAKE LINE
1
C
A fB
RIGHT
DRIVE
MOTOR
LEFT
DRIVE
MOTOR
& BRAKE
L-B AI
UPPER CONTROL VALVE
0-
w
W
0
P
-i
0
11
-i
0
""0
-i
-i
0
3:
0
-i
0
-i
-i
0
.... ....
""Oi
3:
0
.....
c-i ~Q1Q1
CO CO Z
L_
J
GREEN
J
PURPLE
YELL 011
r®:~
~
IN
HYDRAULIC TANK
r
....""
~
LOW
SPEED
VALVE
OUT f - -
;v
3
PRESSURE
0
;v
])
11--
RED..JC!NQ
YAL~
W
;v
0
2
5
m
c
Z
Gl
m
c
z
J
RED
0
ROD END
LOWER
CONTROL
VALVE
r
H
"
r
....
"....
'--
MOTOR
l=rt
ROD END
CAP END
p~~p
J
IN
-<
r
:z:
0
<II
m
OUT
H
Z
LIFT
•
0
rn
CAP END
:lJ
I
&rtT
STEER CYLINDER
our
TO U. C. v ..
-l
()
0
I
ORANGE
BROliN
FIGURE 30 PLATFORM INSTALLATION
, 3:,-- - I
7
2'
101
r-:~r=--=~=-~~b.iiiiii.-llL_fJ1l--~
1
14
13,
19
II
18
/I
~21
~I.
17
---r ®
.,,,/
/
15
16
12
FIGURE 30 PLATFORM INSTALlATION
I
T
.
E
CALAVAR
PART
NUMBER
1 010-A4028-00
2 010-S4034-00
3 010-S4031-00
4 010-S4030-00
5 010-S4029-00
6 FIGURE 31
7 570-A4003-00
8 570-A4004-00
9.392-00031-00
10
11 52963
12 37515
13 50277
14 58419
15 164-00013-00
16: 019-A4028"'OQ
171533";00001-00
18!
19 i BOW30006
20: BOW31401
211BOWl4272
22 i BOW34113
23 245-00008-00
DESCRIPTION
QUANnTY
12345
Weldaent, Platform Frame
'Welament, Right Side Rear Guardrail
We lament , Left Side Rear Guardrail
Welament, Side Guardrail
Welament, Front Guardrail
Assembly, Platform Control (See Fig. 31)
Guard, Deck Hose
Guard, 4" Deck Hose
SWitch, Foot Clipper
Assembly , Platform Floor
Decal, Capacity 1,500 LBS
Decal, 3160
Becal, CORDOR
Tape, Orange and Red 31LF
chain
·Welciment, Platform Frame
Link, Chain
Welciment, Rear Movable Guardrail
Belt, Hex
Washer, Flat
.ut, Lock
R.ivet, Pop
Pin, Lanyard Hitch
1
1
1
2
1
1
1
1
1
1
2
2
2
1
1
1
1
1
1
1
1
AIR
AIR
FIGURE 31 PlATFORM CONlROL BOX ASSEMBLY
rr----17
9 _ _~~~~
10
8--~
-t---H----18
19
$1\\
~
bI---5
2
12
7
6
4
FIGURE 31 PlATFORM CONTROL BOX ASSEMBLY
I
T
E
..
,
..
".",,'
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
11
19
CALAVAR
PART
NUMBER
DESCRIPTION
12345
020-R2047-00! Assembly Control Box
010-R1013-00· • Weldment, Control Box Handle
529-R1083-00 • Cover, Control Box
.620-R1078-00 • Panel, Control Box Side
. 128-00009-00 • Bolt, Hex
·475-00070-00 • Washer, Flat
BOW34272
• h t , Hex Lock
31b-00219-00 Deeal, Control Cover
275-00002-00 Knob, Emergency stop Plastic
392-00009-00 Switch, Emergency On-Off
0.20-A4025-00 Assembly, Platform Control Valve
315-00034-0.0 • Valve, Platform Control
253-96632-00 • Fitting
253-96662-0.0 • Fitting
253-96670-00 • Fitting
310-00159-00 Decal, caution Volt Lines
I
310-00214-00
310-00151-00
QUANlllY
Decal, Operation Sheet
Deeal, Lift Control
Deeal, Read rnstructions
1
1
1
1
12
4
4
1
1
1
1
1
2
3
2
1
1
1
1
FIGURE 32 UPPER CONTROL BOX INSTALLATION
18
11
4 PL
15
17
o
14
92277-003
0
IITEM
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
FIGURE 32 UPPER CONTROL BOX INSTALLATION
PART NUMBER DESCRIPTION
55151
54060
54061
010-R1013-00
54498
020-M1035-00
51913
51914
67872
BOW34273
BOW30037
BOW33848
52672
BOW31127
54192
54193-001
52028
54187
55109
QTY
Upper Control Box Installation .................................................. 1
Cover, Control Box ..................................................................... 1
Panel, Side Control Box ............................................................. 1
Handle, Control Box ................................................................... 1
Spacer, Upper Control Valve ...................................................... 3
Valve Assembly, Upper ControL ............................................... 1
Switch, Emergency Shut Off ...................................................... 1
Contact Block, NC ...................................................................... 6
Switch-Short Arm ....................................................................... 1
Nut, Stop, 5/16-18UNC .............................................................. 3
Bolt, Hex .31 "-18UNC x 3.00" ................................................... 3
Screw, Self-Tap .25" x 1.00" ...................................................... 8
Base + INO Contact ZB2-BZI01 ............................................... 1
Screw Grade 5, #6-32 ................................................................. 2
Plug, Hole 1.25" Dia................................................................... 1
Plug, Hole 1.125" Dia................................................................. 1
Operator, 2 Pos. Rot. ZB2-BD2 .................................................. 1
Decal, Lift Control ....................................................................... 1
Decal, 3146/60 Upper Control Top ............................................ 1
92277-003
FIGURE 50 LIFT INSTALLATION
5 -_ _ _'\
9
1
~~~~~~~~~----~~
FIGURE 50 LIFT INSTALlATION
I
T
.
E
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
CALAVAR
PART
NUMBER
124-00028-00
124-00032-00
128-00013,-00
8OW34278
010-S4020-00
010-S4025-00
010-S4026;"00
020-H5015-00
010-S4022-00
010-S4024-00
010-S4027-00
010-S4018-00
124-00030-0,0
167-00002-00
8OW40541
524-00006-00
DESCRIPTION
QUANnTV
12345
BuShing
cam, 2" Flower
Bolt, Hex
Nut, stop
We I dment, Upper outer Arm
Weldment, Upper Inner Arm
Weldment, Middle Inner Arm
Assembly, Lift Cylinder (See Fig. 51)
Weldment, Middle outer Arm
Weldment, Lower outer Arm
We I dment, Lower Inner Arm
We I dment, Arm Stand (See Fig. 52)
Bushing
Collar, Shaft
Screw, Set
Cable, Arm
16
4
16
12
2
1
1
2
2
2
1
1
6
6
6
1
~
FIGURE 51 LIFT CYLINDER ASSEMBLY
2
3
L------3
7
8
I
..
-CALAVAR
PART
NUMBER
1
2
621-G91l1-00
128-00026-00
3
4
5
6
7
8
9
331-00098-00
162-96438-00
I
253-96618-00
154-00007-00
257-00·001-00
253-~6C;09-00
DESCRIPTION
QUANl1TY
12345
Pin, Lift cylin4er
Bolt, Hex
»ut, Esna
Assembly, Lift Cylinder
• Kit, Seal
Pittinq
Clamp, Hose
ru.8, Velcty
Pit.tilVJ, Adapt.er
4
4
4
1
1
1
1
1
1
FIGURE 52 ARM STAND ASSEMBLY
1
5
I
T
E
.
1
2
3
4
5
6
CALAVAR
PART
NUMBER
531-G9125-00
BGW16055
BOW34274
010-54018-00
BOW34113
245-00008-00
DESCRIPTION
QUANnTY
1 2345
B:racket, Alt1I stand pivot
801't, Hex
.'u.t, Lock
weldment, Arm stand
Rivet, Pop
pin, Lanyard Hitch
!.
2
8
8
1
1
1
FIGURE 70 CHASSIS INSTALIATION
8
I
I
..
CALAVAR
PART
NUMBER
1 010-04000-JA
2 315-00035-00
3 FIGUD 71
4 47 6-0·Q02i"';oo
5 315-00037-00
6. 020-A4049-00
7 FIGURE 74
8 FIGURE 75
9 355-00006-00
10 355-00016-66
11 322-00015-00
12 026-S4042-(}0
13 396-00003-00
14 289-00007-(}0
15 321-00002-00
16 FIGURE 77
DESCRIPTION
QUANl1lY
WeldlBent, 3160 Chassis
Valve, Creep
In&talla'tion, Drive and Brake (~,-ee~!'CJl._71)
Assembly, TiJie
Valve, Transaission
Assembly, Hydra.ulic Tank (See Fig. 73)
Installa.tion", steering (See Fig. 74)
Installation, Battery (See Fig. 75)
1
1
1
4
12345
Assembly, Battery Charger
Assembly, Pump (See Fig. 76)
Assembly, Electric Motor
Assembly, Motor Hub
• Stud, Wheel
• Drive, Hub
• Assembly, Motor
Assembly, Ground Control (See Fig. 77)
1
1
1
1
1
1
1
1
5
1
1
1
FIGURE 71 DRIVE AND BRAKE INSTALLATION
6
5
4
®
I
T
CALAVAR
PART
..
NUMBER
1
2
3
4
5
6
396-00003-00
289-0Cil007-00
126-10007-00
253-96506-00
321-10005-00
253-96610-00
E
DESCRIPTION
QUANllTY
12345
stud, Wheel
5
Drive,
Brake,
Elbow,
Motor,
Elbow,
1
1
1
1
2
Il\H)
Eskridqe (See Fiq. 72)
90
Brake Wheel
90
FIGURE 72 BRAKE ASSEMBLY
9
5
22
FIGURE 72 BRAKE ASSEMBLY
I
T
E
.
CALAVAR
PART
NUMBER
tmJ01034
DRJ01035
D&J01036
DBJ01037
Dal01038
DlU01039
DRJ01040
DRJ01041
mu01042
DlU01043
DRJ01044
DRJ01045
DRJ.01047
DRJ01048
EmJ01049
l ' DRJ01050
-17 0&101051
18
19
20
21
22
23
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
DESCRIPTION
QUANllTY
12345
.,ut, Slotted Jam
Screw, Socket Head cap
PlUCJ, Hollow Hex
case, Brake
Bearinq, output
Key
Shaft
Spacer
Plate, Separate
Plate, Bronze Friction
Piaton
Sprinq, Blue
COver, Brake
.Bearinq, Input
·lling
,
, Snap
Ring, Snap
Kit,' Seal
• Rinq, Piston Backup
• G-Rinq, Piston
• O-Rinq, Piston
• ainq, Piston Backup
• O-Rinq, Case Seal
• Gasket Mountinq
1
4
1
1
1
1
1
1
9
8
1
12
1
1
1
1
1
1
1
1
1
1
1
FIGURE 73 HYDRAULIC TANK ASSEMBLY
11
4
10.-~
16
9----<
r----22,
3
FIGURE 73 HYDRAULIC TANK ASSEMBLY
I
T
E
.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
CALAVAR
PART
NUMBER
DESCRIPTION
QUANlllY
12345
(U;O-S.401l"'eO Weld.Jaellt, Hydraulic Tank
254-96611-00 Elbow, street
450-00051-00 Valve, Ball Shut Off
253-96612-00 Pitting, Adapter
260-00001-00 Gauge, oil Level
310-00160-00 Decal, Hydraulic Fluid
254-00051-00 Plug, Black Steel
253-96618-00 alhow, 90
259-00001-00 Gasket, Tank
529-S1076-00Cever, Hydraulic Tank
152-00008-00 cap, Breather
BOW36002
Bolt, Hex
BOW36725
Washer, SPL Lock
253-96596-00 Fitting
253-96597-00 It.educer
253-96616 ... 00 Bl·bow, 90
33430
!'ilter, Return
61408
• Blement, Filter
254-00042-00 Elbow, Steel
254-00009-00 Ripple, Close Pipe
254-00008-00 Hipple, Close Pipe
254-00041-00 Blbow, Steel
2'54-00084-00 Pl.uq, Pipe
1
1
1
1
1
1
1
1
1
1
1
8
8
1
1
1
1
1
1
1
1
1
1
FIGURE 74 STEERING INSTALlATION
1
2'
8
9
16.
15---1
®
FIGURE 74 STEERING INSTALlATION
I
T
E
.
CALAVAR
PART
NUMBER
1 289-00002-00
2 396-00003-.0
3 BOW30160-3
4 BOW30160-2
5 BOW34278
6 119-00012-00
7 BOW32278
8 663-54151-00
9 010-54009-00
10 010-S4010-00
11 350-00017-00
12
13
14 BOW40541
15
16 124-00028-00
17 475-00062-00
18 124-00033-00
19 020-ROO'55-GO
20 253-96659-00
21 1'2-96440-00
22
DESCRIPTION
QUANnlY
1 2345
Hub Dri'V'e
-Stud, Wheel
Bolt, Hex
Bolt, Hex
Rut, Elastic stop
End, Male Rod
Hut, Jam
lloci, Tie
Weldment, Spindle Left
Weldment, Spindle Right
Set, King Pin
• Shim
• Bearing, Sealed
• Screw, Set
• Pln
Bushing
Bblm
Bushing
Assembly, Steering Cylinder
• Elbow, 90
• €ylinder, Steering
• • lCit, Seal
2
10
1
1
2
2
2
1
1
1
2
2
1
1
1
3
2
2
1
2
1
1
-,
FIGURE 75 BATTERY INSTALlATION
I
T
E
.
CALAVAR
PART
NUMBER
1 010-S4013-'00
2 121-00004-00·
3 010-S4016-00
4 1:.12-00014-00
5 1:.12-00015-00
6 122-00017-00
7 122-00020-00
8 (U.0-S4017-00
S0070
10 010-S4015-00
,
DESCRIPTION
QUANnrv
1 2345
Weldment, Right Side Cover
kittery, 6 Volt
Weldment, Battery Box Mount
caDle, Battery 7.2 5LG
eable, Battery 22LG
eable, Battery 59LG
QUle, Battery 28LG
weldment, Battery Hold Down
Decal, Battery Service
tfeldment, Battery Tray
1.
6
1
6
2
2
2
2
2
1
FIGURE 76 PUMP ASSEMBLY
I
T
.
E
CALAVAR
PART
NUMBER
1 018-00110-00
-2 018-00053-00
3
4
5
6
7
8
9
10
11
12
13
, 14
15
16
17 .
018-00114-00
018-00113-00
018-00112-00
018-00111.-00
DESCRIPTION
QUANllTY.
12345
'Cover, Back
Kit, Seal
• O-Rinq
• Plate, Thrust
• Plate, Wear
• Shield, Heat
• Gasket
• V-Seal
• Seal, Shift
Gear, Driven
Gea,r, Drive
Section, center
pin, Dowel
COver, Front
Washer, SPL Lock
Screw, Cap
SCrew, Hex
1
1
2
1
1
1
1
1
1
1
1
1
2
1
8
6
2
FIGURE 77 GROUND CONTROL ASSEMBLY
13
9I
1
1
16---r--flta
5
21
23
20
1----24 221
25
~/
2
17
®
7
FIGURE 77 GROUND CONlROL ASSEMBLY
I
T
.
E
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
CALAVAR
PART
NUMBER
020-A4020-00
253-96662-00
253-96667-00
315-0.0036-00
253-96626-00
253-96605-00
253-96631-00
310-00153-00
394-00009-00
010-54014-00
310-00161-00
392-00021-00
310-00157-00
312-00008-00
G20-A4030-00
0-2335
315-00047"'()()
315-00048-00
253-96516-00
2·53-96605-()()
315-00052-00
020-A4015-00
253-95538-00
450-00072-00
253-96614-00
DESCRIPTION
QUANllTY
12345
AsseUly, Lower Control
• FittiRCJ
• J'itting
• Valve, Lower Control/Lift
• Elbow, 90
• Elbow, 90
• 'fee
Dacal, Warning Arm Stand
Se1enoid, 36 Volt
Weldment, Left Side Cover
Decal, Free Wheeling Valve
Switch, Push Button
Deeal, Master Disconnect switch
SWitch, Master Disconnect
Assembly, P /R Valve
• Blbow, 90
• 'Valve, Cartridge
• Valve, Body
• Connector, STR
• Fitting
• Valve, Shuttle
• Assembly, Freewheel Valve
• • Elbow, 90
• • Valve,. Freewheel
• • Elbow, 90
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
2
2
1
1
1
1
1

3160 #92277

Transcription

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