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A div. of TIME Manufacturing Company
A div. of TIME Manufacturing Company

SELF-PROPELLED ELEVATING WORK PLATFORM

MODEL V2033XL, V2033

Serial Number X935-97051

OPERATOR'S, MAINTENANCE, ANO PARTS MANUAL

X935-97051 OPERATOR'S, MAINTENANCE, ANO PARTS MANUAL SHIPPING ADDRESS CONDOR® A DN. OF TIME MFG. CO. 8300

SHIPPING ADDRESS

CONDOR®

A DN. OF TIME MFG. CO.

8300 IMPERIAL DRIVE

WAco,TEXAs76712

(817) 420-5200

MANUAL 92350

JANUARY 1997

SIN X935-9705I

MAlLING ADDRESS

CONDOR®

A DN. OF TIME MFG. CO.

P.O. Box 21447

WAco,TEXAs76702-1447

(817) 420-5200

"

,

A div. of TIME Manufacturing Company
A div. of TIME Manufacturing Company

SELF-PROPELLED ELEVATING WORK PLATFORM

MODEL V2033XL, V2033

Serial Number X935-97051

OPERATOR'S MANUAL

~\ \ \

Serial Number X935-97051 OPERATOR'S MANUAL ~\ \ \ SHIPPING ADDRESS CONDOR® A DIV. OF TIME MFG.

SHIPPING ADDRESS

CONDOR®

A DIV. OF TIME MFG. co.

8300 IMPERIAL DRIVE

VVACO, TEXAS 76712 (817) 420-5200

MANUAL 92350.001

JANUARY 1997

SIN X93S-970S1

MAILING ADDRESS

CONDOR®

A DIY. OF TIME MFG. co.

P.O. Box 21447 VVAco,TEXAS 76702-1447 (817) 420-5200

i

INTRODUCTION

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

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

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

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

manufacturer ofthis CONDOR® cannot control the wide range of applications that may be

carrying out a variety ofjobs. Therefore, IT IS THE USER'S RESPONSIBILITY to personnel when making decisions regarding the intended use ofthis CONDOR®.

.

decisions regarding the intended use ofthis CONDOR®. . It is also YOUR RESPONSIBILITY to understand and

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

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

DO NOT ALTER OR MODIFY THIS CONDOR® WITHOUT PRIOR WRI7TEN APPROVAL FROM THE MANAGEMENT OF CONDOR Div.

SERVICE ~ MAINTENANCE

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

MANUAL 92350-001

JANUARY 1997

SIN X935·97051

ii

A div. of TIME Manufacturing Company
A div. of TIME Manufacturing Company

CONDOR® SERVICE INFORMATION

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

(817) 420-5200 Telephone (817) 420-5299 Voice Mail (800) 443-5803 FAX

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

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

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

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

MANUAL 92350-001

JANUARY 1997

SIN X935-97051

iii

TABLE OF CONTENTS

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

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

A.

Overall Machine Condition

1

B.

Lower Control Station

1

C.

Emergency Lowering

1

.D.

Platfonn and Upper Control Station

2

E.

Hydraulic System

2

F.

Batteries

2

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

A. Rated Work Load

:

2

B. LowerControls

:

2

C. Upper Controls

3

D. Emergency Lowering

3

E. Lift-up Entry Gate

3

F. Deck Extension

5

G. Removable Upper Control Box

5

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

A. Loading and Unloading

5

B. Ramp Method

5

C. Forklift Loading and Unloading Method

5

D. Transporting

6

E. Freewheel Operation

6

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

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

ANSIISIA A92.6 -1990 MANUAL OF "RESPONSmILITIES

MANUAL 923S0'()()1

JANUARY 1997

SIN X9JS-97OS 1

IMPORTANT: A COPY OF THE ANSI/SIA A92.6 - 1990 MANUAL OF RESPONSmILITIES IS ATTACHED TO TmS OPERATOR'S MANUAL. IT CONTAINS IMPORTANT OPERATING INFORMATION FOR TmS CONDOR®. READ IT BEFORE OPERATING TmS CONDOR®.

I. PREPARATION. INSPECTION. AND MAINTENANCE

The condition ofthis CONDOR® is very important, as it directly affects the operator as well as others. The operator must perform a

thorough walk-around inspection each day prior to operating the CONDOR®. Any damage or faulty operation should be reported immediately.

A DO NOT OPERATE tag outlining the

problem should be attached to the lower control station and any discrepancies should be corrected before operating this CONDOR®.

KNOW TmS CONDOR® AND ITS CAPABILITIES. REPORT ANY UNUSUAL OPERATION, SUCH AS ERRATIC SWAY OR MOTION OF THE ARMS OR PLATFORM.

Some major areas to check daily are:

A. OVERALL MACmNE CONDITION

MISSING, BROKEN, OR DAMAGED PARTS:

D

D

D

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

STRUCTURAL: .

Check for damaged or cracked welds on structural components-arms, platform, chassis.

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 nut).

D

D

D

STEERING:

Check steering link to knuckle connections and steering cylinder for proper and secure mounting.

BRAKES:

Check for abnormal wear between deadbolts and hubs, and for loose or missing bolts, nuts, and pins.

DECALS:

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

CAUTION

Defective components, structural damage, missing parts, and equipment malfunction jeopardize the operator and other personnel and may cause excessive damage to the unit. A poorly maintained CONDOR® could become the greatest operational hazard you may encounter.

B. LOWER CONTROLS

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

C. EMERGENCY LOWERING

D Check emergency lowering function by pulling red T-handle.

MANUAL 92350-001

JANUARY 1997

SlNX93S-970SI

D. PLATFORM AND UPPER CONTROL STATION

D

D

D

D

Check that lift-up entry gate is functional and that chain is secure.

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

Check for missing bolts & nuts - Replace before operating.

Check that extension deck is locked in place.

o Check function ofred button. It disconnects power to the controls and, when pushed, stops all powered functions.

D Check that drive control lever returns freely to neutral.

E. HYDRAULIC SYSTEM

D

Check the hydraulic tank fluid level with the platform all the way down. Fluid must be visible in sight glass. Add Shell Tellus T-32 Hydraulic Fluid if required. Ensure that the breather cap is clean and in place on the tank.

D

Check for hydraulic leaks at all fittings and valves.

D Check all hydraulic hoses and tubes for damage and kinks.

F.

BATTERIES

CAUTION Keep flame, sparks and metal away from the batteries.

D Check Electrolyte level daily in each cell. Ifnecessary, add 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. Only add water after charging cycle is complete.

D

Keep

battery tops clean and dry.

D

Keep vent caps tightly in place.

D

Check that battery cable connections are tight and clean and free of corrosion.

D

Make sure the battery charger and the indicator lights and meter are not dam- aged.

ll. CONDOR® OPERATION

CAUTION CONDOR® MUST BE OPERATED ON FIRM, LEVEL GROUND ONLY.

A. RATED WORK LOAD

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

Rated work load, on extension deck only, is not to exceed 250 lbs. (113 kg) including one occupant. Total rated work load is not to exceed 750 Ibs. (340 kg) including two occupants.

B. LOWER CONTROLS

CAUTION ARM STAND MUST BE USED WIlEN MAINTENANCE PERFORMED ON CONDOR® REQUIRES SCISSOR ARM'S TO BE RAISED.

1. To engage arm stand, raise platform,

then rotate stand until it hangs vertically.

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

MANUAL 923S()'()()1

JANUARY 1997

SIN X93S·970S 1

2. To store arm stand, raise platform so that

arm stand can be rotated until it rests on the stop provided on the scissor arms.

Tum "controls" switch to "lower" position, to operate from ground.

In an emergency, push red button. To operate, button must be pulled out. (Also, if applic- able, battery disconnect switch must be "on" to operate.)

Push "raise" or "lower" switches to move platform.

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

C. UPPER CONTROLS

Turn "controls" switch, on lower control panel, to "upper" position to operate from platform.

NOTE; Chain should be snapped in place across entry. Gate should be lowered and closed when operating CONDOR® from upper controls.

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

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

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

To drive forward or reverse, squeeze lever switch

on handle, and push or pull handle in the intended direction of travel. Release lever switch to stop movement. Letting go of handle also will stop

movement.

Brakes are automatically released whenever the drive handle is moved. Let go of the handle to automatically set the brakes.

To improve drive traction, depress and hold "positraction" switch. (This will automatically cut-out high drive speed.)

To steer left or right, squeeze lever switch on handle, and depress rocker switches on top of handle in the intended direction oftravel. Steering is not automatically self-centering. Be sure the steering wheels point in the direction you want before letting go of the steer switch.

D. EMERGENCYLOWERlNG

For emergency lowering, grasp the Tee-handle located below the rear bumper. Gently pull to lower the platform. Release handle to stop lowering.

E. LIFT-UPENTRYGATE

To load 4' wide sheets, lift entry gate up until lockpins snap in place. After loading, pull at both lockpins, to let gate fall into place. Keep gate down, except for loading and unloading.

MANUAL 92350-001

JANUARY 1997

SIN X93 5-9705 1

LOWER CONTROLS

LOWER CONTROLS RED EMERGENCY STOP BUTTON ----~- OPERATING INSTRUCTIONS I . RAISEILOWER BUTTONS CONTROL
LOWER CONTROLS RED EMERGENCY STOP BUTTON ----~- OPERATING INSTRUCTIONS I . RAISEILOWER BUTTONS CONTROL

RED EMERGENCY STOP BUTTON

----~-

OPERATING

INSTRUCTIONS

I

.

RAISEILOWER

BUTTONS

CONTROL STATION_--.2::::,~--'::::':'--!~

SELECTOR SWITCH

CONTROL

CIRCUIT

BREAKER

upPER CONTROLS

RIGHTILEFT

STEER ROCKER SWITCH 'i ~ H ~Ii~ I! ! ! II! :t/~'Vl! ~ ,
STEER
ROCKER
SWITCH
'i
~
H ~Ii~
I!
!
!
II!
:t/~'Vl!
~
,

POSITRACTION

SWITCH

DRIVE

CONTROL

HANDLE

REDEMERGENCY_---+-~~~~~~

STOP BUTTON

RAISEILOWER

BUTIONS

HIGHILOW/CREEP DRIVE SPEED SELECTOR SWITCH

POWER

BUTTON

MANUAL 92350-001

JANUARY 1997

SIN X93S-970SI

F. DECK EXTENSION

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

CAUTION Do not lower extension deck onto people or any objects!

G. 'REMOVABLE' UPPER CONTROL BOX

Unsnap overcenter latch at bottom of upper control box and pull plug out of receptacle. Bend cable so

that plug faces down. Snap cover onto receptacle at bottom of box. Lift box and store it in a secure place to prevent unauthorized use of the

CONDOR®.

III. MOVING FROM JOB-SITE TO JOB-SITE

A. LOADING AND UNLOADING

Although this CONDOR® is somewhat small compared with larger construction equipment, it requires the same care and attention in loading, transporting, and unloading. At no time should its size,or weight be under estimated. Before loading or unloading, inspect the CONDOR® for any physical damage or defects.

The means by which you load or unload the CONDOR® should be of sufficient strength to withstand its weight.

MODEL

WEIGHT(#)

2633 3,3001bs.

WEIGHT(KG)

1496 kg'

B. RAMP METHOD

Ensure that the ramp is sufficiently strong to support the weight ofthe CONDOR®.

The ramp should be set, not steeper than this CONDOR®'s rated gradeability, which for Model V2033/XL is 14° or 25%, or a rise of30 inches in a run of 10 feet.

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

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

The front of the CONDOR® should be uphill, meaning: Drive forward uphill and reverse down.

Keep CONDOR® in alignment with the ramp during loading and unloading procedures.

C. FORKLIFT LOADING AND UNLOADING METHOD

Ensure that the forklift has sufficient capacity to handle the weight of this CONDOR®. (SEE III. A. )

This CONDOR® can be lifted from the rear, using the forklift pockets provided.

NOTE THAT THE CENTER OF GRAVITY IS 50 INCHES FROM THE END OF THE CONDOR®.

The CONDOR® should only be raised to a height sufficient to clear any obstructions.

Keep forklift travel to a minimum, carry CONDOR® as close as possible to the ground, and set it down gently.

MANUAL 92350-001 JANUARY 1997 SIN X935-9705 1

D. TRANSPORTING

This CONDOR® can be easily transported between job-sites ifthe following rules and procedures are followed:

Block all wheels to prevent forward and reverse motion.

Tie down the CONDOR® with chains or cables, running them through the tie-down holes only. Do not tie down over the guardrails or entry steps.

Always tum the power off at the lower control station.

E. FREEWHEEL OPERATION

CAUTION

This CONDOR® must be on firm, level ground when releasing the parking brakes. To put the CONDOR® into freewheel mode, use the brake release handles on the rear axle. One handle is on the front side of the axle and the other is on the rear side ofthe axle. Tum each release handle 90 0 and at the same time, slightly rotate it. The brakes are now released. (Released brakes will automatically reset the next time forward or reverse drive is used, then will engage when drive is stopped;)

Never exceed 5 mph when moving the CONDOR® in the freewheel mode.

IV. STORAGE

When you get out ofthe platform, leave it all the way down.

CAUTION Never park the CONDOR® with platform raised.

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

NOTES

MANUAL 92350-001

JANUARY 1997

SIN X935-97051

APPENDIX: DECALS IllUSTRATION

APPENDIX: DECALS IllUSTRATION WI,-----IJli PARTIAL SECTION A-A FRONT 2 3 , 14~ I ., • ~~8

WI,-----IJli

PARTIAL

SECTION

A-A

DECALS IllUSTRATION WI,-----IJli PARTIAL SECTION A-A FRONT 2 3 , 14~ I ., • ~~8 LJ

FRONT

2 3 ,
2
3
,

14~

I

.,

~~8

LJ

J

il~!

BACK

22

23

SEC71C~ a-2

A-A FRONT 2 3 , 14~ I ., • ~~8 LJ J il~! BACK 22 23

13

A-A FRONT 2 3 , 14~ I ., • ~~8 LJ J il~! BACK 22 23

MANUAL 92350-001

1ANUARY 1997

SIN X935·97051

.,

APPENDIX: DECALS ILLUSTRATION

ITEM

PART NUMBER

DESCRIPTION

QTY

Ref

55487

Decal Installation

Ref.

*1

54984-00 I

Decal, Upper Oper. Instructions "

1

*2

54652-001

Decal, Itemized Caution Notes

1

*3 54984-002

Decal, Rated Work Load

2

*4

55480-002

Decal, Lower Oper. Instructions

1

*5

54652-003

Decal, Guardrail/Chain Caution

1

6

54984-007

Decal, Hydraulic Fluid

1

*7

54652-002

Decal, Arm Stand Caution

1

*8

54984-005

Decal, Rear Bumper

1

*9

66973

Decal, Electric Hazard Keep Clear

2

10

54984-006

Decal, 110 Volt Ext. To Platform

1

11

69473-002

Decal, Die-Cut, CONDOR 3.45 x 23

2

12

54985

Decal, Die-Cut

2

13

55291

Tape,OrnlRed3"

17.75LF.

* 14

55480-001

Decal, Lower Controls

1

15

53259

Tape, Non-Skid 6"W Black

1.67LF.

16

66921

Coating, Non-Skid Jet Black

27GL.

21

Nameplate, Scissors

Ref.

*22

54976-001

Decal, Upper Control Box Top

1

*23

54976-002

Decal, Upper Control Box Front

1

*

55487-001

Decals, V2033 Essential

Ref.

- Indicates Items Not Shown *Indicates Included In Essential Decals

MANUAL 92350-001

JANUARY 1997

SIN X93S·970S 1

APPENDIX: DECALS ILLUSTRATION 1 i OPERA TING INSTRUCTIONS ,.+:

APPENDIX: DECALS ILLUSTRATION

1

i

OPERA TING INSTRUCTIONS

,.+::NU:~"~\;~;;~~~~~,S~'~~~,\~;~~:~r:~~.C~~~~~~R:~~~;~;~~~~:~;~~\/J3S~~;~R~~~~~~~\~~."~0~O~\~::~7":;RV.

I

I

J.

I

AND

ON

~::>"ER CONTROLS,

'lUST BE PUL'-.:::

10

OR

RAISt

: ND

Lv',\!::"'K

~

"lO'::::q" BUTTON.

I

Pt

A

-

.,

p- J!"(:VI.

r-'u~H Ai\:.;

~"

RELE.A.5E

BU"TTONS

TO

Oi '~.

'-'UL

S,OP

r-

,

::,. u+<r

,

:.~ ~_

V;OVt:MEN~.

i-""O'

~"

_,

c.""(

H

Bu!. '

,,

,

~.

,

.:.~c ;::

5

;

iHE

.,

RA

S:::

ll. SELECT JRVE SPEED v'iITf-! TH:: "HiGH/LOt//eR::::?" s;·,nCH.

AS

A

liMIT S: TCH

THE

AUTOMA TICALl Y CUTS

OR

OF

BACK

Tri~ SpEED

~.EVER S:ir,CH

Ti-IE

ON

PLA T;ORM

/S

q:. SED.

OR

I · TO DRIVE

, IN

, RELEASE _:::VER SW:TCH TO STOP

REvERSE,

"JRWARD

' -~NDED

SQUEEZE

7RAVEl.

MOVEMENT.

HANDLE,

A.ND ;::\.:5-

C\.;,,_

YANDLE

DIRECTION

_:::TT:NG GO O=- HANDLE ALSC;,:,-_ STOP V::: '::::V:ENT.

2

• BRAKES

"RE

AUTOMAT/CALLY RELEASED

TO

WHENEVER

T;-,t:

7HE DRIVE

BRAKES.

lET GO ::::- THE HANDLE

AUTOMA TICALl Y SET

HANDLE

:S

'lOVE:).

• TO IMPRC'/E DRIVE

TRACTION.

DEPRESS

AND

HOLD

!

THIS

WILL

A.UTOMA TICALL Y

GuT-OUT HIGH

S;::::E9.

• TO STEER

:

EFT

OR

RIGHT,

SQUEEZE lEVER

S:·.nCH

"cOS/TRACT'ON"

S:,:TCH.

SN

hANQlE.

AND

DEPRESS

=:::;::;KER

S:. ~::;HES

I

,

ON

TOP

CO'

HANDLE

iN

THE

iNTENDED

DIRECi:ON

C=

TRAVEL

STEERING

S NOT

AUTOMA TiOAlLY SELF -CE~iTERING. 3E

SURE

THE

S-:-t:i::RiNG

:.'-::::::_S

PO.\ T

iN

THE J ~~CTION YCU

.\i~.NT 3E;:-CRE L.E:TT!NG GO

J;

7:-:E ST::t:R

S":;:-:-CH.

 

Iit, CAUT~ONI

 

1. DO NOT~AjfE:';iSCONDOR"

UNTIL

YO:.;

CiAVE BEEN

PROPERLY TRAINED

AND

HAVE

COMPLETELY READ

AND

UNDERSTOOD

THE

OPERATOR'S MANUAL

THAT IS

0\ -:-:"'S CONDO,,:"

2. PRIOR

TO EACH

DAY'S

'JSE.

CHECK

TO MA'<E

SJRE

ALL

FUNCTIONS

ARE

C=:::R4 T'NG

"'RC"ERL Y.

=:ERFORM

ALL

iNSPECTIONS

REQUIRED

BY S:::C;:ON

6

OF

TriE

ANSI

92.5

S-!"V)ARD.

3. \0'"

DO

uSE

THE

CONCOR"'.

':-

T IS MALi'":';\C;:'JNING OR

OAMAGED

iN

A",v

:.~v,

OR

,:-

:HE

WIND

8LO::S

OVER

i 5

MPH.

4.

DO

5. RAISE

\)OT DRIVE ON

THE

A SLOPE

ONLY

PLA TFORM

UNLESS

WHEN

THE PL.ATFORM

IS

CO\:DOR'"

THE

IS FULLY LO.vERED.

ON

FIRM.

lEVEL GROUNLi.

6:

ALI'IA YS LOOK

IN

THE

DIRECTION

IN

'/IHICI-i

ThE

PLATFORM

IS MOVING.

\"ATC!-i

FOR,

AND

AVOID,

OVERHEAD

06STRUCT'ONS

AND

ANYTHING ELSE

TCiAT MAY STRXE

DlA TFORM,

PERSONNEL,

OR

CONTROLS.

 

7.

THIS

::ONDOR'" IS NOT ELECTRICALLY iNSULA TED.

 

MAINTAIN

SAFE

CLEARANCES FROM

ElECTR!CAl

POWER

LINES.

8. FOLL(W INSTRUCTIONS IN

OPERA TOR'S MANUAL

WHEN

SERVICING

6A TTERiES.

EACH

REPLACEMENT

8ATTERY \1UST i'lEIGH

Ai

LEAST 55

Ibs.

DRY AND

66

1::5.

,VET.

9. A.CEMENT

REPc

TIRES

MUST BE

SAME

AS FACTORY ORIGINALS.

 

10.

iN

CASE

OF

A.N

EMERGENCY.

PUSH

THE

;:(E!:)

":::V,ERGENCY STCP"

MANUAL 92350-001

JANUARY 1997 SIN X93S·970S 1

BUTTON.

3

6

APPENDIX: DECALS ILLUSTRATION

RA TED WORK LOAD

;

:

(""I::

JI\J

=-X~::-N:'C::;·"N,: j'.:-;"/

_

11-'

,'-

,.;,

-',-,-",r'\

,"'.\':

'-"i\JI

-

v

~

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

TO~A~ RAT~D !.ORK ~JAJ

:S

-::-SOL8S

OR

T'i.'O

TO~A~ RAT~D !.ORK ~JAJ :S -::-SOL8S OR T'i.'O OCCUP.L\NTS. 5 GLARDRAILS AND SAFETY C:-iil,INS IvlUST BE

OCCUP.L\NTS.

5

!.ORK ~JAJ :S -::-SOL8S OR T'i.'O OCCUP.L\NTS. 5 GLARDRAILS AND SAFETY C:-iil,INS IvlUST BE SECl ;KED

GLARDRAILS AND SAFETY C:-iil,INS IvlUST BE SECl ;KED

~~D

USED

AT

ALL

TIVES

5 4 552-CC.3

HYDRAULIC

FLUID

54984-CD7i

7

!~ Cfo\UT~ONI

STAND

CLEAR

UNLESS

is

!\i

ARM

STAND

PLACE

54652-CC2

I STAND CLEAR UNLESS is !\i ARM STAND PLACE 54652-CC2 8 FORKLIFT POCKET EMERGENCY LOWERING ;>ULL

8

FORKLIFT

POCKET

EMERGENCY LOWERING

;>ULL T-HANDLE. TO LOWER PLA TFORM.

TO

RELEASE HANDLE

STOP MOVEMENT.

BRAKE RELEASE

ONLY ON FiRII. LEVEL GROUND.

ROTATE BOTH LEVERS TO RELEASE BRAKES.

FORKLIFT

POCKET Icr:p,

MANUAL 92350-001

JANUARY 1997

SIN X93S-970S1

9 APPENDIX: DECALS ILLUSTRATION ELECTROCUTION HAZARD KEEP CLEAR DEATH OR SERIOUS INJURY CAN RESULT FROM

9

APPENDIX: DECALS ILLUSTRATION

9 APPENDIX: DECALS ILLUSTRATION ELECTROCUTION HAZARD KEEP CLEAR DEATH OR SERIOUS INJURY CAN RESULT FROM CONTACT

ELECTROCUTION HAZARD KEEP CLEAR

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

21882-001

OR VEHICLE IF IT SHOULD BE ELECTRICALLY CHARGED. 21882-001 4 THIS MACHINE IS NOT INSULATED ELECTROCUTION

4

OR VEHICLE IF IT SHOULD BE ELECTRICALLY CHARGED. 21882-001 4 THIS MACHINE IS NOT INSULATED ELECTROCUTION

THIS MACHINE IS NOT INSULATED

ELECTROCUTION HAZARD

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

THIS AERIAL WORK PLATFORM DOES NOT PROVIDE PROTECTION FROM CONTACT WITH OR PROXIMITY TO AN ELECTRICALLY CHARGED CONDUCTOR.

YOU MUST MAINTAIN A CLEARANCE OF AT LEAST 10 FEET BETWEEN ANY PART OF THE WORK PLATFORM OR LOAD AND ANY ELECTRICAL LINE OR APPARATUS CARRYING UP TO 50,000 VOLTS. ONE FOOT ADDITIONAL CLEARANCE IS REQUIRED FOR EVERY ADDITIONAL 30.000 VOLTS OR lESS. DEATH OR SERIOUS INJURY WILL RESULT FROM CONTACT OR INADEQUATE CLEARANCE.

MANUAL 92350-001

JANUARY 1997

SIN X935-970SI

DEATH OR SERIOUS INJURY WILL RESULT FROM CONTACT OR INADEQUATE CLEARANCE. MANUAL 92350-001 JANUARY 1997 SIN

APPENDIX: DECALS ILLUSTRATION

10

21

110

VOLT

EXTENSION

TO

j

PLATFORM

549r!4-CC6~

170PERAT1NG iNSTRUCTIONS)

.7CJ"N

;:-:;:;::;)/.

•• N AN EMERGE"GY,

"CONTRD,-S"

OPERATE

-0

S1i;TCH

is

GROUND.

F'USH

REO

"~::.::,," :>:;S·7:D:\; •.

"\J~~S".

, -:-0 C~ERATE. 50 "'!"TON MUST 8E PUL_::O C>"::.

'ALSO, iF

APPU:AtlLE.

BA TTERv D:S::::',,;::::

SWITCH

MUST B[

"eN" TO DP~RATE.~

'.• PUSH

"RAISE"

SR

"LOWER"

81.: 7 '01\S

i

TO MOVE PLA TFDRM.

TO

,0 OPERA TE rRC~~ PLATFORM.

i. 'uRN

SWiTCH

"UPPER"

POS!7ION

PLATFORM. i. 'uRN SWiTCH "UPPER" POS!7ION I MANUFACTL:RED !N U.S.A. I ! SER!AI 8300 ;;VDERIAL

I MANUFACTL:RED

!N

U.S.A.

I

! SER!AI

8300 ;;VDERIAL DR'VE WACC, -:::::XAS 76 7~ 2

0,10.

o

8300 ;;VDERIAL DR'VE WACC, -:::::XAS 76 7~ 2 0,10. o ;=1 C=O=N=D=O=R==M=O=D=E=L==2=5=3===3====::::! i

;=1C=O=N=D=O=R==M=O=D=E=L==2=5=3===3====::::!

i RATE':)

WORK· OA::

750#

 

! PLATFORM Ht.IGHT

20'-0"

i H':"D.

DRES:::,0R=-

2.700

DS!

I SYSTEM

VOL IAGE

24

V.

DC

Tf-!,S

UNIT

IS

NOT

ELECTRICA:

L

Y

INSULA -'-E::.

 
 

THIS

SELF-PROPELLED

ELEVATING

WORK

PLAT::-ORM

CON=-2RMS

o

TO

ALL

APPLICABLE

REQUIREMENTS

OF

ANSi

A92.6-1990

0

22

EMERGENCY

0~ ~

PLATFORM

I RAISE I

i

I

ILOWERI

I

,

I

I

CONTROLS

I

/\UPPER I

I

\

'.

/

OFF!

I ~LOWERi

1

,.-001

I

i

23

51.340

IpOSITRACTION I

I

I

10

'I

I

1

IEMERGENCY ,~--------,\

(F~D "; I

"C/

\ I

~IGH IJ~~Rli

\

)

lOW i

! ~CREEP \

IDRIVE SPEED

REVERSE)

,.".-01,,1

24

i

POWER

I i

I

f'\

i

I

15.4976-002

\J

MANUAL 92350-001 JANUARY 1997 SIN X93S·970S 1

RAISE

LOWER

I

A div. of TIME Manufacturing Company
A
div. of TIME Manufacturing Company

SELF-PROPELLED ELEVATING WORK PLATFORM

MODEL V2033XL, V2033

Serial Number X935-97051

MAINTENANCE MANUAL

V2033XL, V2033 Serial Number X935-97051 MAINTENANCE MANUAL SHIPPING ADDRESS CONDOR® A my. OF TIME MFG. co.

SHIPPING ADDRESS

CONDOR®

A my. OF TIME MFG. co.

8300 IMPERIAL DRIVE

VVAco,TEXAs76712

(817) 420-5200

MANUAL 923S0-002

JANUARY 1997

SIN X93S-970S I

MAILING ADDRESS

CONDOR®

A DN. OF TIME MFG. CO.

P.O. Box 21447

VVAco,TEXAs76702-1447

(817) 420-5200

i

INTRODUCTION

Theprimarypurpose ofthis manualis to providethe userwith a thorough understandingofthe proper operating procedures necessary to comply with the intended use ofthe CONDOR®, and to provide the infonnation necessary to maintain and service the CONDOR®.

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

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

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

turer ofthis CONDOR® cannot control the wide range ofapplications that may be used in carrying out

a variety of jobs. Therefore, it is THE USER'S RESPONSIBILITY to consider all personnel when making decisions regarding the CONDOR®'s intended use.

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

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

DO NOTALTER OR MODIFY THIS CONDOR® WITHOUTPRIOR WRITI'ENAPPROVAL FROM THE MANAGEMENT OF TIME MANUFACTURING-CONDOR DIVISION

SERVICE & MAINTENANCE

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

NOTE:

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

ii

ii ~, A div. of TIME Manufacturing Company • • CONDOR®SER~CEThWORMATION 1. If you need assistance

~,

A div. of TIME Manufacturing Company

ii ~, A div. of TIME Manufacturing Company • • CONDOR®SER~CEThWORMATION 1. If you need assistance

CONDOR®SER~CEThWORMATION

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

(817) 420-5200 Telephone (817) 420-5299 Voice Mail (800) 443-5803 FAX

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

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

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

CONDOR DIVISION

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

iii

A div_ of TIME Manufacturing Company
A div_ of TIME Manufacturing Company

Condor® Self-Propelled Booms and Scissors WARRANTY

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

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

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

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

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

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

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

Form No.S13-3M-392

Effective Dale 9/1190 Printed in U.S.A

EffectiyeJaDuaryl,1993

WARRANTYPRQGBAM

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

Condor Division Warranty states, in general, that Condor Division will replace free of charge any components found to be defective within the time frame ofthe warranty period. There are exceptions to

some components which are not the responsibility of Condor Division. subsequent paragraphs.

These will be outlined in

A. WARRANTY PERIOD

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

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

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

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

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

NOTE:

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

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

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

1. Each Self-Propelled Boom or Scissor CONDOR® shipped from Time Manufacturing- Condor Division's facility will have a Pre-Delivery Inspection (P.0.1.) sheet enclosed in the Safety Manual holder tube.

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

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

NOTE:

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

C. ITEMS NOT COVERED UNDER WARRANTY

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

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

2. Hvtlraulic Filters and Fluid:

These are considered general maintenance and service

items, and are not covered by warranty.

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

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

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

6. Troubleshooting: Troubleshooting is not covered or reimbursable. However, Condor Division Warranty will cover reasonable labor charges for the removal and replacement ofdefective components.

D.

PROCESSING OF WARRANTY CLAIM

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

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

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

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

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

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

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

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

NOTE; WARRANTY CLAIMS Wll

AFTER 45 DAYS AFTER FAILURE

L

NOT BE ACCEPTED BY CONDOR DIVISION

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

E. RETURN AUTHORIZATION

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

2. It will be necessary for you to call the Condor Division Service Department and ask to be issued a Return Authorization (R/A) number. You will be asked for a Dealer Claim Number. As noted in Section 2, Item A, ofthe WarrantyClaim Procedure, this isanumber assigned by the dealer for the purpose oftracking the claim, as there may be more than one claim for the same CONDOR®. The R/A number issued must be logged in the appropriate section of the claim form, and the gold copy (RIA) of the form must be returned with the parts being returned.

NOTE:

DO NOT SHIP ANY RETURN PARTS WImOUT A RETURN AUTHORIZATION (RIA) NUMBER

Doing so mayresult in parts getting lost in the system and may delay processingthe claim,

or may cause denial due to the time element of the claim.

3. All RIA parts must be received at Condor Division within 45 days from the date the RI

A number was issued. Failure to do so will cause the claim to be denied.

4. All parts claimed under Warrrantywill be required to be shipped back to CondorDivision FREIGHT PREPAID. No freight collect shipments will be accepted.

CONDOR® Model V2033XL, V2033

NUUNTENANCENL\NUAL

TABLE OF CONTENTS

INTRODUCTION

 

i

CONDOR® SERVICE INFORMATION

ii

SELF-PROPELLED WARR.AN"TY

iii

Table of Contents

1

Specifications

3

Recommended Tool List

 

4

Serial Number Location

5

Serial Number To

Model Designation

6

Hydraulic System Description

 

7

Pressure Adjustment Procedures

11

Electrical System Description

15

Machine Options Description

19

Assembly Diagrams Section

:

23

Battery Service

45

Preventive Maintenance

 

53

Hydraulic Fluid

Specifications

;

63

Battery Charger Troubleshooting Guide

 

;

65

Bolt Torque Chart

75

MANUAL 92350-002

JANUARY 1997

SIN X935·9705 I

NOTES

MANUAL 92350-002 JANUARY 1997 SIN X935-9705 I

SPECIFICATIONS

SPECIFICATIONS

V2033XL

Maximum Working Height

26

ft.

Platform Height

20

ft.

Stowed Platform Height

39.5"

Overall Length

93"

Overall Width

33"

Overall Height

79"

Overall Height With Rails Removed

50"

Platform Size

92.5" x 30"

Platform Capacity

7501bs.

Gross Weight

3,3610Ibs.

Power System

24

volt DC

Battery Capacity

235 amp hour

Number of Batteries

4

Battery Voltage

6 volt

Battery Charger

25

amp

WheelBase

75"

Tires

16x5

(Solid Rib)

Inside Turning Radius

24"

Drive Speed

.7511.5/3 mph

Gradeability

25%/14°

LiftlLower Time

35/30 sec

OPTIONS

* Battery Condition Indicator

*

MotionIMovement Alarm

* Strobe Light

* 250 Amp Hour Deep Cycle Batteries

* Travel Alarm

*

* Hour Meter

*

*

Descend Alarm 5° Slope Alarm

Low Volt Waming/Interrupt Battery Protection System

* Key Switch

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

ANSI Standard A92.6 - 1990

SelfPropelled 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 ofthe employer utilizing the equipment.

MANUAL 923S0-002

JANUARY 1997 SIN X93S-970S I

RECOMMENDED TOOL LIST

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

each

1 Volt/Ohm Test Meter

each

1 Hydraulic Flow Meter, 0-10 GPM

each

1 Hydraulic Flow Meter, 0-50 GPM

each

1 Hydraulic Quad Meter Pressure Gauge

each

1 Battery Hydrometer

each

1 Battery Load Tester

each

1 112" Drive Torque Wrench, 0-250 ftIlbs

each

1 Pry Bar

each

1 Strap Type Filter Wrench

1 each

Grease Gun

1 each

Hammer, 24 oz.

1 each

Vice Grip Pliers

each

1 Combination Wrench Set, 114" to 1-112"

each

1 3/8" Drive Socket Set, 114" to 3/4"

each

1 112" Drive Socket Set, 3/8" to 1-112"

1 Hex Key (allen wrench) Set, up to 112"

1 Screwdriver Set, Phillips Tip & Slot Tip

each

each

each

1 Punch Set; Drift, Lineup and Straight

pair

1 Wire Stripping Pliers

pair

1 Wire Crimping Pliers

pair

1 Wire Cutting Pliers

1 Needle Nose Pliers

pair

pair

2 Jumper Wires with Alligator Clips

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

MANUAL 92350-002

1ANUARY 1997

SIN X935·97051

2

Serial Number Location •

1

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

I.

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

2.

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

kingpin.

MANUAL 92350-002

JANUAB.Y 1997

SIN X935-970SI

MANUAL 92350-002

JANUARY 1997

SIN X93S-97051

HYDRAULIC SYSTEM DESCRIPTION

The following is a detailed description ofthe hydraulic system used on the CONDOR® model

To assist in understanding the system, this description

V2033IXL scissor, and how it designed to operate.

should be used in conjunction with the hydraulic schematics found at the end of this section.

GENERAL

The hydraulic system on the CONDOR® model V20331XL consists primarily of a single manifold assembly, used to control all the hydraulic functions through the use ofhydraulic cylinders and motors. The system is electric over hydraulic, meaning that the hydraulic valve assembly is activated by electrical signals from the function controls. The system is also 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. All lift and drive functions can be performed from the platform console, while ONLY lift functions are available from the lower control console.

HYDRAULIC TANK

The hydraulic tank is an "L" shaped weldment having a fluid capacity of 7 US gal- lons. The main portion of the tank is located between the batteries in the belly pan, with the smaller portion extending outward to the right side ofthe unit (See FIG. 1) nextto the hydraulic pump. A filler neck and cap, and a sight glass are provided at the extended section of the tank for checking and maintaining the fluid level. Filtra- tion ofthe hydraulic oil is provided through a 10 micron spin-on return filter, and a 100 mesh, 10 GPM, tank-mounted strainer. The filter, and strainer are located at the end of the tank, just behind the pump. The use ofa tank strainer and shut-offvalve (ball valve) for the tank has been discontinued. Although the tank configurations differ between models, the attaching compo- nents are identical.

between models, the attaching compo- nents are identical. Ball Valve FIG. 1 NOTE: Only check the

Ball

Valve

FIG. 1

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

DO NOT MIX HYDRAULIC FLUIDS.

MANUAL 92350-002

JANUARY 1997

SIN X935-97051

PUMPIMOTOR

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

MAIN VALVE ASSEMBLY

Located in the left side of the belly pan between the batteries and battery charger is the main valve assembly which performs all ofthe hydraulic functions ofthe machine (See FIG. 3). This assembly includesthree directional control valves and a varietyofcartridgevalvesto achieve the operation ofthe cylinders and motors for the machine functions. These individual functions are described in detail below.

MACIDNE FUNCTIONS

HYDRAULIC TANK

PUMP/MOTOR CONTACTDR
PUMP/MOTOR CONTACTDR

FIG. 2

Batteries
Batteries

Main Valve

Assembly

FIG. 3

Battery Charger

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

DRIVE FUNCTION

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

FIG. 4).

MANUAL 92350-002

JANUARY 1997

SIN X93S-97051

Drive Directional

Control Valve

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

0,------,/ Creep Speed
0,------,/
Creep Speed

Creep Speed

Solenoid Valve

Flow Divider/Combiner

Needle Valve

FIG. 4

DRIVE FUNCTION (cont'd)

Pump flow circulates through the main valve assembly and back to tank if no functions are

activated when the pump is

of the load control valves in its free-flow direction, and then to the normally open positraction valve. Fluid flows through the positraction valve cartridge, then to both drive motors which each have an 11.9 cubic inch per revolution displacement and are located on the steer axle. When the positraction button is depressed at the upper control box, the 4-way normally open positraction valve closes, blocking the flow offluid through it, but forcing the fluid through the flow divider/combiner to enhance tire traction.

_Once the directional control valve shifts, fluid is directed to one

running.

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

The V2033IXL has a creep speed which is either automatically activated at platform heights above seven feet by a limit switch, or is operator selectable at heights below seven feet. Creep speed is a situation in the drive circuit whereas when the creep speed solenoid valve is energized, some ofthe drive flow is diverted back to the tank. The speed at which the machine travels when in creep, is controlled by the creep speed needle valve (See FIG. 4). The creep speed is factory set to obtain a travel speed of

80-100 sec/88 feet, on firm, level ground; (Ref section).

75/.6

mph), (see note #2 on schematic at end ofhydraulic

MANUAL 92350-002

JANUARY 1997

SIN X93S-970S1

DRIVE FUNCTION (cont'd)

When the speed selector switch is in the high position, the drive speed increases by the addition of the P2 pump's fluid displacement (steerllift pump) being diverted to the drive circuit. This is accomplished by activation of the selectdirectional control valve. The hydrau- lic pump containstwo individual pump sections, one ofwhich is used solely for the drive circuit. The other pump section supplies fluid for the operation of lift and steer, and will supply fluid to the drive circuit when the machine is in high speed. A check valve cartridge is used to isolate the drive-only pump flow for use in the drive circuit (See FIG. 5).

STEERING FUNCTION

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

LIFT FUNCTION

Select Directional Control Valve (between drive and steer)

Steer Directional

Control Valve (between drive and steer) Steer Directional Control Valve Creep Valve Check Valve Cartridge FIG.

Control Valve

Creep Valve

Check Valve

Cartridge

FIG. 5

Control Valve Creep Valve Check Valve Cartridge FIG. 5 Steer Cylinder Connecting Arm FIG. 6 Lifting

Steer Cylinder

Connecting Arm

FIG. 6

Lifting of the platform is accomplished by energizingthe selectdirectional control valve. This will direct fluid from the P2 pump to the base end ofthe lift cylinder, with the rod end of the lift cylinder being vented back to the tank. Located on the cylinder body (See FIG. 7), is the holding valve, which consists of a manifold body, a 2-way normally closed cartridge with a manual override, and an electric coil. Attached to the cartridge is a cable assembly used for

manually lowering the platform via aT-handle located at the rear ofthe machine, under the rear bumper plate. Descent speed is controlled by a flow control valve (See FIG. 3), in which clockwise rotation decreases descent speed, while counterclockwise rotation increases the descent speed.

while counterclockwise rotation increases the descent speed. Cylinder Manifold Coil Cable FIG. 7 MANUAL 92350-002

Cylinder

Manifold

Coil

Cable

FIG. 7

MANUAL 92350-002

JANUARY 1997

SIN X935-97051

PRESSURE ADJUSTMENT PROCEDURES NOTES: All pressure adjustments are to be made with the pump motor

PRESSURE ADJUSTMENT PROCEDURES

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

Drive Pressure Adjustment

1. Chock both drive wheels to prevent them from spinning in the forward drive direction.

2. With the drive speed selector in the low position, activate forward drive with the drive controller.

3. While drive is activated, adjust "RVI" to 2700 psi while observing the gauge reading from the "01" port.·

4. After setting, lock the adjustment screw with the jam nut.

High Drive Pressure Adjustment

1. Select high speed at upper control box.

2. Observe the pressure reading at the "01" port while climbing a grade, and note pressure reading at which the high drive shifts to low.

3. Adjust the "SEQ" valve until the pressure reading is 1100 psi when high drive shifts to low.

4. After setting, lock the adjustment screw with the jam nut.

NOTE: The load control valves, "CB1" and "CB2", are factory set. Ifthey are not functioning properly, they must be replaced; DO NOT ATTEMPT ADmSTMENT.

Lift PressurelDescent Speed Adjustment

1. With pump running, and platform raised completely (cylinder bottomed out), observe the pressure reading on the gauge connected to the "02" port. Adjust "RV2" to 2700 psi.

2. Adjust "FC}" to obtain a 25-35 second descent from a fully raised position.

MANUAL 92350-002

JANUARY 1997

SIN X93S-970S 1

To aid troubleshooting, some ofthe valves and cartridges are identical to others and can be

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

I.

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

2.

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

3.

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

4.

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

5.

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

"DECEL" solenoid cartridge valves are identical. 1-+----- "G2" Gauge Port (Reads Steer/Lift! High

1-+-----

"G2" Gauge Port (Reads Steer/Lift! High Drive Pressure)

"G1" Gauge Port (Reads Drive Only Pressure)

"FC1" - Controls Platform Descent Speed
"FC1" - Controls Platform
Descent Speed

"RV2" Relief For Steer/Lift ("G2" Gauge Port)

"RV5" Secondary

Lift Relief

Creep Speed

Adjustment

"SEQ" (Sequence) Valve Controls High Drive Shifting

"RV1" Relief For Drive Only ("G1" Gauge Port)

Relief For Drive Only ("G1" Gauge Port) "CB1" and "CB2" Load Control Valves (DO NOT

"CB1" and "CB2" Load Control Valves (DO NOT ADJUST)

FIG. 8

MANUAL 92350-002

JANUARY 1997

SIN X935·97051

"CB1" and "CB2" Load Control Valves (DO NOT ADJUST) FIG. 8 MANUAL 92350-002 JANUARY 1997 SIN
"CB1" and "CB2" Load Control Valves (DO NOT ADJUST) FIG. 8 MANUAL 92350-002 JANUARY 1997 SIN

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MANUAL 92350-002

JANUARY 1997

SIN X935-97051

ELECTRICAL SYSTEM DESCRIPTION The following is a detailed description of the electrical system used on

ELECTRICAL SYSTEM DESCRIPTION

The following is a detailed description of the electrical system used on the CONDOR® model V20331XL scissor, and how it designed to operate. To assist in understandingthe system, this description should be used in conjunction with the electrical schematics found at the end of this section.

GENERAL

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

BATTERIES

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

BATTERY CHARGER

The battery charger has a 25 amp @ 24 volt DC nominal rating, and operates offofaIlS volt alternating current (AC), 160 Hz, 8 amp input. The charger features contains an ammeter for reading the DC amp output, and two LED status indicator lights; a red LED indicates the charger is on, charging, while a green LED indi- cates the charging is complete. The charger- is located on the left side ofthe belly pan, between the main valve assembly and the fixed axle (See FIG. 9). More detailed information ofthe charger can be found in the Battery Charger Trouble- shooting Guide beginning on page

CIRCUIT BREAKERIFUSE

Main Manifold

Assembly

Ground Controls

CIRCUIT BREAKERIFUSE Main Manifold Assembly Ground Controls Located below the control selector switch on the lower

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

MANUAL 92350-002 JANUARY 1997 SIN X93S-9705 I

PUMP MOTOR

The CONDOR® model V2033XL uti- lizes a pump motor which is a 24 volt DC unit, rated 6hp@3600rpm. SincethemodelV2033XL utilizes a gravity lowering system, the motor does not run while the lowering function is activated.

PumplMotorContactor

the lowering function is activated. PumplMotorContactor FIG. 10 LOWER CONTROL FUNCTIONS Located above the left rear

FIG. 10

LOWER CONTROL FUNCTIONS

Located above the left rear wheel is the lower control box, which provides a junction connection through the use oftwo terminal strips, for the limit switch cable, the hydraulic valve cable, the pump motor contactor cable, and the cable to the upper controls. At the lower controls are switches (see FIG. 11), to provide operation of the lift function only; drive is not available from this control box. The lower control box contains an emergency stop buttonwhich mustbe pulled out to supply power to both control boxes. The control selector switch is a 3-position main-

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

I
I

_ ---!<H--@

I

I

I

.J I

Emergency Stop Button

Platform Lift Control

Control Selector Switch ---n;.+4~!""J

IF

15 Amp Circuit Breake~

use

FIG. 11

UPPER CONTROL FUNCTIONS

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

MANUAL 92350-002

JANUARY 1997

SIN X93S-970S I

UPPER CONTROL FUNCTIONS (cont'd)

PositractionButton

(black)

LiftControls

PowerButton

(green)

PositractionButton (black) Lift Controls PowerButton (green) Drive Speed Selector Emergency Stop Button

Drive

Speed

Selector

Emergency Stop Button

rr----------------------------\

Emergency Stop Button rr----------------------------\ Cable Hamess Plug Hidden View of Slip-FitInsert FIG. 15

Cable Hamess

Plug

Hidden View of Slip-FitInsert

FIG. 15

Cut-Away View

ofSlip-Fit Insert

Drive Controller

w/SteerRocker

Switch

View ofSlip-Fit Insert Drive Controller w/SteerRocker Switch Integrated in the forward edge ofthe drive handle is

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

MANUAL 92JS()"oo2

JANUARY 1997

SIN X9JS-970S1

NOTES

MANUAL 92350-002

JANUARY 1997

MACHINE OPTIONS DESCRIPTION The following descriptions are intended to be used with wiring diagrams at

MACHINE OPTIONS DESCRIPTION

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

STROBE LIGHT (OPTION)

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

5°SLOPE ALARM (OPTION)

This option sounds an alarm when the V20331XL is ormore outoflevel. A omni-directional sensor is mounted in the belly pan to sense a 5° out-of-Ievel condition. In this situation, a fast pulse/loud tone alarm at the upper control box (See FIG. 13), is activated until the machine is returned to a less than

The sensor is mounted on a

spring loaded base which is adjustable to allow leveling. Testing of the system is accomplished by manually tilting the sensor against its spring tension mount, to physically put the sensor in a 5° out-of- level condition, causing the alarm to sound. Power is supplied to the sensor, and the alarm, only when the machine is in the "UPPER" control position. When the sensor is activated (5° or greater), the sensor's white wire (connected to the alarm), becomes grounded after a few second delay, through circuits inside the sensor.

5° condition. This serves as a warning, and does not inhibit any functions.

BATTERY CONDITION INDICATOR (OPTION)

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

SIGNAL HORN (OPTION)

Battery

Condition

Indicator

SIGNAL HORN (OPTION) Battery Condition Indicator FIG. 13 S\opeAIann This option consists of a 133 db

FIG. 13

S\opeAIann

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

MANUAL 92350-002

JANUARY 1997

SIN X93S-97OSI

LOW VOLTAGE BATTERY PROTECTION SYSTEM (OPTION)

This option prevents operation when the batteries are in a low voltage condition. It be- comes energized whenever the control selector switch is in either "UPPER" or "LOWER" posi- tion (loweremergency stopbuttonmustbe pulled out). While energized, the module monitors the

batteries'voltage level, andwill preventthe pump motor contactor from being activated once the battery voltage reaches 12.5% undervoltage, or approximately 21 volts~ This condition must be present for 21 seconds to activate the interrupt

Terminals 3 & 4 of the module are

system.

Low Volt Override Pushbutton

ignal Horn

(w/Amber Indicator Lamp)

Pushbutton

ignal Horn (w/Amber Indicator Lamp) Pushbutton (white) Slope Alarm Cable Harness Plug FIG. 14 normally

(white)

Slope

Alarm

Cable Harness Plug

FIG. 14

normally closed contacts which complete the pump motor contactor circuit, and it is these contacts which are opened during a low voltage condition.

Terminal 7 ofthe module is the battery input voltage, while terminal 6 is machine ground. Terminals 1 & 2 are normally open contacts which close during a low voltage condition and turns on an amber indicator light (pushbutton) at the upper control box. The system can be overridden by pressing the pushbutton on the side ofthe upper control box (See FIG. 14), which energizes terminalS ofthe module. However, the override will only allow three repeated by-pass cycles of2 minutes 30 seconds each. The LVI module will reset when the battery voltage reaches approximately 25.5 volts during re-charging. Once the batteries have been properly charged and the LVI module has automatically reset, the CONDOR® can be operated once again.

TRAVEL ALARM (OPTION)

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

DESCEND ALARM (OPTION)

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

MOTION ALARM (OPTION)

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

HOUR METER (OPTION)

This option is to record the "run time" ofthe machine for maintenance scheduling, rental usage, The meter runs only when the pump motor contactor is energized (pump running); therefore, the

etc

meter does not run when the machine is sitting idle, or when the platform is being lowered.

MANUAL 923SO-OO2

JANUARY 1997

. SIN X93S-970SI

BATTERY SERVICE

BATTERY SERVICING TOOLS

Use propertools when performing battery service to preventdamage to battery, cables, terminals and hold-downs, and to save time and energy.

Suggested battery tools and their use are described below.

FILLING DEVICES

tools and their use are described below. FILLING DEVICES One of the most important routine battery

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

SCRAPER AND WIRE BRUSH

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

BATTERY CARRIER

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

SERVICE PROCEDURES

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

CAUTION

Low batteryvoltage (discharged) requires highercurrentdrawto dothe same work. This high current draw WILL DAMAGE the electric motor, relay contacts and the batteries. DO NOT OPERATE the CONDOR® with a battery DISCHARGED or that has a specific gravity of 1.130 or LESS.

Routine servicing of the battery should proceed as follows:

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

When there is corrosion onthe 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 orbaking soda in water.

MANUAL 923S()'oo2

JANUARY 1997

SIN X93S-970S I

Next, wipe with a cloth with clear water. After rust is removed from a part

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

Ifcorrosion 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.

with a spray corrosion inhibitor or high temperature grease. The second item in routine servicing ofconventional

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

BATTERY TESTING

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

STEP 1-

VISUAL INSPECTION

For protection, wear a face shield. First, visually inspect the battery. Check for container, cover or terminal damage that might cause leakage ofelectrolyte or internal damage. Ifserious damage

is found, replace the battery. Check the electrolyte level in each cell. If below the tops of the plates in

any cells, fill all cells with water to just above the tops ofthe separators and charge for 15 minutes at 15- 25 amps to mix the water with the electrolyte. If electrolyte levels are above the tops of the plates, continue to Step 2.

STEP 2 -

HYDROMETER TEST

Using the hydrometer, measure and record the specific gravity (sp. gr.), corrected to 80 degrees

F (26.7 C) ofthe electrolyte in each cell. Ifthe range (highest-lowest) is 50 points (0.050 sp. gr.) or greater

orthe lowest is lessthan 1.225 sp.gr., charge the battery atthe recommended rate oruntil all cells are 1.225

If no amount of charging will achieve these

sp.gr. or greater and the range is less than 50 points.

DANGER

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

MANUAl 92350-002

JANUARY 1997

SIN X93S-970S1

The average state ofcharge ofthe cells in a battery can be determined by measuring the stabilized.

voltage of the battery. The voltage is stabilized if the battery has been on open circuit overnight or for a period of several hours. A voltage reading of 12.4 (6.2 on a 6 volt battery) is equivalent to a specific gravity of 1.225. The disadvantage ofmeasuring 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

of0.05 volts between the highest and lowest cells corresponds to a 50 point variation in specific gravity.

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

STEP 3 -

ADJUSTABLE LOAD TEST

The following instructions are intended as guidelines.

manufacturer's instructions should be followed. Follow all precautions.

When available, the instrument

A. Disconnect battery cables starting with ground cable.

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

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

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

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

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

G.

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

H.

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

I.

, If test voltage

is below minimum, replace battery.

TESTING WIm FIXED LOAD TESTER AND OPEN CIRCUIT

Fortesting batteries with a fixed loadtester and an open circuitvoltmeter, referto "Battery Testing Chart" Figure Y.

STEP 1 -

VISUAL INSPECTION

First, visually inspectthe battery and checkthe electrolyte levels as described in Step 1of"Testing

with Adjustable Load Tester and Hydrometer"; take the same corrective actions.

MANUAL 92350-002 JANUARY 1997 SIN X935-9705 I

Continue to Step 2.

.STEP 2 -FIXED LOAD TEST

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

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

A. Disconnect battery cables starting with ground cable.

B.

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

C.

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

D.

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

E.

Apply test load for 15 seconds.

 

F.

Read

battery performance from instrument meter at 15 seconds, then

remove the load.

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

H.

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

STEP 3 -

OPEN CIRCUIT VOLTAGE TEST

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

F.)

OPEN CIRCUIT VOLTS

PERCENT CHARGE

12.6 or greater

100%

12.4

- 12.6

75-100%

12.2

- 12.4

50-75%

12.0

- 12.2

25-50%

11.7

- 12.0

0-25%

11.7orless

0%

The change of voltage with state of charge is small and must be measured accurately using a digital meter or an analog meter with an expanded scale. Ifthe state ofcharge is 75% or greater and the battery failed the load test, it should be replaced. Ifthe state ofcharge is less than 75%, the battery should be charged at the recommended rate and time, and the load test repeated. Ifthe battery passes the load test, return it to service. If it fails the load test again, replace it and refer to the next chapter to determine the cause offailure.

MANUAL 92350-002

JANUARY 1997

SIN X93S-97051

DETERMINING CAUSES OF BATTERY !AllJURE Whether the battery passes or fails either of the above

DETERMINING CAUSES OF BATTERY !AllJURE

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

1. Corroded Battery Terminals or Connectors

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

2. Electrical Circuit Leakage

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

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

B. Ohmmeter - Disconnect the positive cable at the battery. Connect an ohmmetertothe disconnected cable end and to the chassis. A resistance measurement ofunder 100 ohm indicates a load of0.1 amp or more and indicates the equipment electrical system should be tested and repaired.

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

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

3. Charging System

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

MANUAL923SG-002

JANUARY 1997

SIN X93S-970SI

FIGURE: X

BATTERY TESTING CHART

STEP 1

VISUAL INSPECTION

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

I OBVIOUS DAMAGE I

IREPLACEBATTERVI

BELOW TOP OF PLATES IN ONE OR MORE CELLS

ADD WATER TO JUST ABOVE SEPA- RATORS. CHARGE FOR 15 MINUTES AT15-25AMPS. PROCEED TO STEP 2

I NO OBVIOUS DAMAGEj

I