Condor V2033XL 92350

CJ
SELF-PROPELLED
ELEVATING WORK PLATFORM
MODEL V2033XL, V2033

Serial Number X935-97051
OPERATOR'S, MAINTENANCE,
AND PARTS MANUAL
SHIPPING ADDRESS
MAILING ADDRESS
TIME CONDOR
TIME CONDOR
8300 IMPERIAL DRIvE

WACO, TEXAS 76712
(254) 420-5200
WACO, TEXAS 76702-1447
P.O. Box 21447

(254) 420-5200
MANUAL 92350
JANUARY 1997
SIN )(935-97051
~
INTRODUCTION
The primary purpose ofthis 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 AT ALL TIMES.
Do not attempt to operate this CONDOR until you have read and
understood all information provided in this manual. Familiarize
yourself with the functions and operations of the upper and lower
controls. A good understanding of the controls, their limitations, and
their capabilities wili maximize operating efficiency. The various decals
attached to this CONDOR contain vital information. Read all decals
before operating this CONDOR.
It is YOUR RESPONSIBILITY to follow procedures while operating this CONDOR. The

manufacturer of this CONDOR cannot control the wide range of applications that may be used in
carrying out a variety of jobs. Therefore, IT IS THE USER'S RESPONSIBILITY to consider all of the
personnel when making decisions regarding the intended use of this CONDOR.
It is also YOUR RESPONSIBILITY to understand and obey all federal, state, and local regulations
regarding the operation and use of aerial work platforms. A copy of the ANSI/SIA A92.6-1990 Manual of
Responsibilities is attached for your use.
Condor Div. reserves the right to modify, improve, add, and/or delete certain design features of its
products without any obligation to incorporate new features into products previously sold. Manuals are
continually updated to reflect these changes.
DO NOT ALTER OR MODIFY THIS CONDOR WITHOUT PRIOR WRITTEN

APPROVAL FROM THE MANAGEMENT OF CONDOR Div.
SERVICE & MAINTENANCE

Many ofthe parts used in the manufacture of this CONDOR have specific properties, and the
manufacturer recommends that replacement parts be purchased through Condor Div. in order to ensure the
original integrity of the product. Repairs and adjustments should only be made by trained and qualified
personnel. Please refer to the maintenance and parts sections of the Condor Operation, Parts & Maintenance Manual for information on service and maintenance ofthis CONDOR.
MANUAL 92350-001
JANUARY 1997
SIN X935-97051
ii
A div. of TIME Manufacturing Company

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

service and parts personnel are always available by phone or fax. The telephone
numbers are:
(817) 420-5200 Telephone
(817) 420-5299 Voice Mail
(800) 443-5803 FAX
2.
There are numerous written Maintenance Procedures available for this CONDOR.
These procedures are available through the CONDOR Service Department to anyone
who requests them.
3.
Service and maintenance are not a substitute for trained, qualified service technicians.
CONDOR conducts service schools on a continuing basis. Call any of our service or
sales persons for a schedule. Remember, training of mechanics is the responsibility of
their employer, but CONDOR Service Schools help you provide this training.
4.
CONDOR Service School Training Manuals are available for purchase through the
parts department. The part numbers for these manuals are: #92333 for self-propelled
models; and #92334 for truck-mounted models.
8300 IMPERIALDRIVE,P.O. Box21447, WACO, TEXAS 76702-1447 817-420-5200, 817-666-4544 FAX

0
MANUAL 92350-001
JANUARY 1997
SIN X935-97051
i)
iii
TABLE OF CONTENTS
IN'TRODUCTION ....................................................................................... ;
SERVICE INFORMATION .......................................................... u
TABLE OF CONTENTS ................~ .............................................. iii
I. PREPARATION, INSPECTION, AND MAINTENANCE .............................................................. 1

A.
B.
C.
D.
E.
F.
Overall Machine Condition ....................................................................................................... 1

Lower Control Station ............................................................................................................... 1
Emergency Lowering ................................................................................................................ 1
Platform and Upper Control Station ...................................................................... ,................... 2
Hydraulic System ...................................................................................................................... 2
Batteries ..................................................................................................................................... 2
II. MACIllN"E OPERATION .................................................................. 2

A.
B.
C.
D.
E.
F.
G.
Rated Work Load ...................................................................................................................... 2

Lower Controls .............................. :........................................................................................... 2
Upper Controls .......................................................................................................................... 3
Emergency Lowering ................................................................................................................ 3
Lift-up Entry Gate ................... ,................................................................................................. 3
Deck Extension ......................................................................................................................... 5
Removable Upper Control Box ................................................................................................. 5
ill. MOVING FROM JOB-SITE TO JOB-SITE ................................................ 5

A.
B.
C.
D.
E.
Loading and Unloading ............................................................................................................. 5

Ramp Method ............................................................................................................................ 5
Forklift Loading and Unloading Method .................................................................................. 5
Transporting .............................................................................................................................. 6
Freewheel Operation ................................................................................................................. 6
IV. STORAGE ............................................................................. 6
APPENDIX: DECALS ILLUSTRATION ................................................................................................ 8

ANSIISIA A92.6 - 1990 MANUAL OF RESPONSIBILITIES
)
MANUAL 92350-001
JANUARY 1997
SIN X935-97051
---_
....
(.
IMPORTANT: A COPY OF THE ANSIISIA A92.6 - 1990 MANUAL OF RESPONSIBILITIES IS

ATTACHED TO TIDS OPERATOR'S MANUAL. IT CONTAINS IMPORTANT OPERATING
INFORMATION FOR mIS CONDOR. READ IT BEFORE OPERATING THIS CONDOR.
I.
PREPARATION. INSPECTION. AND

MAINTENANCE
STEERING:
The condition of this 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
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:
KNOW TillS CONDOR AND ITS

CAPABILITIES. REPORT ANY UNUSUAL
OPERATION,SUCHASERRATICSWAYOR
MOTION OF THE ARMS OR PLATFORM.
Check that all decals and warning

signs are in place and are clearly
legible.
Some major areas to check daily are:

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.
A. OVERALL MACHINE CONDITION

MISSING, BROKEN, OR DAMAGED
PARTS:
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.
B. LOWER CONTROLS
TIRES AND WHEELS:
Check that all functions operate

properly, that switches return freely
to neutral position. Do not operate
the CONDOR with sticking controls
for cracks, tears, cuts, or missing or

D Check
loose lug nuts (a rust line running down the
rim from the lug nut indicates a loose lug
nut).
C. EMERGENCY LOWERING
MANUAL 92350-001
JANUARY 1997
SIN X935-97051
Check emergency lowering

function by pulling red T-handle.
D. PLATFORM AND UPPER

CONTROL STATION
that lift-up entry gate is functional
D Check
and that chain is secure.
D
D
D
D
Re-check the structural condition of the

platfonn-pins, railings, and floor.
tight and clean and free of corrosion.
Check for missing bolts & nuts - Replace

before operating.
indicator lights and meter are not damaged.
II. CONDO" OPERATION

Check function of red button. It disconnects
power to the controls and, when pushed,
stops all powered functions.
Check that drive control lever returns freely
to neutral.
the hydraulic tank fluid level with

D Check
the platfonn all the way down. Fluid must
CAUTION
CONDOR MUST BE OPERATED
ON FIRM, LEVEL GROUND ONLY.
A. RATED WORK LOAD
The platfonn will support a combined weight

equal to the unit's rated work load-including
personnel, tools, and equipment-throughout the
working envelope of the CONDOR.
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.
Rated work load, on extension deck only, is not to

exceed 250 Ibs. (113 kg) including one occupant.
Total rated work load is not to exceed 750 Ibs.
(340 kg) including two occupants.
Check for hydraulic leaks at all fittings

and valves.
B. LOWER CONTROLS
CAUTION
ARM STAND MUST BE USED WHEN
MAINTENANCE PERFORMED ON
CONDOR REQUIRES SCISSOR
ARM'S TO BE RAISED.
D Check
all hydraulic hoses and tubes for
damage and kinks.
F. BATTERIES
CAUTION
Keep flame, sparks and metal away
from the batteries.
D Make sure the battery charger and the
Check that extension deck is locked in

place.
E. HYDRAULIC SYSTEM
D Keep battery tops clean and dry.

D Keep vent caps tightly in place.
D Check that battery cable connections are
Check Electrolyte level daily in each cell.

Ifnecessary, add clear, odorless, mineral
free water to bring the level to 112" above
the top of the separators, or to the Level
Indicator (if equipped), in each cell. Only
add water after charging cycle is complete.
1. To engage ann stand, raise platfonn,

then rotate stand until it hangs vertically.
Lower the platfonn until the arm stand rests
on the cross tube on the frame. Maintenance
can now begin.
MANUAL 92350-001
JANUARY 1997
SIN X93597051
,)
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.
Select desired drive speed with the "high/low/

creep" switch. (A limit switch automatically cuts
drive speed to "creep"as the platform is raised.)
Tum "controls" switch to "lower" position, to

operate from ground.
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.
In an emergency, push red button. To operate,

button must be pulled out. (Also, if applicable, battery disconnect switch must be "on" to
operate.)
Push "raise" or "lower" switches to move
platform.
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.)
Tum switch to "upper" position, to operate

from platform.
C. UPPER CONTROLS
Tum "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.
To steer left or right, squeeze lever switch on

handle, and depress rocker switches on top of
handle in the intended direction of travel. 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. EMERGENCYLOWEruNG
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 X93597051
LOWER CONTROLS
RED EMERGENCY
STOP BUTTON
OPERATING --:-_ _ _
INSTRUCTIONS
RAISEILOWER
BUTTONS
~_~
I
CONTROL STATION_--~~--~-:T
SELECTOR SWITCH
! i
CONTROL
CIRCUIT
BREAKER
1 .
UPPER CONTROLS
RIGHTILEFT
STEER
ROCKER
SWITCH
POSITRACTION
SWITCH
DRIVE
CONTROL
HANDLE
REDEMERGENCY __----+-~~~~~~
STOP BUTTON
~
~~
'i
'i J
V!
,i
/i
RAISEILOWER
BUTTONS
I"
HIGHILOW/CREEP
DRIVE SPEED
SELECTOR
SWITCH
/>-.
rf/ :
!
Ii
,~I,
POWER
BUTTON
MANUAL 92350-001
JANUARY 1997
SIN X935-97051
:)
F. DECK EXTENSION
B. RAMP METHOD
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.
Ensure that the ramp is sufficiently strong to

support the weight of the CONDOR.
CAUTION
Do not lower extension deck onto
people or any objects!
The ramp should be set, not steeper than this

CONDOR's rated gradeability, which for Model
V2033IXL is 140 or 25%, or a rise of 30 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.
G. 'REMOVABLE' UPPER CONTROL

BOX
CAUTION
Select "low" drive speed,
not "high" and not "creep".
Unsnap overcenter latch at bottom of upper control

box and pull plug out of receptacle. Bend cable so
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.
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.
m. MOVING FROM JOB-SITE TO
-)
JOB-SITE
C. FORKLIFT LOADING AND

UNLOADING METHOD
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
2633
WEIGHT(#)
3,300Ibs.
WEIGHT(KG)
1496 kg .
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 X935-97051
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 orentIy steps.
Always turn the power off at the lower control
station.
E. FREEWHEEL OPERATION
CAUTION
This CONDOR must be on firm, level
ground when releasing the parking brakes.
To put the CONDOR into freewheel mode,
use the brake release handles on the rear axle.
One handle is on the front side of the axle and
the other is on the rear side of the axle. Turn
each release handle 90 and at the same time,
slightly rotate it. The brakes are now released.
(Released brakes will automatically reset the
next time forward or reverse drive is used,
then will engage when drive is stopped.)
Never exceed 5 mph when moving the

CONDOR in the freewheel mode.
IV. STORAGE
When you get out of the platform, leave it all the
way down.
CAUTION
Never park the CONDOR
with platform raised.
)
MANUAL 92350-00 I
JANUARY 1997
SIN X935-97051
NOTES
)
~AL 92350-001
SANIJARY 1997
IN X935-9705 1
APPENDIX: DECALS ILLUSTRATION
'\
SEC7iC\l 8-i3
PARTIAL
SECTION A-A
22
1,0
~
23
,-,
:2
1;~
<:
,----- i~ i~ucrn,~,
!
o~~
1':)
;--
""
FRONT
""
,
13
4-
LEFT SIDe:
11
"
'
1'9
<3ACK
MANUAL 923S()"()()1
JANUARY 1997
SIN X93S-970S1
APPENDIX: DECALS ILLUSTRAnON
PART NUMBER
Ref
*1
*2
*3
*4
*5
6
*7
55487 ............................ Decal Installation ...................................................................... Ref.

54984-001 ..................... Decal, Upper Oper. Instructions .................................................... 1
54652-001 ..................... Decal, Itemized Caution Notes ...................................................... 1
54984-002 ..................... Decal, Rated Work Load ............................................................... 2
55480-002 ..................... Decal, LowerOper. Instructions ................................................... 1
54652-003 ..................... Decal, Guardrail/Chain Caution .................................................... 1
54984-007 ..................... Decal, Hydraulic Fluid .................................................................. 1
54652-002 ..................... Decal, Arm Stand Caution .............................................................. 1
54984-005 ...................... Decal, Rear Bumper ...................................................................... 1
66973 ............................ Decal, Electric Hazard Keep Clear ................................................ 2
54984-006 ..................... Decal, 110 Volt Ext. To Platform .................................................. 1
69473-002 ..................... Decal, Die-Cut, CONDOR 3.45 x23 ............................................ 2
54985 ............................ Decal, Die-Cut ............................................................................... 2
55291 ............................ Tape, OrnlRed 3" .............................................................. 17.75LF.
55480-001 ..................... Decal, Lower Controls .................................................................. 1
53259 ............................ Tape, Non-Skid 6"W Black ................................................ 1.67LF.
66921 ........... :................ Coating, Non-Skid Jet Black ............................................... .27GL.
*8
*9
10
11
12
13
*14
15
16
21
*22
*23
QTY
ITEM
DESCRIPTION
...................................... Nameplate, Scissors Ident........................................................ Ref.

54976-001 ..................... Decal, Upper Control Box Top ..................................................... 1
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 X93597051
OPERA TING INSTRUCTIONS

TUR~ ":::\~ROLS" SWITCH, S\J LO'~'jER CO~TRc)L ?;'.~::L. TO '~UPPER" ::::Sl~:C~ -: :::;::c:~;;:-=: =-QOM PLATF0~M.
IN AN ::\/::~GENCY, PUSH RE;J BUTTON. 'f0 OPERA 7~ ~~OM ?LA. TFOR\/. 3JT~ ~::= 3,j:'C;,\S, ,:;-..j LQ'XER
AND ON .;"ClER CONTROLS, )/UST BE PULLED OL'-:-.
TO RAISE .l.ND LC'XER PLAT;:-JRM, PL;SH AND HOi...: :-i~ GREt:\ "~O:.;:~" BLi~:="", ':">.jD P~S~ iHt: "RA;St:"
OR "LO'::;::~" BUTTON. RELEASE BU"TTONS TO STOP VOVEMEN~.
SELECT :RVE SPEED ViIT" ,:-1'0 "!-i:GH/LO':':/CRE;::P" S,'iiTCH.
A liMIT S:.. "TCH AUTOMATICALLY CUTS BACK THE S"'EED AS T;.jE PLA~;:-CRM :S p" S;::O.
TO DRIVE O'CRWARD OR REV;::RSE, SQUEEZE LEVER S;'iITCH aN HANDl;::, AND ::e;S- OR "'0L.L. ;.jANDLE
iN THE \, -[\jDED DIRECTION OF TRAVEL,
RELEASE _EVER SWiTCH TO SiOP MOVEMENT. LE',:NG GO Or HANDLE A,,-SO :.,:.._ STOP ;g;VEMENT.
BRAKES ':''<E AUTOMATICALLY RELEASED WHENEVE'< ,HE DRIVE HAND:..E :S \.10V;::J.
LET GO cO' THE HANDLE TO AUTOMA TlCALL Y SET ,;-iE BRAKES.
TO IMPRC'/;:: DRIVE TRACTICN, DEPRESS AND HOLD "POSITRACT!ON" S;.:TCH.

THIS WILL AuTOMA TICALL Y CUT-OUT HIGH SPEED.
!
II.
TO STEER :..t:f'T OR RIGHT, SQUEEZE LEVER SVVITCH ON HANDLE, AND SEPRESS ::::;CKER S~\'TCHES
ON TOP cO' HANDLE IN THE iNTENDED DIRECTION C<=" nAVEL.
STEERING S NOT AuTOMA TICALL Y SELF -CENTERiNG. 3E SURE THE S-:-;::ERiNG :.'-,EE_S PO,:-';T
fN THE =: ~~CTIQN YOU :/t..NT 2EFOR:: LEiTING GO
!~E STt:i:R S:.:-:-':H.
:=-
)
2
DO NOT OPERATE THiS CONDOR'" UNTiL YOU ;-iAVE BEEN PROPER:'" Y TRAINE::: "ND HAVE
COMPlt:TEL Y READ AND-uNDERSTOOD THE O?t:RA TOR'S MANUAL ,;--A T :s L.C:::; -t:D 0\ ;'-i!S CONDOR.'"
2.
PRIC~ TO EACH DAY'S ~SE. CHECK TO MAKE S...:Rt: ALL FUNCTIONS AKC :,::::=<.t.,:-:i\G ::JqCP~RLY.
?ERFO;=(M ALL i~SPECT:C~S REQUIRED BY SEC-;-,QN 6 OF Ti-iE ANSi 92.3 S- ~.'<~ARD.
3. DO '\J~ USE THE CONCOR"', ,,,. T IS MAi..FU":::~;'JN!NG OR JAMAGEC ,\; A1\ v :.~ v,
GR ,O' "'I-'E WiND BL.OHS ::JVER i5 MPH.
4
DO \iOT DRIVE ON A SLOPE UNLESS T'-<E PlATFCRM IS rUlLY LO.\ERED.
5. RAiSe: THE PLA TFORM ONLY WHEN THE CONDOR" 'S ON FIRM, LEVEL GROu:-,;C.
6. ALWAYS LOOK IN THE DiRECTION IN liHICH ,H'O: PLATFORM IS MOV:NG.
,'jATC'" FOR, AND AVOiD, OVERHEAD OBSTRUCT'ONS AND ANYTHING EL.SE bA -;- \/JAY STR!KE
PLATFORM, PERSONNEL, OR CONTROLS.
7. THIS CONDOR'" IS NOT ELECTRICALLY iNSULA -;-EJ.
MAINTAIN SAFE CLEARANCES FROM ELECTRICAL POv'jER L:NES.
8. FOLLO:: INSTRUCTIONS IN OPERA TOR'S MANUAL ":HEN SERVICING SA TTER!ES.
EACH REPLACEMENT BA. TTERY MUST 'SEIGH Ai ,-EAST 55 Ibs. DRY AND 66 ::s.:JET.
REP:"'AC::MENT TIRES MUST BE SAME A.S F"AC,CRY ORIGINN_S.
10. iN CASE OF AN EMERGENCY, PUSH THE RED ";C\\ERGENCY STep" su nON.
~.
)
MANUAL 92350-001
JANUARY 1997
SIN X935-97051
RA TED WORK LOAD

ON :::XTENSiJN
;S 250L8SJK
is
:::;=:=~
CNL Y,
750L8S OR
GUARDRAILS AND SAFEiY

C:-iAiNS rv1UST BE SEC~~ED
L,ND USED A.T ALL nlES
545S2-CC3
HYDRAULIC
FLUID
10
LD
::4984-CC7:
fA n n'l?r~rr\n
~~U u ~VU~
rf"":,
ii
STAND CLEAR
UNLESS ARM STAND
is i\.J PLACE
54652-0C2
8
FORKLIFT
POCKET
EMERGENCY LOWERING
)
MANUAL 92350001
JANUARY 1997
SIN X93597051
BRAKE RELEASE
FORKLIFT ::
POCKET
ELECTROCUTION HAZARD
KEEP CLEAR
DEATH OR SERIOUS INJURY CAN RESULT FROM
CONTACT WITH THIS EQUIPMENT OR VEHICLE
IF IT SHOULD BE ELECTRICALLY CHARGED.
21882-001
THIS MACHINE IS NOT INSULATED

ELECTROCUTION HAZARD
MAINTAIN SAFE CLEARANCES FROM ELECTRICAL LINES AND
APPARATUS. YOU MUST ALLOW FOR BOOM SWAY, ROCK OR
SAG AND ELECTRICAL LINE AND LOAD SWAYING.
THIS AERIAL WORK PLATFORM DOES NOT PROVIDE
PROTECTION FROM CONTACT WITH OR PROXIMITY TO AN
ELECTRICALLY CHARGED CONDUCTOR.
YOU MUST MAINTAIN A CLEARANCE OF AT LEAST 10 FEET
BETWEEN ANY PART OF THE WORK PLATFORM OR LOAD AND
ANY ELECTRICAL LINE OR APPARATUS CARRYING UP TO
50,000 VOLTS. ONE FOOT ADDITIONAL CLEARANCE IS
REQUIRED FOR EVERY ADDITIONAL 30.000 VOLTS OR LESS.
DEATH OR SERIOUS INJURY WILL RESULT FROM CONTACT OR
INADEQUATE CLEARANCE.
MANUAL 92350-001
JANUARY 1997
SIN X935-97051
1,0 VOLT
EXTENSION TC
PLATFORM
10
,OPERA ilNG iNSTRUCTIONS
17
~~~N "C:JNTRGLS'
--:-0 ::;::>ERATE
54964-006'
:=-~GM
S/. ;TCH
rs ". :=:.::~"
?::S:-:-;D~,
::;~OUNO.
:. iN A\l EMERGENCY, ;::iJSH RED 3LT-::~;.

-:-0 2PERA TE. BUTiCN MUST 8E ~UL_::::: Q\.,;: .
.. ALSO. iF A.PPUCABL. BA TTER':" JiS::::~~Nt::~
S~V1TCH MUST BE 'C~" TO OP;::RA. 7E.~
:. F'USI-i 'RAISE" QR "~:JWER" gt.:7~GI\S

TO MOVE PLA TFORM.
i!
;. 'uRN SWiTCH TO "uPPER" PQS,"'lON

"'0 OPERATE ,ROM "LATFORM.
~7$-1X!21
21
IIcmLAJ~~>YLAJOOII~4---1Rf
CALAVAR
I MANUFACTL.:Rc..D
ICONDOR
i PLA TFORM
I ~YSTEM
THIS
TO
U.S.A.
: SERI A'-
i RA TED
2533
H::.IGHT
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SELF-?ROPELLED ELEVATiNG WORi< P,-AT~ORM CONFORMS
ALL APPLICABLE REQ~IREMENTS OF ANSi A92.5-'990
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MANUAL 92350-001
JANUARY 1997
SIN X93S-970SI
LOWER
SELF-PROPELLED

Serial Number X93S-970S1
MAINTENANCE MANUAL
r)
SHIPPING ADDRESS
MAILING ADDRESS
TIME CONDOR
TIME CONDOR
8300 IMPERIAL DRIVE

VVACO, TEXAS 76712
(254) 420-5200
VVACO, TEXAS 76702-1447
P.O. Box 21447

(254) 420-5200
MANUAL 923S()'OO2
JANUARY 1997
MANUAL 923S0002
JANUARY 1997
SIN X93S970S1
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 of theCONDOR, and to provide the
information necessary to maintain and service the CONDOR.
THEOPERATOR'SMANUALMUSTBERETAINEDONTHECONDORATALL TIMES.
Do not attempt to operate or service the CONDOR until you have read and
understood all information provided in this manual. Familiarize yourself with
the functions and operations of the upper and lower controls. A good understanding of the controls, their limitations, and their capabilities will maximize
operating efficiency. The various decals attached to this CONDOR also
contain vital operational instructions. Read the decals before operating this
CONDOR.
It is YOUR RESPONSIDILITY 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 RESPONSIDILITY to consider all personnel when
making decisions regarding the CONDOR's intended use.
It is also YOUR RESPONSIDILITY 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 Boom-Supported
Elevating Work Platforms, and ANSI/SIA A92. 6-1990 is provided for Self-Propelled Elevating Work
Platforms.
Time Manufacturing-Condor Division reserves the right to modify, improve, add, and/or delete certain
design features of its products without any obligation to incorporate new features into products
previously sold. Our manuals are continually updated to reflect these changes.
DO NOT ALTER OR MODIFY THIS CONDOR WITHOUT PRIOR WRITTEN APPROVAL

FROM THE MANAGEMENT OF TIME MANUFACTURING-CONDOR DIVISION

Many of the parts used in the manufacture of the CONDOR have specific properties, and the
manufacturer recommends that replacement parts be purchased through Condor Division in order to
ensure the original integrity of the product. Repairs and adjustments should only be made by trained and
qualified personne1. Please refer to the maintenance and parts sections ofthe Condor Division Operation,
Maintenance, & Parts Manual for information on service and maintenance of the CONDOR.
NOTE:
Please refer to the Condor Division section of the Operation, Maintenance, & Parts Manual
for information pertaining to your CONDOR.
ii
1. If you need assistance or have any service or maintenance questions, Condor Division service
and parts personnel are always available by phone or fax. The telephone numbers are:
(817) 420-5200 Telephone
(817) 420-5299 Voice Mail
(800) 443-5803 FAX
2. There are numerous written Maintenance Procedures available for this CONDOR.
These procedures are available through the Condor Division Service Department to anyone
who requests them.
3. Service and maintenance are not a substitute for trained, qualified service technicians.
Calavar conducts service schools on a continuing basis. Call any of our service or sales
persons for a schedule. Remember, training of mechanics is the responsibility of their
employer, but Condor Division Service Schools help you provide this training.
4. Condor Division Service School Training Manuals are available for purchase through the
parts department. The part numbers for these manuals are: #92333 for self-propelled models;
and #92334 for truck-mounted models.
CONDOR DIVISION
)
8300 IMPERIAL DRIVE, P.o. Box21447, WACO, TEXAS 76702-1447' 817-420-5200, 817-666-4544 FAX
-'~'---
iii
Condor Self-Propelled Booms and Scissors

WARRANTY
Time Manufacturing (Condor Division) warrants to the purchaser that each new aerial work platform made
by Condor Divisionis free from defects inmaterial and workmanship arising under normal use and servicein the case of majorweldments, (chassis, turret, and booms), for a period of five (5) years after the original
shipment of the aerial work platform from Condor Division's plant; and in the case of all other parts, for a
period of one (1) year after the aerial work platform is placed in service or two (2) years after the original
shipment of the aerial work platform from Condor Division's plant, whichever comes first
The obligation and liability under this Warranty is expressly limited to repairing or, at Condor Division's
option, replacing free of charge at its factory in Waco, Texas or at an authorized repair facility designated
by Condor Division, the defective part. In no event shall Condor Division or its suppliers be liable to the
purchaser or any other person for transportation charges or for any incidental, collateral, special, or
consequential damages, including without limitation damages for loss of profits, loss of customers, loss of
goodwill or work stoppage, claims by any party other than the purchaser, or any other similar damage or loss
even if Condor Division, its suppliers, or its representatives have been advised of the possibility of such
damages.
Parts claimed to be defective and for which repair or replacement is desired shall be returned transportation
prepaid to Condor Division's factory for inspection. This Warranty applies to replacement parts provided
under the terms of this Warranty only for the remainder of the Warranty period applicable to the original
purchase.
Any operation of the equipment beyond rated capacity, improper use or application of the equipment,
substitution upon it ofparts not approved by Condor Division or alteration or repair of the 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 e}..iend this Warranty in any way. If the
purchaser has used its own order form, no additional or different warranty terms contained in the purchasers
form willbe honored by Condor Division. This Warranty covers only new and unused aerial work platforms
manufactured by Condor Division. Products or parts manufactured by others are covered only by such
warranties as are extended to the purchaser by Condor Division's suppliers.
This Warranty is in lieu of all other warranties, expressed or implied, including but not limited to warranties
of merchantibility and fitness for a particular putpose. Any applicable implied warranty shall be limited in
duration to the warranty period.
8300ImperialDrive, P.O. Box21447, Waco, Texas76702-1447817-666-4545,817-666-4544FAX
Form No.513-3M-392
Effective Date 9/1/90

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.
Condor Division Warranty states, in general, that Condor Division will replace free of charge any
components found to be defective within the time frame of the warranty period. There are exceptions to
some components which are not the responsibility of Condor Division. These will be outlined in
subsequent paragraphs.
A.
WARRANTY PERIODl.
The Self-Propelled Boom and Scissor Warranty is one (1) year from placing the
CONDOR in service or two (2) years following shipment from Condor Division,
whichever comes first. In the case of major weldments (chassis, turret, and booms), the
Warranty Period is five (5) years following shipment from Condor Division.
2.
The Truck-Mounted CONDOR Warranty Period is one (1) year from shipment ofthe
CONDOR from Calavar's plant.
3.
For parts sold through the Parts Department, the Warranty Period is six (6) months from
utilizing the component or placing it in service, or twelve (12) months following
shipment from Condor Division, whichever comes first, unless the part is furnished to
correct a defective part on the original shipment still under Warranty.
4.
Replacement parts provided under the terms of the Warranty are for the Warranty Period
applicable to the unit in which they were installed as if such parts were original
components of the aerial work platform.
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 timetheCONDOR is
first used for any purpose. An example: The dealer may have purchased aCONDOR
to have in stock, but may not use it. After three months, theCONDOR 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.
,_0_,'_0
B.
PRE-DELIVERY INSPECTION SHEET (P.D.I.)

1.
Each Self-Propelled Boom or Scissor CONDOR shipped from Time ManufacturingCondor Division'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 of the original recipient oftheCONDOR 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.D.1. sheet and return itto Condor Division within the time frame
given will result in voiding the Warranty on the CONDOR.
NOTE:
The form must be filled out completely, giving the name of the dealer, address, model
number, serial number, person inspecting the CONDOR 's, signature, and date of
inspection. (The date of inspection does not constitute the "In Service" date.)
C.
ITEMS NOT COVERED UNDER WARRANTY

Some components are used on the CONDOR which are not warranted by Condor Division.
However, these are warranted by the component manufacturer. Some of these are:
1.
Tires and Batteries: These are normal wear items and are considered normal
maintenance items. However, if they are found to be defective, contact can be made with
the manufacturer's local dealer.
2.
Hvdraulic Filters and Fluid: These are considered general maintenance and service
items, and are not covered by warranty.
3.
Oth er components: Products or parts manufactured by others are covered only by such
warranties as are extended to Condor Division by its suppliers.
4.
Freight and Charges: The warranty does not include any transportation, other charges,
or the cost of installation or any liability for direct, indirect, or consequential damages or
delay resulting from the defect.
5.
Travel Time / Mileage: Travel time and the mileage to and from dealer facilities to
CONDOR location are not covered or reimbursable.
6.
Troubleshooting: Troubleshooting is not covered or reimbursable. However, Condor

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

During the Warranty Period, should a component failure be encountered within the guidelines of
the Condor Divison Warranty Policy, the following procedure is to be followed:
1.
Upon identifying the defective component, the replacement can be obtained by:
a.
Issuing an order to our Parts Department through normal channels, which

entails your being invoiced.
b.
You may have previously purchased the part from Condor Division for your
stock and will utilize it for this replacement.
The above two methods will enable you to indicate on the claim the Condor Division
invoice number to substantiate the parts purchase and the amount to be credited.
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.
Condor Division 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 puchased from Condor Division, 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 Condor Division to thoroughly
evaluate the claim and process it in the shortest amount of time possible.
NOTE:
WARRANTY CLAIMS WILL NOT BE ACCEPTED BY CONDOR DIVISION
AFTER 45 DAYS AFTER FAILURE
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 Condor Division Service Department and ask to
be issued a Return Authorization (RIA) number. You will be asked for a Dealer Claim
Number. As noted in Section 2, Item A, ofthe W arrantyClaim 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 RIA 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 WITHOUT
A RETURN AUTHORIZATION (RIA) NUMBER
Doing so may result in parts getting lostin the system and may delay processing the claim,
or may cause denial due to the time element of the claim.
3.
All RIA parts must be received at Condor Division within 45 days from the date the RI
A number was issued. Failure to do so will cause the claim to be denied.
4.
All parts claimed under Warrranty will be required to be shipped back to Condor Division
FREIGHT PREPAID. No freight collect shipments will be accepted.
..
CONDOR Model V2033XL, V2033
MAINTENANCE MANUAL
TABLE OF CONTENTS
IN"lRODUCTION ................... ........ .......... ........ .............. .......... ...... ............... ... ...... ............... i
CONDOR SERVICE INFORMATION ............................................................................ ii
SELF-PROPELLEDWARRAN"TY ....................................................................................... iii
Table ofContents ...................................................................................................................
Specifications .........................................................................................................................
Recommended Tool List .........................................................................................................
Serial Number Location ..........................................................................................................
Hydraulic System Description ..................................................................................................
Pres sure Adj ustment Procedures ................................. ................ ...... ...... ...............................
11
Electrical System Description... .............. ...... .......... .. .. ........ .......... ................ ...... .. .......... ........
15
Machine Options Description ........... .................... ............ ................ .................... .......... ........
19
Battery SeIVice .....................................................................................................................
23
Preventive Maintenance ..... .. .... .... .. .................... .............. ................ ............ .......... ................
31
HydraulicFluid Specifications ................................................................................................
41
BatteryChargerTroubleshootingGuide ..................................................................................
43
BoltTorqueChart ................................................................................................................
53
)
MANUAL 92350002
JANUARY 1997
SIN X935-97051
NOTES
)
MANUAL 92350-002
JANUARY 1997
SIN X935-97051
SPECIFICATIONS
SPECIFICATIONS
V2033XL
Maximum Working Height

Platform Height
Stowed Platform Height
Overall Length
Overall Width
Overall Height
Overall Height With Rails Removed
Platform Size
Platform Capacity
Gross Weight
Power System
Battery Capacity
Number of Batteries
Battery Voltage
Battery Charger
Wheel Base
Tires
26 ft.
20 ft.
39.5"
93"
33"
79"
50"
92.5" x30"
7501bs.
3,36101bs.
24 volt DC
235 amp hour
4
6 volt
25 amp
75"
16 x 5
(Solid Rib)
24"
.75/1.5/3 mph
25%114
35/30 sec
Inside Turning Radius

Drive Speed
Gradeability
LiftlLower Time
OPTIONS
*
*
*
*
*
*
Battery Condition Indicator

Strobe Light
250 Amp Hour Deep Cycle Batteries
Hour Meter
Travel Alarm
Key Switch
*
*
*
*
MotionlMovement Alarm
Descend Alarm
5 Slope Alarm
Low Volt WarninglInterrupt Battery
Protection System
The CONDOR Model V2033/XL is designed and built to conform to Condor Div. understanding
and interpretation of all applicable OSHA rules and regulations as well as ANSI standards:
ANSI Standard A92.6 - 1990 ................... Self Propelled Elevating Work Platform
CAUTION
It is imperative that all owners and operators of the CONDOR read, understand and conform to
these regulations. Ultimate compliance to prevailing OSHA regulations is the RESPONSIBILIT
of the employer utilizing the equipment.
MANUAL 92350002
JANUARY 1997
SIN X93597051
RECOMMENDED TOOL LIST

The following is a list of tools 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 Flow Meter, 0-10 GPM
Hydraulic Flow Meter, 0-50 GPM
Hydraulic Quad Meter Pressure Gauge
Battery Hydrometer
Battery Load Tester
112" Drive Torque Wrench, 0-250 ftllbs
Pry Bar
Strap Type Filter Wrench
Grease Gun
Hammer, 24 oz.
Vice Grip Pliers
Combination Wrench Set, 114" to 1-112"
3/8" Drive Socket Set, 1/4" to 3/4"
112" Drive Socket Set, 3/8" to 1-112"
Hex Key (allen wrench) Set, up to 112"
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 not intended to be all inclusive ofthe tools required to perform every maintenance
function that may be required on this specific CONDOR model. However, these tools will greatly
assist in troubleshooting problems and conducting routine maintenance on the equipment.
)
MANUAL 923 50-002
JANUARY 1997
SIN X935-97051
Serial Number Location . .
1
2
The CONDOR Model V20331XL 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, 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
JANUARY 1997
SIN X93597051
..
This Page Intentionally
Left Blank
MANUAL 923S0-002
JANUARY 1997
SIN X93S-970S1
HYDRAULIC SYSTEM DESCRIPTION
The following is a detailed description of the hydraulic system used on the CONDOR model
V20331XL scissor, and how it designed to operate. To assist in understanding the system, this description
should be used in conjunction with the 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 of the open-center valve type, meaning
that the hydraulic fluid circulates back to the tank when the pump is running and no functions are being
operated. All lift and drive functions can be performed from the platform console, while ONLY lift
functions are available from the lower control console.
HYDRAULIC TANK
The hydraulic tank is an ilL" shaped
weldment having a fluid capacity of 7 US gallons. 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 of the unit (See FIG. 1) next to 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. Filtration of the 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 of a tank strainer and
shut-off valve (ball valve) for the tank has been
discontinued. Although the tank configurations
differ between models, the attaching components are identical.
Filler Cap
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
PUMP/MOTOR
The pump and motor assembly is located 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 driven from the
same shaft. Both sections have a size of .194
cubic inch per revolution, which equals to 2.7
GPM of hydraulic flow at 3600 rpm. One
section of the pump is only used for drive, while
the other pump section supplies fluid for steering, lift, or to increase the drive speed when
directed to the drive circuit.
HYDRAULIC TANK
ELECTRIC MOTOR
PUMP/MOTOR CONTACTOR
FIG. 2
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 of the
hydraulic functions ofthe machine (See FIG. 3).
This assembly includes three directional control
valves and avariety of cartridge valves to achieve
the operation of the cylinders and motors for the
machine functions. These individual functions
are described in detail below.
Batteries
Ground Controls
Main Valve
Assembly
Battery Charger
FIG. 3
MACHINE FUNCTIONS
The hydraulic functions of the CONDOR model V20331XL includes: forward and reverse
drive with three selectable speeds at limited height, spring appliedlhydraulically released brake cylinders,
left and right steering, and platform raising or lowering. Each of these functions are performed by the
main valve assembly via electrical control signals. A detailed description of the electrical controls and
their circuits can be found in the Electrical System Description of this maintenance section.
DRIVE FUNCTION
The drive function is only available at the platform controls. Movement of the drive control
handle 13 from its center position in either direction will turn the pump motor on and energize the
respective forward/reverse electrical circuit. The forwardlreverse electrical circuits consist solely of
the drive controller and the drive directional control valve located on top of the main valve assembly (see
FIG. 4).
\)
MANUAL 92350002
JANUARY 1997
SIN X93597051
~------------~~--------------------~~
Drive Directional
Control Valve
Control Valve
r-----,
Flow Divider/Combiner
Valve
Creep Speed
Solenoid Valve
Creep Speed
Needle Valve
FIG. 4
DRIVE FUNCTION (cont'd)
Pump flow circulates through the main valve assembly and back to tank if no functions are
activated when the pump is running. Once the directional control valve shifts, fluid is directed to one
of the load control valves in its free-flow direction, and then to the normally open positraction valve.
Fluid flows through the positraction valve cartridge, then to both drive motors which each have an 11.9
cubic inch per revolution displacement and are located on the steer axle. When the positraction button
is depressed at the upper control box, the 4-way normally open positraction valve closes, blocking the
flow of fluid through it, but forcing the fluid through the flow divider/combiner to enhance tire traction.
The deceleration valve is utilized to cushion the braking action of the drive circuit. This is
accomplished by letting fluid by-pass between the two drive motors. Since the deceleration valve is a
2-way normally open spool valve, it allows fluid to flow through it at all times. When the drive control
handle is actuated, energizing the drive circuit, the deceleration valve becomes energized and closes,
blocking the flow of fluid through it. When the drive handle is released (circuit de-energized), the
deceleration valve opens, and lets the drive pressure by-pass to the opposite drive motor, allowing the
two drive motors to continue to roll momentarily without creating a hydrostatic lock in the circuit. A
0.040 dia. orifice, located under the deceleration valve, is used to control the amount of by-pass that
occurs which affects the deceleration of the machine.
The V2033IXL has a creep speed which is either automatically activated at platform heights
above seven feet by a limit switch, or is operator selectable at heights below seven feet. Creep speed is
a situation in the drive circuit whereas when the creep speed solenoid valve is energized, some ofthe drive
flow is diverted back to the tank. The speed at which the machine travels when in creep, is controlled
by the creep speed needle valve (See FIG. 4). The creep speed is factory set to obtain a travel speed of
80-100 sec/88 feet, on firm, level ground; (Ref. .75/.6 mph), (see note #2 on schematic at end of hydraulic
section).
,)
MANUAL 92350'()02
JANUARY 1997
SIN X93S-970S1
DRIVE FUNCfION (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
(steer/lift pump) being diverted to the drive
circuit. This is accomplished by activation of
the select directional control valve. The hydraulic pump contains two individual pump sections,
one ofwhich is used solely for the drive circuit.
The other pump section supplies fluid for the
operation oflift 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).
Select Directional
Control Valve
Steer Directional
Control Valve
Check Valve
Cartridge
Creep Valve
FIG. 5
STEERING FUNCTION
Steering is accomplished with a cylinder, knuckle, and connecting arm arrangement,
which in its configuration provides a tight turning radius. The drive motors are mounted to the
steering knuckles, thus enhancing driveability.
The steering cylinder, located just behind the
front bumper plate of the chassis, is controlled
by the steer directional control valve on top of
the manifold assembly (See FIG. 5&6).
Connecting Arm
Steer Cylinder
FIG. 6
LIFT FUNCTION
Lifting of the platform is accomplished
by energizing the select directional control valve.
This will direct fluid from the P2 pump to the
Cylinder
base end of the lift cylinder, with the rod end of
Manifold
the lift cylinder being vented back to the tank.
Coil
Located on the cylinder body (See FIG. 7), is the
holding valve, which consists of a manifold
Cable
body, a 2-way normally closed cartridge with a
manual override, and an electric coil. Attached
to the cartridge is a cable assembly used for
FIG. 7
manually lowering the platform via aT-handle
located at the rear of the machine, under the rear
bumper plate. Descent speed is controlled by a flow control valve (See FIG. 3), in which clockwise
rotation decreases descent speed, while counterclockwise rotation increases the descent speed.
MANUAL 92350-002
JANUARY 1997
SIN X935-97051
()
PRESSURE ADJUSTMENT PROCEDURES

NOTES: All pressure adjustments are to be made with the pump motor running, and with the hydraulic
fluid at operating temperature. Ensure that the tank is filled to its recommended level, and that the
batteries are fully charged. To simplify the adjustment procedure, install a pressure gauge at the "GI"
port, and install another pressure gauge at the "G2" port, which are both located at the creep valve end
of the main valve assembly. All relief valves 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 FIG. 8 for
adjustments.
Drive Pressure Adjustment
1.
2.
3.
4.
Chock both drive wheels to prevent them from spinning in the forward drive direction.
With the drive speed selector in the low position, activate forward drive with the drive controller.
While drive is activated, adjust "RVI" to 2700 psi while observing the gauge reading from the
"GI" port.
After setting, lock the adjustment screw with the j am nut.
High Drive Pressure Adjustment
1.
2.
3.
4.
Select high speed at upper control box.

Observe the pressure reading at the "GI" port while climbing a grade, and note pressure reading
at which the high drive shifts to low.
Adjust the" SEQ" valve until the pressure reading is 1100 psi when high drive shifts to low.
After setting, lock the adjustment screw with the jam nut.
NOTE: The load control valves, "CBI" and "CB2", are factory set. If they are not functioning properiy,
they must be replaced; DO NOT ATTEMPT ADJUSTMENT.
Lift PressurelDescent Speed Adjustment
1.
2.
With pump running, and platform raised completely (cylinder bottomed out), observe the
pressure reading on the gauge connected to the "G2" port. Adjust "RV2" to 2700 psi.
Adjust "FCI" to obtain a 25-35 second descent from a fully raised position.
)
MANUAL 92350-002
JANUARY 1997
SIN X93597051
-""-"
-~'---"
To aid troubleshooting, some of the valves and cartridges are identical to others and can be swapped to
help determine faulty components:
..
1.
"RV3" and "RV4" steer reliefs are identical with same pressure settings.
2.
"FCl" and "FC2" brake and descend flow control valves are identical while settings may differ.
3.
"CB l" and "CB2" are identical -- DO NOT ADJUST!
4.
"RVl" and "RV2" are identical with the same pressure settings.
5.
"CREEP" and "DECEL" solenoid cartridge valves are identical.
"G2" Gauge Port

(Reads Steer!lift!
High Drive Pressure)
-7+-+----
"G1" Gauge Port

(Reads Drive Only
Pressure)
"FC1" - Controls Platform

Descent Speed
"RV2" Relief For Steer/lift
("G2" Gauge Port)
"RV5" Secondary
lift Relief
Creep Speed
Adjustment
"RV1" Relief For Drive Only
("G1" Gauge Port)
"SEQ" (Sequence) Valve

Controls High Drive Shifting
"CB1" and "CB2" Load

Control Valves
(DO NOT ADJUST)
FIG. 8
MANUAL 92350002
JANUARY 1997
SIN X93597051
"OL6~E6X
NIS
L661 klIVflNVr
woo~rn;'IVnNVW
LIFT CYl
5248
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2.50 ROD
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~~~~
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~OR 2632 &; 2648
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Left Blank
)
MANUAL 92350-002
JANUARY 1997
SIN X935-97051
ELECTRICAL SYSTEM DESCRIPTION

The following is a detailed description of the electrical system used on the CONDOR model
V20331XL scissor, and how it designed to operate. To assist in understanding the system, this description
should be used in conjunction with the electrical schematics found at the end of this section.
GENERAL
The CONDOR model V20331XL uses a 24 volt direct current (DC) electrical system
consisting of four, 6 volt DC batteries, an electric motor to drive the hydraulic pump, and various
electrical controls to operate the system. Included in this system description is a Machine Options
section, describing options which are available on the model V20331XL. All of the options contained
in this description are electrical only, and do not affect the hydraulic performance of the machine.
BATTERIES
The model V2033 IXL scissor uses four, 6 volt DC batteries, each having a 23 5 amp hour capacity.
There are two batteries on each side ofthe belly pan nearest the 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 off of a 115
volt alternating current (Ae), 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 indicates the charging is complete. The charger is
located on the left side of the belly pan, between
the main valve assembly and the fixed axle (See
FIG. 9). More detailed information of the charger
can be found in the Battery Charger Troubleshooting Guide beginning on page 67.
Main Manifold
Assembly
FIG. 9
CIRCUIT BREAKER/FUSE
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 X935-97051
PUMP MOTOR
The CONDOR model V2033XL utilizes a pump motor which is a 24 volt DC unit,
rated 6 hp @3600 rpm. Since the model V2033XL
utilizes a gravity lowering system, the motor does
not run while the lowering function is activated.
Pump/MotorContactor
Electric Motor
LOWER CONTROL FUNCTIONS

Located above the left rear wheel is the
lower control box, which provides a junction
:r
Emergency Stop Button
connection through the use of two terminal strips,
for the limit switch cable, the hydraulic valve
cable, the pump motor contactor cable, and the
Platform Lift Control
cable to the upper controls. At the lower controls
are switches (see FIG. 11), to provide operation
Control Selector Switch
of the lift function only; drive is not available
from this control box. The lower control box
a
15 Amp Circuit Breaker/Fuse
contains an emergency stop button which must be
4
pulled out to supply power to both control boxes.
The control selector switch is a 3 -position mainFIG. 11
tained rotary switch that directs power to either
control box for operation of the machine,
while the box not selected, will not have power. The platform lift control consists of two pushbuttons,
which, through the use of contact blocks, energize the pump motor and selector valve for raising, or the
holding valve for lowering. The pump motor does not run during lowering.
EMERGENCY
PLATFORM
RAISE
LOWER
OPP
CONTROLS
LOWER
UPPER CONTROL FUNCTIONS

The upper control box, located at the right hand forward corner of the platform, is a fiberglass
enclosure which contains two slip-fit inserts on its underside that allow the box to press onto two pins
which are part of the platform weldment. The control box is removeable by disconnecting the cable
harness plug underneath, and lifting upward on the box assembly. The feature allows for disabling the
machine, storage of the box, or ease of repair to the controls. Some of the controls used are identical to
the those found at the lower control box (See FIG. 12), primarily the emergency stop button and the lift
controls. The platform lift control buttons operate similar to the lower control pushbuttons. However,
at this control box, the green "POWER" pushbutton must be depressed to supply power to either the raise
or lower lift button. To provide electrical power to the upper control box,both emergency stop buttons
must be in the "out" position, the control selector switch must be in the "UPPER" position.
MANUAL 92350-002
JANUARY 1997
S/N )C935-97051
UPPER CONTROL FUNCTIONS (cont'd)
PositractionButton
(black)
Cut-Away View
of Slip-Fit Insert

/
_____ m
__ m _ m
_ _ _ _ _ _ _ _ _ _ ~\
Lift Controls
Power Button
(green)
Cable Harness
Plug
Drive Controller
w/Steer Rocker
Switch
Drive
Speed
Selector
Hidden View of
Slip-Fit Insert
FIG. 15
Integrated in the forward edge of the drive handle is a grip lever which is a substitute for the foot
switch commonly used on other machines. The grip lever must be squeezed to perform drive (movement
of the handle), or steer (activation of the rocker switch) functions. This lever, however, does not affect
the lift controls. Movement of the drive handle 13 in either direction will tum the pump motor on, and
energize the drive directional control valve, thus initiating drive motion. Drive speeds are selectable
from the drive speed selector switch. Selecting "fast" will energize the select directional control valve
and increase drive speed by adding the second pump's flow to the drive hydraulic circuit. Selecting "low"
will de-energize the select valve, and drive speed will then rely on the single pump output. Pressing the
black positraction button energizes the positraction valve in the main manifold assembly, thus forcing
hydraulic flow through the flow divider/combiner. When in "fast" or "low", the creep valve is always
energized because it is a normally open valve. When "creep" speed is selected, or when the platform is
above six to seven feet, it is de-energized, thereby letting fluid by-pass to tank through an adjustable
needle valve.
MANUAL 92350-002
JANUARY 1997
SIN X935-97051
NOTES
)
MANUAL 92350-002
JANUARY 1997
SIN )(935-97051
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 of 2 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.
5SLOPE ALARM (OPTION)
This option sounds an alarm when the V2033!XL is 50 or more out oflevel. A 50 omni-directional
sensor is mounted in the belly pan to sense a 50 out-of-level 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
50 condition. This serves as a warning, and does not inhibit any functions. The sensor is mounted on a
spring loaded base which is adjustable to allow leveling. Testing of the system is accomplished by
manually tilting the sensor against its spring tension mount, to physically put the sensor in a 50 out-oflevel 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 (50 or greater), the sensor's
white wire (connected to the alarm), becomes grounded after a few second delay, through circuits inside
the sensor.
BATTERY CONDITION INDICATOR (OPTION)

This option is to monitor the batteries'
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 of an analog 10-LED bar display, the
indicator provides a visual reference for reading
properly charged batteries (top LED lit), batteries
at 70% depth-of-discharge (second from bottom
LED flashes), and when the batteries have reached
an 80% depth-of-discharge (bottom two LED's
flash alternately).
Slope Alann
Battery
Condition
Indicator
FIG. 13
SIGNAL HORN (OPTION)
This option consists of a 133 db automotive type hom mounted in the chassis, and a white
pushbutton on the side of the upper control box (See FIG. 14). The hom is only operable when the control
selector switch is in the "UPPER" position.
MANUAL 92350002
JANUARY 1997
SIN X93597051
LOW VOLTAGE BATTERY

PROTECfION SYSTEM (OPTION)
This option prevents operation when the

batteries are in a low voltage condition. It beLow Volt Override Pushbutton
ignal Horn
comes energized whenever the control selector
(w/Amber Indicator Lamp)
Pushbutton
(white)
switch is in either "UPPER" or "LOWER" position (lower emergency stop button must be pulled
out). While energized, the module monitors the
batteries' voltage level, and will preventthe pump
motor contactor from being activated once the
battery voltage reaches 12.5% undervoltage, or
Slope
E=~r--- Cable Harness Plug
approximately 21 volts. This condition must be
Alarm
present for 21 seconds to activate the interrupt
FIG. 14
system. Terminals 3 & 4 of the module are
normally closed contacts which complete the
pump motor contactor circuit, and it is these contacts which are opened during a low voltage condition.
Terminal 7 of the module is the battery input voltage, while terminal 6 is machine ground. Terminals 1
& 2 are normally open contacts which close during a low voltage condition and turns on an amber
indicator light (pushbutton) at the upper control box. The system can be overridden by pressing the
pushbutton on the side of the upper control box (See FIG. 14), which energizes terminal 5 of the 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 lowering of the platform. The alarm
signal is activated from two different circuits; one energizes the pump motor contactor, and the other
energizes the holding valve for platform lowering (pump not running). A diode is used in each circuit
to prevent unintended feedback.
HOUR METER (OPTION)
This option is to record the "run time" of the machine for maintenance scheduling, rental usage,
etc.. The meter runs only when the pump motor contactor is energized (pump running); therefore, the
meter does not run when the machine is sitting idle, or when the platform is being lowered.
MANUAL 92350002
JANUARY 1997
SIN X935-97051
)'
I~OL6-~E6X
N!S
L661 AWflNVr
wo-o~rn; 1VflNVW
r3~
___________________________R_m-{,~)..:Bl::K-,-_ _.:,1
~3-----------------------i
hORN
13
WH2J
5L.OP[ SENSOR OPTION
SLOPE AlARM oPTION
.L'M1ITE
~3_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _~
0--"'6'----------~~H<CORN'""'_J'SIGNAL OPTION
r5~8L-_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
...(7)Q)7
~5~8L--------------------------""""A:\----~1
lOW VOLT OPTION (SENSOR)
STROBE UGHT OPTION
3-POS
SELECTOR:
58
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:....1-)5.D
3
UPPER
'\5.D
o-=---=:.=~.l..~5])
LOWER
La'
'-'5"'B'-_ _ _ _ _ _L;;::lHH~5~"~_""\__'
PLATFORM
~8~_U_P_ _ _ _~~~~8~A~_{3
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9
PLATFORM
BE
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DO"'"
SA
'---:1,
r------1o-!-'--l--+-+---+J------+-<>-'Ir'>-+-'t
V
STEE~
PUMP MOTOR CONTACTOR
LOW VOLT
OPTION
(INTERRUPT)
PUMP MOTOR
;iJ
i.
~;~~~~-----4Bl----------~~
L_'_:..J
??
'HOUR METER OPTION
MonON ALARM OPTION
VAlVE ON LIFT CYl
DESCEND ALARM OPTION
RIGHT
(STEER VALVE)
LEFT
o
X
EMERGENCY
STOP
SA
GRIP 3B
i
~4:2L
--i-+--1-----JI________+:,--~,
-o-{~t-,'i,
~----~L- _DRI~_~~L---~-4--+--------~I------------~L__~_~_1,
3B
8])
GREEN
SA
FORWARD
(DRIVE VALVE)
REVERSE
.1
PLA WORM
.f..
. L 3C
~I-<>~
3C
.f..
TRAVEL ALARM OPTION

9
00","
8D
DECELERATION VALVE
PLATFORM
'--I'
UP
uFT PLATFORM
(SELECTOR VALVE)
FAST DRIVE SPEED
BLACK
SA
.f..
F--~
'2
CREEP DRI\/[ SPEED VALVE

POSITRAcnON VALVE
r-::--i
SA
:.f..
~--------;--y
!L
8A
I: ,.
B~'~'5~______________~1
__ ~
lOW VOLT OPTION (OVERRIDE)
~~
LOW VOLT OPnON (WARMNGj
Left Blank
)
MANUAL 92350-002
JANUARY 1997
SIN X935-97051
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 of the 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.
SERVICE PROCEDURES
The user should realize that the battery is a perishable item and requires periodic attention. With a
reasonable amount of care, the life of the battery can be appreciably extended. Neglect and abuse will
invariably cause shorter life.
CAUTION
Low battery voltage (discharged) requires higher current draw to do the same
work. This high current draw WILL DAMAGE the electric motor, relay
contacts and the batteries. DO NOT OPERATE theCONDOR with a
battery DISCHARGED or that has a specific gravity of 1.130 or LESS.
Routine servicing of the battery should proceed as follows:
First, make a visual inspection for defective cables, loose connections, corrosion, cracked cases
or covers, loose hold-downs and deformed or loose terminal posts. If any parts such as cables, hold-downs
or the battery appear to be unserviceable, it is recommended that they be replaced.
When there is corrosion on the terminal posts or hold-down, the tray or hold-down parts are rusty,
or the battery is very dirty, it is recommended that time be taken to clean the parts. A wire brush can be
used to remove dirt, corrosion or rust from parts. Clean dirt from the battery top with a cloth wetted with
ammonia or baking soda in water.
MANUAL 92350-002
JANUARY 1997
SIN X9359705!
Next, wipe with a cloth with clear water. After rust is removed from a part with a wire brush,
rinse with clear water, dry and paint with an acid-resistant paint.
If corrosion is found on the terminal posts, remove the cable terminals from the battery (ground
cable first), using the proper end wrench. A wire cleaning brush can be used to clean the posts and the
mating surfaces of the cable clamps. Connect the cables to the terminal posts (ground cable last). Coat
the terminal connections with a spray corrosion inhibitor or high temperature grease.
The second item in routine servicing of conventional batteries is to check the electrolyte level in
all cells. Ifnecessary, add clear, odorless, mineral free water to bring the liquid level to the level indicator
in all cells. If the battery does not have a level indicator, bring the level to 112" (13mm) above the tops
of the separators. Do not overfill any cell. When a cell is overfilled, the excess electrolyte may be
forced from the cell by the gas formed in the battery. This will cause excessive corrosion of adjacent
metal parts, reduced performance and shorter life.
BATTERY TESTING
Battery testing should be considered an integral part of periodic equipment maintenance and should be
performed whether or not a starting problem has occurred. Servicing the battery in the equipment as
described will help prevent premature battery failure from external causes and periodic battery failure
from both external and internal causes or merely from the battery reaching the end of its useful life.
STEP 1 - VISUAL INSPECTION

For protection, wear a face shield. First, visually inspect the battery. Check for container,
cover or terminal damage that might cause leakage of electrolyte or internal damage. If serious damage
is found, replace the battery. Check the electrolyte level in each cell. Ifbelow the tops of the plates in
any cells, fill all cells with water to just above the tops of the separators and charge for 15 minutes at 1525 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 (26.7C) ofthe electrolyte in each cell. If the range (highest-lowest) is 50 points (0.050 sp. gr.) or greater
or the lowest is less than 1.225 sp.gr., charge the battery at the recommended rate or until all cells are 1.225
sp.gr. or greater and the range is less than 50 points. If no amount of charging will achieve these
DANGER
Lead acid batteries generate highly explosive hydrogen gas especially during the
charging cycle. To AVOID the possibility of an explosion, charge batteries ONLY
in a well VENTI LATED 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 X93597051
The average state of charge ofthe cells in a battery can be determined by measuring the stabilizefD
voltage of the battery. The voltage is stabilized if the battery has been on open circuit overnight or for
a period of several hours. A voltage reading of 12.4 (6.2 on a 6 volt battery) is equivalent to a specific
gravity of 1.225. The disadvantage of measuring the open circuit voltage is that a lower voltage cell can
be masked by the remaining cells. If the cell connectors are accessible for voltage measurements, a range
of 0.05 volts between the highest and lowest cells corresponds to a 50 point variation in specific gravity.
A cell voltage of 2.07 is equivalent to a specific gravity of 1.225.
STEP 3 - ADJUSTABLE LOAD TEST
The following instructions are intended as guidelines. When available, the instrument
manufacturer's instructions should be followed. Follow all precautions.
A.
Disconnect battery cables starting with ground cable.
B.
Measure temperature of a center cell. If instrument has an integral temperature

compensator, use attached probe.
C.
Connect voltmeter and load test leads to appropriate battery terminals, make certain
terminals are free of corrosion.
D.
Connect current transducer (if necessary) to appropriate lead.
E.
Apply test load equivalent to 50% of Cranking Performance rating of battery for 15
seconds. If Cranking Performance is unavailable, use 3 times the 20 ampere-hour
capacity.
F.
Read the voltage at 15 seconds, then remove the load.
G.
Determine minimum voltage required at electrolyte test temperature from chart in

Figure X.
H.
If test voltage is above minimum, return battery to service.
I.
If test voltage is below minimum, replace battery.
TESTING WITH FIXED LOAD TESTER AND OPEN CIRCUIT

For testing batteries with a fixed load tester and an open circuit voltmeter, refer to "Battery Testing Chart"
Figure Y.
STEP 1- VISUAL INSPECTION
First, visually inspect the battery and check the electrolyte levels as described in Step 1 of"Testing
with Adjustable Load Tester and Hydrometer"; take the same corrective actions. Continue to Step 2.
MANUAL 92350-002
JANUARY 1997
SIN X935-97051
.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 manufacturers 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%
of the Cranking Performance rating or 3 times to 20 ampere-hour capacity of the 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 of charge from the following chart (Battery temperature 60-100 degrees
F.)
OPEN CIRCUIT VOLTS
PERCENT CHARGE
12.6 or greater
12.4 - 12.6
12.2 - 12.4
12.0 - 12.2
11.7 - 12.0
11.70rIess
100%
75-100%
50-75%
25-50%
0-25%
0%
The change of voltage with state of charge is small and must be measured accurately using a
digital meter or an analog meter with an expanded scale. If the state of charge is 75% or greater and the
battery failed the load test, it should be replaced. If the state of charge is less than 75%, the battery should
be charged at the recommended rate and time, and the load test repeated. If the battery passes the load
test, return it to service. If it fails the load test again, replace it and refer to the next chapter to determine,
the cause of failure.
MANUAL 92350002
JANUARY 1997
SIN X93597051
,)'
.
DETERMINING CAUSES OF BATTERY FAILURE
Whether the battery passes or fails either of the above tests, the results must be believed. If the battery
passed the load test only after a recharge, the cause of the discharge condition should be determined.
Ifthe battery has been returned previously or is otherwise still questionable, one final test should be made.
Fully charge the battery and place it on open circuit stand for three days. If the loss in specific gravity
of any cell is greater than 35 points or the open circuit voltage drops by more than 0.20 volts, replace the
battery. If not, return the battery to service and determine the cause for the discharged condition.
The following should be checked:
1.
Corroded Battery Terminals or Connectors
A corrosion layer between the battery terminals and the cable connectors can prevent good
electrical contact even when the connectors are tight. The cables should always be removed
before testing a battery and any corrosion cleaned from the terminals.
2.
Electrical Circuit Leakage
There may be a fault in the equipment's electrical system that can discharge the battery even when
all the accessories are turned off. To check for such leakage, turn off all accessories in the equipment.
Check for leakage using one of the following methods.
A.
Ammeter - Cover battery with a damp cloth. Disconnect the ground cable. Using a DC
ammeter with a resolution of at least 0.1 amp, measure the current between the
disconnected cable and the battery terminal. (DO NOT CONNECT AMMETER
ACROSS BATTERY TERMINALS!) A leakage current measurement of 0.1 amp or
more indicates the equipment electrical system should be tested and repaired.
B.
Ohmmeter - Disconnect the positive cable at the battery. Connect anohmmetertothe

disconnected cable end and to the chassis. A resistance measurement of under 100 ohm
indicates aload of 0.1 amp or more and indicates the equipment electrical system should
be tested and repaired.
C.
Voltmeter - Disconnect the ground cable (negative) at the battery. Connect a low
resistance voltmeter (100 ohms - see Note 1) between the disconnected battery post
and the chassis. A voltage measurement of 6 volts or more indicates a leak of 0.1 amp
or more and the equipment electrical system should be tested and repaired.
Note 1: The voltmeter test cannot be made with high resistance voltmeters.
3.
Charging System
To complete the determination of the cause for the battery's discharged condition, check the
equipment's charging system.
)
MANUAL 92350'()02
JANUARY 1997
SIN )(93597051
FIGURE: X
SATTERY TESTING CHART

STE P1
VISUAL INSPECTION
CHECK FOR OBVIOUS DAMAGE SUCH AS
CRACKED OR BROKEN CASE THAT SHOWS
LOSS OF ELECTROLYTE. ALSO CHECK FOR
TERMINAL DAMAGE.
IOBVIOUS DAMAGE I
I NO OBVIOUS DAMAGE I
I REPLACE BATTERYI
I CHECK ELECTROLYTE LEVELl
BELOWTOP OF PLATES IN ONE OR I

MORE CELLS
ELECTROLYTE LEVEL ABOVE TOP OF

PLATES IN ALL CELLS - PROCED TO
STEP 2
ADD WATER TO JUST ABOVE SEPARATORS. CHARGE FOR 15 MINUTES

AT 15-25 AMPS. PROCEED TO STEP 2
STE P2
I HYDROMETER TEST I
SPECIFIC GRAVITY LESS THAN 1.225

OR CELL VARIATION 50 POINTS OR
GREATER.
SPECIFIC GRAVITY 1.225 OR GREATER

OR CELL VARIATION LESS THAN 50
POINTS.
I
I RECHARGE
I
/DISCHARGE AT 150 AMPS FOR 15\

SECONDS
SPECIFIC GRAVITY LESS THAN 1.225

OR CELL VARIATION 50 POINTS OR
GREATER.
I
CONTINUE TO STEP 31
IREPLACE BATTERyJ
I LOAD TEST I
STEP 3
I
1. PLACE THERMOMETER IN CENTER CELL.
COVER BATTERY WITH A DAMP CLOTH.
2. CONNECT VOLTMETER AND AMPERE LOAD
EQUAL TO 1/2 THE COLD CRANKING AMPERES
AT OaF (-18C) RATING OF THE BATTERY FOR
15 SECONDS.
3. OBSERVE VOLTAGE AT 15 SECONDS WITH
LOAD ON.
4. REFER TO VOLTAGE CHART BELOW.
I
I
I VOLTAGE BELOW CHART VALUEI
I VOLTAGE EQUAL TO OR ABOVE CHARTI

VALUE - RETURN TO SERVICE
I
I REPLACE BATTERyl
VOLTAGE CHART
ESTIMATED ELECTROLYTE TEMPERATURE
MINIMUM REQUIRED VOLTAGE UNDER 15 SEC. LOAD

(USE 1/2 THESE VALVES FOR 6-VOLT BATTERIES)
70F 21C) & ABOVE

60F 16C)
50F 10C)
40F 4C)
30F -1 DC)
20F (-7"C)
10F (-12C)
OaF (-18C)
9.6
9.5
9.4
9.3
9.1
8.9
8.7
8.5
MANUAL 92350002
JANUARY 1997
SIN X935-97051
FIGURE:Y
SATTERY TESTING CHART

STEP 1
VISUAL INSPECTION
CHECK FOR OBVIOUS DAMAGE SUCH AS
CRACKED OR BROKEN CAS E THAT SHOWS
LOSS OF ELECTROLYTE. ALSO CHECK
FOR TERMINAL DAMAGE.
I
I
IOBVIOUS DAMAGE I
NO OBVIOUS DAMAGE I
\ REPLACE BATTERY\
CHECK ELECTROLYTE LEVEl. ADD

WATER IF NECESSARY. PROCEED
TO STEP 2 .
. STEP 2
I FIXED LOAD TESTI
I
1. ATTACH TESTER CLAMPS TO BATTERY TERMINALSIN CORRECT
POLAITY - USUALLY RED TO POSITIVE (+) AND BLACK TO NEGATIVE (-).
2. SET SELECTOR SWITCH ON LOAD TESTER TO 1/2 CRANKING AMPERAGE
RATING OF BATTERY (AT OaF, -18C).
3. IF TESTER DOES NOT HAVE AN AUTOMATIC BATTERY TEMPERATURE
COMPENSATOR, PLACE A THERMOMETER IN CElL, READ AND SET TEMPERATURE DIAL ON TESTER. WITHOUT ANY TEMPERATURE CORRECTION,
MAKE LOAD TESTS ONLY ON BATTERIES ABOVE 60F (16C).
4. APPLY LOAD FOR 15 SECONDS AND READ LOAD TESTER JUST BEFORE
RELEASING THE LOAD.
IPROCEED TO STEP 3 I
STEP 3
BATTERY PASSES LOAD TESl1

RETURN TO SERVICE.
I
\ BATTERY FAILS LOAD TESTJ
\ OPEN CIRCUIT VOLTAGE TESlj
I
1. ALLOW 10 MINUTES FOR BATTERY VOLTAGE TO STABILIZE
AFTER LOAD TEXT.
2. READ OPEN CIRUIT VOLTAGE.
I
UNDER 12.4 VOLTS-BATTERY SHOULD
BE CHARGED AND LOAD TESTED AGAIN
(REPEAT STEP2). IF BATTERY AGAIN
FAILS THE LOAD TEST, REPLACE IT. IF IT
PASSES, RETURN TO SERVICE AFTER
PROCEEDING TO STEP 4.
STEP 4
12.4 VOLTS OR ABOVE -IF BATTERY

DID NOT PASS THE LOAD TEST, IT
SHOULD BE REPLACED - THEN PROCEED TO STEP 4.
CAUSES OF BATTERY FAILURE:

1. CORRODED BATTERY POSTS OR CONNECTORS - ALWAYS CLEAN THE BATTERY POSTS OR
SIDE TERMINALS AND THE BATTERY CABLE CONNECTIONS WHEN CHARGING OR REPLACING
A BATTERY.
2. ELECTRICAL LEAKAGE - CHECK FOR ELECTRICAL LEAKAGE WITH ALL ACCESORIES TURNED
OFF:
A) DISCONNECT THE BATTERY GROUND CABLE AND CONNECT A SUITABLE VOLTMETER
BETWEEN DISCONNECTED BATTERY POST AND GROUND (A READING OVER 6 VOLTS
INDICATES AN EXCESSIVE LEAK).
OR
B) DISCONNECT THE BATTERY CABLE THAT GOES TO THE STARTER AND CONNECT AN
OHMMETER BETWEEN THE CABLE AND THE GOUND (A RESISTANCE OF UNDER 100 OHMS
WILL DRAIN THE BATTERY).
3. CHARGING SYSTEM SHOULD ALWAYS BE CHECKED AFTER CHARGING OR REPLACING A
BATTERY.
MANUAL 92350-002
JANUARY 1997
SIN X935-97051
NOTES
)
MANUAL 92350-002
JANUARY 1997
SIN X935-9705\
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:
1.
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.
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 CO NDOR
from service until the spindle assembly is replaced, and contact
the Condor Div. Service Department to report the damage.
Repack cone bearings using fresh wheel bearing grease, install
new dust seal, then reassemble components in reverse order of
disassembly. Tighten spindle nut until hub will not 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 92350-002
JANUARY 1997
SIN X935-97051
2.
Hydraulic System
Fluid Level:
Check level daily. Maintain fluid level so that it is visible

between the marks on the sight glass with platform all the
way down.
Return Filter:
Replace filter element after first 50 hours of operation. Thereafter, replace filter element every 500 hours of operation.
Tank Breather:
Clean every 50 hours of operation. Remove from tank and clean

with solvent; air blow-dry.
Hydraulic Tank:
Drain fluid from tank and replace annually. Add hydraulic fluid
to required level using only Shell Tellus T -32 or equivalent.
Suction StrainerMDL, MD1, ANDMDC:
Drain oil from tank and replace strainer annually. If operating

in dusty or harsh conditions, inspect filter more frequently and
replace if necessary.
DO' NOT MIX DIFFERENT HYDRAULIC FLUIDS

3.
Battery Servicing
FOR PROTECTION WHEN SERVICING BATTERIES,

ALWAYS WEAR A FACE SHIELD AND DO NOT SMOKE!
Visual Inspection:
Inspect for defective cables, loose connections, corrosion,

cracked or swelling cases or covers, loose hold downs, and loose
or deformed terminal posts.
Cleaning:
When needed, a wire brush can be used to remove rust, corro

sion, or dirt from terminal ends or posts. The battery top can be
cleaned with a cloth wetted with ammonia, or baking soda with
water, then wiped with a cloth and clear water.
Electrolyte Level:
Check electrolyte level daily in each cell. Ifnecessary, add clear,

odorless, mineral free water to bring the level to 112" above the
top of the separators, or to the level indicator (if equipped), in
each cell. Only add water after the charging cycle is complete.
)
MANUAL 92350002
JANUARY 1997
SIN X93597051
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
Div. recommends that a maintenance log be maintained, and that abnormal conditions of any kind be recorded.
To help assist in starting a maintenance log, there are inspection checklists included after each inspection list.
These are intended to be used with the field inspection lists to help gain familiarity with the repetitive tasks.
DAILY INSPECTION
A.
VISUAL INSPECTION
Overall Condition:
Inspect platform, armstack, and carriage to make certain that no physical

damage is evident. Look for missing components and hardware, loose
components, etc.
Tire Condition:
Inspect tires for wear, cuts, and abrasions.
Battery Cable
Connections:
Hydraulic Fluid
Leaks:
Decals and Placards:
B.
For protection, wear a faceshield. Inspect for swelling of battery sides,

tightness and corrosion of terminals. If corrosion is present, remove cables
from the battery (ground cable first). Clean terminals and posts with a wire
brush and reconnect to battery (ground cable last). Coat the terminal
connections with a spray corrosion inhibiter, or high temperature grease.
Inspect to ensure that there is no evidence of leaking hoses or fittings.
Verify that all decals and placards are in place and are legible. It is recom
mended that any decals or placards which are tom, damaged, missing, or
painted over, be replaced. Essential decals must be legible, or must be
replaced.
FLUID LEVEL CHECK

Hydraulic Tank
Level:
Battery Electrolyte
Level:
Check level daily. Maintain fluid level so that it is visible between the
marks on the sight glass with platform all the way down.
For protection, wear a faceshield. Check electrolyte level in each cell.

If necessary add electrolyte or clear, odorless, mineral free water as required
to bring the level to 112" above the tops of the separators or to the level
indicators (if equipped), in each cell. Add only after the charging cycle is
complete.
MANUAL 92350002
JANUARY 1997
SIN X93597051
c.
OPERATIONAL TEST
Instrument C h e c k )
Hour Meter:
Ensure that meter is recording properly.
Battery Condition Indicator:
Ensure that indicator is monitoring the batteries state-ofcharge properly.
Lower Controls
Operation Check
Emergency Stop Button:
Ensure that machine will not operate with button pushed in.
Check that button maintains its in or out position.
Control Selector Switch:
Ensure that switch controls the selection of "UPPER or

LOWER" properly. Make certain that machine will not
operate with switch in its center position.
Lift Control Buttons:
Check that buttons and toggle switch retum to their normal

position when released, and that buttons and toggle switch
properly operate the lift function.
Upper Controls
Operation Check
Emergency Stop Button:
Ensure that machine will not operate from upper controls with
button pushed in. Check that button maintains its in or out
position.
Lift Control Buttons:
Check that buttons retum to their normal position when

released, and that buttons properly operate the lift function.
Make certain that lift function does not operate unless green
power button is depressed.
Drive/Steer Functions:
Squeeze handle grip and operate drive and steer functions.
Drive Speed Selector:
Ensure that each speed selection works properly while driving.
Positraction Button:
Ensure that speed shifts to low when button is depressed

(platform below seven feet), regardless of speed selector
position.
Slope Alarm:
Tilt sensor more than 5 (located in belly pan), and check for
audible alarm at platform control box. Selector switch must be
in "UPPER" position.
)
MANUAL 92350-002
JANUARY 1997
SIN X935-97051
DAILY INSPECTION
MON
ITEM
TUES
WED
HOURS
Overall Condition
Tire Condition
Battery Cable Connections
Hydraulic Fluid Leaks
Battery Electrolyte Level
Verify Legibility of Decals & Placards
OPERATIONAL TEST
Hour Meter
Battery Condition Indicator
--'
FRI
SAT
SUN
Z 1// / / / / /
VISUAL INSPECTION
-,
THURS
LOWER CONTROLS
Control Selector Switch
Lift Control Buttons
UPPER CONTROLS
Lift Control Buttons
Drive/Steer Functions
Drive Speed Selector Switch
Positraction Button
Slope Alarm
.-'1
MANUAL 92350-002
JANUARY 1997
SIN X935-97051
PREVENTIVE MAINTENANCE INSPECTION

50 HOUR INSPECTION
A.
CHASSIS
Visual Inspection:
Inspect for cracks in welds, dents or bends in material.
Steering Cylinder:
Check cylinder, pins, and cotter pins holding cylinder in place

for proper installation.
Steering Connecting Arm:
Check pins and retaining rings for proper installation. Ensure

that arm does not bind or contact chassis throughout range of
steering travel.
Steering Knuckles:
Inspect thrust washer for wear, and make certain that both pivot
pin retainers are installed properly. Ensure there is no binding
through out range of travel.
Wheels:
Check for loose or missing lug nuts, loose hub assemblies (fixed
axle), and damaged or cracked rims.
Drive Motors:
Check motor hydraulic lines for leakage. Check wheel hub

retaining nut and cotter pin for proper installation.
Brake Cylinders:
Check hydraulic lines for leakage. Check for proper brake

operation. Check for proper brake release lever operation.
Inspect cylinders and retaining bolts for damage and proper
installation.
Hydraulic Hoses
and Fittings:
Inspect for leaks, cuts, and abrasions. Check fittings for tightness.
Tires:
Inspect for excessive or abnormal wear, cuts and abrasions.
Belly Pan:
Check belly pan to chassis weldment bolts for tightness and

proper installation. Check for security of components.
Battery Charger:
Inspect for damage. Verity proper charging operation.
Wiring and Electrical

Connections:
Electric Motor and Pump:
Inspect for damage, defective cables, fraying or cracked insula

tion, tightness of terminal ends, loose connections, corrosion,
cracked or swelling cases, or covers, loose hold downs or
deformed terminal posts on batteries.
Inpect motor and pump mounting hardware for tightness, cable
connections for tightness, corrosion, fraying, or damage.
MANUAL 923S0-002
JANUARY 1997
SIN X93S-970S1
B.
ARMSTACK
Visual Inspection:
Lift Cylinder Hoses
and Fittings:
Inspect for fraying or cracked insulation. Check for proper

slack throughout range of movement.
Lift Cylinder:
Inspect for damage to chrome on lift cylinder rod, damage

to cylinder body, and all welds for cracks. Inspect holding
valve bolts for tightness.
Limit Switch:
UpperlLower Electrical
Junction:
)
Armstack Bearing Pads
(chassis):
Inspect cylinder pins and retaining bolts for security.

Inspect for damage to switch housing, or to arm lever. Inspect
for security of internal wiring, proper strain relief sealing, and
security of switch mounting.
Remove terminal strip cover and inspect wiring for corrosion

and tightness. If rust or corrosion are present, clean with a
wire brush and coat terminal connections with a spray corrosion inhibiter 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 antisieze compound.
PLATFORM
Visual Inspection:
Platform Pivot Shafts and

Retaining Bolts:
Inspect security of retaining bolts and pin.
Platform Bearing Pads:
Inspect for leaks, cuts, and abrasions. Check for tightness and
proper routing.
Electrical Cable:
Lift Cylinder Pins and

Retaining Bolts:
C.
Platform Entrance Lift Gate

and Latch Assemblies:
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 antisieze compound.
Inspect for damage. Ensure that gate slides (operates) freely
MANUAL 92350-002
JANUARY 1997
SIN X935-97051
C.
PLATFORM (conttd)
Extension Deck and Latch
Assembly:
Electrical Cable:
D.
Inspect for damage. Ensure that deck slides freely and latch
assembly functions properly.
Inspect for damage, fraying or cracked insulation, and proper
routing.
LOWER CONTROL BOX

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

Ensure that enclosure lid seals watertight and that controls are
secure.
Internal:
Inspect for tightness of terminal strip mounting, all wire ends,

and cable strain reliefs. Ensure that no corrosion is present and
that box drain holes are open.
Manual Tube Holder

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

Visual Inspection
External:
Inspect for proper operation of electrical cable quick disconnect plug. Inspect for damage to enclosure or controls. Ensure
that box fits snugly onto mounting posts and that controls are
secure.
Internal:
Inspect for tightness of wire ends at all locations. Ensure that

enclosure lid seals water tight, and lid hinges are not damaged.
)
MANUAL 92350-002
JANUARY 1997
SIN X93597051
50 HOUR INSPECTION
MON
ITEM
TUES
WED
Visual Inspection
Steering Cylinder
Steering Connecting Arm
Steering Knuckles
Wheels
Drive Motors
Brake Cylinders
Hydraulic Hoses and Fittings
Tires
~-"
Belly Pan
~-'
Battery Charger
Wiring and Electrical Connections
Electric Motor and Pump
ARMSTACK
Visual Inspection
Lift Cylinder Hoses and Fitting
Electrical Cable
Lift Cylinder
Lift Cylinder Pins and Retaining Bolts
Limit Switch
UpperlLower Electrical Junction
Armstack Bearing Pads (chassis)
PLATFORM
FRI
SAT
SUN
rzV IVV V IVV IV

HOURS
CHASSIS
THURS
Visual Inspection
MANUAL 923 50-002

JANUARY 1997
SIN X935-97051
50 HOUR INSPECTION
;)
(cont'd)
MON
ITEM
rz /
HOURS
TUES
WED
THURS
FRI
SAT
SUN
/ ; // 1// /
PLATFORM (cont'd)
Platfonn Pivot ShaftslRetaining Bolts

Platfonn Bearing Pads
Platfonn Entrance Lift GatelLatches
Extension Deck and Latch Assembly
Electrical Cable
Manual Storage Container
MDL MOl and MDe Models
LOWER CONTROL BOX

Visual Inspection--External
Visual Inspection--Internal
/~)
Manual Tube Holder

MDDModels
UPPER CONTROL BOX

Visual Inspection--External
Visual Inspection--Intemal
)
MANUAL 92350-002
JANUARY 1997
SIN X935-9705J
HYDRAULIC FLUID SPECIFICATIONS

FOR
CONDOR AERIAL WORK PLATFORMS
Shell Tellus - T32 Hydraulic Fluid
Viscosity
SUS@ 100F
SUS@210F
155
47
Viscosity Index
154
Flash Point of
325
Pour PointOF
-54
COLD TEMPERATURE OPERATION
For continuous operation in sub-zero temperatures, a fluid change is required. One of the
following should be used:
A)
Conoco DN-600 Antiwear Hydraulic Fluid

Manufacturer: Continental Oil Co., Houston, Texas
B)
Sun Low Temperature No.3 Hydraulic Fluid

Manufacturer: Sunoco, Inc., Toronto, Ontario, M5S 2S4, Canada
C)
Fluids Conforming to MIL-H-5606C Specifications.

Examples: Chevron Aviation Hydraulic Fluid-C
Shell L.a. Hydraulic #23
CAUTION
DO NOT MIX DIFFERENT FLUIDS
)
MANUAL 92350-002
JANUARY 1997
SIN X935-97051
NOTES
MANUAL 92350-002
JANUARY 1997
SIN X935-97051
.)
115 VAC BATTERY CHARGER

TROUBLESHOOTING GUIDE
To be able to use the troubleshooting guide effectively, it is important to read this guide
completely before beginning any tests.
CAUTION
REPAIRS BY QUALIFIED PERSONNEL ONLY.
NOTE: Modifying this charger for use other than that for which it was intended, repairs by persons
not qualified, or not using original equipment replacement parts will void the warranty and Lester
liability.
CAUTION
DO NOT DISASSEMBLE THE CHARGER. TAKE IT TO A
QUALIFIED SERVICEMAN WHEN SERVICE OR REPAIR IS
REQUIRED. Incorrect assembly may result in a risk of electric shock or fire.
SECTION 1 - CHARGER DOES NOT TURN ON

In normal operation the charger DC output must be connected to the batteries in order to tum the
charger on. A time delay of 2 to 5 seconds is provided to allow adequate time to make a secure connection
before the charger turns on. After this time delay the power relay closes and an audible "click" should
be heard. When the relay closes, AC power is supplied to the transformer primary coil. If operating
properly, the transformer should hum and the ammeter should indicate the charge rate. If the charger
does not turn on properly, refer to Part A, B, or C for specific test procedures.
WARNING
Do not operate the charger if it is malfunctioning. Personal injury or
property damage could result.
)
MANUAL 92350-002
JANUARY 1997
SIN X935-97051
PARTA-RELAY DOES NOT CLOSE, NO TRANSFORMER HUM AND AMMETER

DOES NOT REGISTER.
Check to be sure the power supply cord is securely connected to a live outlet. Check the
DC output connector and the battery connector for damage, dirt or corrosion that would prevent a
good electrical connection.
WARNING
If the plug or receptacle is broken, twisted, bent or loose and does not make
good electrical contact, have it replaced by a qualified serviceman immediately
DO NOT USE THE CHARGER IN THIS CONDITION AS FIRE OR
PERSONAL INJURY CAN RESULT.
Disconnect the power supply cord from its outlet. With the DC output connector still connected
to the battery connector, measure the voltage at the battery connector using a suitable DC voltmeter. The
voltage reading should be the same as the battery terminal voltage and must be between 24 and 50 volts
DC in order to close the relay. If the DC voltage is within the above limits, remove the charger cover and
verify that the charger is properly wired and you read the same voltage (24 to 50 volts DC) inside the
charger where the white and black wires of the DC cord attach. If the battery DC vol tage measured inside
the charger is now below the above limits or not present, the DC plug or cordset has an internal break and
must be replaced. Ifthe charger is wired correctly and a satisfactory battery DC voltage is measured inside
the charger, a malfunction in the Electronic Timer Kit has probably occurred. Due to its complexity, do
not attempt to make field repairs to any part of the Electronic Timer Kit. If a malfunction exists, simply
remove the entire Electronic Timer Kit and replace it with a new one. Refer to Part D - "Electronic Timer
Kit Replacement" - for correct procedure.
CAUTION
ALWAYS UNPLUG THE ELECTRICAL CORDS FROM THE AC
OUTLET AND THE BATTERIES BEFORE ATTEMPTING ANY
REPAIRS TO THE CHARGER.
The Electronic Timer Kit may be bypassed in order to verify that a malfunction exists. First
disconnect the charger power supply cord from its outlet and the DC output from the battery. Place a
jumper wire between terminals #1 and #3 to bypass the Electronic Timer Kit.
The power supply cord is now connected directly to the primary transformer coil and the
transformer should hum when the power supply cord is connected to a live outlet. The charger operation
may be checked by first connecting the DC output connector to the battery connector, and then connecting
the power supply cord to an outlet. Ifnormal charging current is indicated on the ammeter the Electronic
Timer Kit is defective and must be replaced.
MANUAL 92350002
JANUARY 1997
SIN X935-97051
CAUTION
DO NOT charge batteries with the Electronic Timer Kit bypassed. The charger
will remain on as long as the power supply cord is connected to an outlet.
Severe overcharging and eventual damage to batteries will result.
If the transformer does not hum and the ammeter still does not register with the Electronic Timer
Kit by-passed, a continuity check ofthe charger AC circuit is necessary. Disconnect the power supply
from its outlet and the DC output connector from the battery connector and, with a suitable continuity
tester, check the circuit across the power supply cord prongs. With the Electronic Timer Kit bypassed, the
CIRCUIT SHOULD BE COMPLETE. Ifthe circuit is not complete, individually check the continuity of
the power supply cord, primary transformer coil and all connections.
PART B - RELAY CLOSES BUT NO TRANSFORMER HUM AND AMMETER DOES NOT
REGISTER
Check to be sure the power supply cord is securely connected to a live AC outlet. When three-prong
to two-prong adapters are used, they tend to work loose resulting in a poor connection. Check the AC line fuse
or circuit breaker and, if possible, measure the AC line voltage at the outlet to be sure AC power is present.
If necessary, connect a functioning charger, utility light or other electrical appliance to the outlet to verify the
presence of AC power.
If AC poweris present, disconnect the power supply cord from its outlet and the DC output connector
from the battery connector. By-pass the Electronic Timer Kit as described in Section 1, Part A, and with a
suitable continuity tester check the circuit across the power supply cord prongs. With the Electronic Timer
Kit bypassed, the CIRCUIT SHOULD BE COMPLETE. Ifthe circuit is complete, refer to the wiring diagram
and check the relay wiring and all connections. Ifthe circuit is not complete, check the wiring of the power
supply cord, transformer primary coil leads and the Electronic Timer Kit. Ifthe charger is wired correctly,
individually check the continuity of the power supply cord, transformer primary coil and relay.
PART C- RELAY CLOSES AND TRANSFORMER HUMS BUT AMMETER DOES NOT REGISTER
If the relay closes and the transformer hums, the charger AC circuit and Electronic Timer Kit are
functioning properly. Ifthe ammeter does not register, a fault in the charger DC circuit exists and a continuity
check must be performed. Disconnect the power supply cord from its outlet and the DC output connector from
the battery connector, and check the charger fuse. If a fuse link is blown, refer to Section 2 - "Charger Fuse
Blows" for further tests. If the fuse checks good, use a low voltage continuity tester to perform the following
tests:
1.
Connectthe tester leads to the charger DC output connector and note the reading. Reverse the tester leads
and check the output connector again. The circuit should be complete in only one direction. If the circuit does
not conduct in either direction and the fuse is good, individually check the continuity ofthe DC output cord,
ammeter, diodes and all connections. If the circuit conducts in both directions, a "short" exists in the charger
DC circuit. First check the DC output cord for a "short" between the two wires. It is more likely that one or
both diodes have "shorted." Refer to Section 2 - "Charger Fuse Blows" for continuity test of diodes.
)
MANUAL 92350002
JANUARY 1997
SIN X93597051
2.
If the charger DC circuittest is good, a check ofthe capacitor is necessary. Disconnect the power supply
cord from its outlet and the DC output connector from the battery connector. Then disconnect
both transformer coil leads from the capacitor terminals. Use care when disconnecting the capacitor
leads so the wires do not break. Using an ohmmeter, set the scale to R X 10K ohms and test the capacitor as
follows:
DANGER
HIGH VOLTAGE: With the charger operating, the charger capacitor voltage is
approximately 650 volts AC. Use extreme caution when working near the capacitor terminal
GOOD CAPACITOR - When the ohmmeter leads are connected to the capacitor terminals, the meterneedle
jumps to mid-scale and rapidly moves to high resistance.
OPEN CAPACITOR - When the ohmmeter leads are connected to the capacitor terminals, the meterneedle
does not move and stays at high resistance. A bulge in the top of the capacitor may be visible if the capacitor
has failed "Open."
SHORTED CAPACITOR - When the ohmmeter leads are connected to the capacitor terminals, the
meter needle jumps immediately to zero ohms and remains there.Ifthe capacitor is open or shorted, it
must be replaced.
CAUTION
Use only a 6 Mfd, 660 volt AC rated capacitor for replacement (Part No. 02390S).
The use of a different value capacitor may result in improper charging, capacitor
failure, transformer burnout and/or battery damage.
3.
If the charger DC circuit and capacitor check good, a test of the transformer is necessary. Refer to
Section 7 - "Transformer Short or Burnout" or test procedures.
PART D - ELECTRONIC TIMER KIT REPLACEMENT
The Electronic Timer Kit should always be replaced as a complete assembly. The tools required
are: a Phillips head screwdriver, 3/8" and 11132" wrenches, and pliers. No soldering is required. To
replace the kit, follow the step-by-step procedures listed below.
1.
Disconnect the charger power supply cord from its outlet and the DC output connector from the
battery connector and remove the charger cover.
2.
Disconnect the green, black and red wires of the Electronic Timer Kit. Then remove the black and
white leads of the power supply cord and both primary transformer coil leads from the Electronic Timer
Kit terminal tabs. The Kit can be removed by removing the three mounting screws on the charger front
pane1. Save all hardware for reassembly.
3.
Install the replacement Electronic Timer Kit by reversing the disassembly procedures
described in Step 2. When reconnecting the wires to the Electronic Timer Kit terminal tabs, support the
terminal board to prevent damage to the electronic circuit board. Connect either transformer primary lead
to terminal #2 and the remaining primary I lead to terminal #3.
MANUAL 92350002
JANUARY 1997
SIN X93597051
Connect the black lead of the power supply cord to tenninal # I on the Electronic Timer Kit
and the white lead of the power supply cord to tenninal #2.
Connect the red wire of the Electronic Timer Kit along with the white lead of the DC cord to
the Heat Sink Assembly. Connect the black wire of the Electronic Timer Kit along with the black lead of
the DC cord to the ammeter post. Do not allow the ammeter post to tum when tightening the nut. Reconnect the green wire of the Electronic Timer Kit along with the transfonner secondary lead to the diode
lead terminal.
CAUTION
Be sure all connections are clean and tight. Also check to be sure all wires
and tenninals are positioned so they do not short together or to the charger case.
4.
Replace the charger cover and check the Electronic Timer Kit for proper operation as follows:
A.
With the DC output connector disconnected from the battery connector, insert the power
supply cord into an outlet. The relay on the Electronic Timer Kit should not close. A DC
voltmeter connected across the DC output connector should indicate zero volts.
B.
Disconnect the power supply cord from its outlet and connect the DC output connector to the
battery connector. The relay on the Electronic Timer Kit should close with an audible" click"
after a two to five second delay.
C.
If the Electronic Timer Kit does not operate as (a) and (b) above, refer to the wiring diagram
and check to be sure the charger is wired correctly. If the Electronic Timer Kit operates
properly, the charger is ready for use. Always monitor the first charge cycle to verify that
the charger is turning off properly.
DANGER
Lead acid batteries generate highly explosive hydrogen gas especially
during the charging cycle. To AVOID the possibility of an explosion,
charge batteries ONLY in a well VENTILATED AREA. Keep fire, sparks
and burning material away from the charging area. Do Not smoke near a
battery, and always shield the eyes when working near a battery.
SECTION 2 -
CHARGER FUSE BLOWS
The charger fuse assembly consists of a dual element fuse link under a transparent cover mounted
on the charger front panel. Each fuse element is electrically connected in series with a rectifier diode to
provide protection for the transformer in the event of a diode failure. Visually inspect and electrically
testthe fuse to determine if one or both fuse links are blown and refer to Part A or PartB fortestprocedures.
LOCATE AND CORRECT CAUSE OF TROUBLE BEFORE REPLACING BLOWN FUSE. DO
NOT attempt to repair the fuse link as inadequate protection will result.
MANUAL 92350-002
JANUARY 1997
SIN X935-97051
PART A- SINGLE FUSE LINK BLOWS

This condition is normally caused by a short circuit failure of one diode. The fuse link will blow
when the charger DC output connector is connected to the battery connector, regardless of whether the
power supply cord is connected to an outlet. To check the diodes, disconnect the power supply cord from
its outlet and the DC output connector from the battery connector, and then disconnect one transformer
secondary coil lead from the diode terminal. Using a low voltage continuity tester, connect one tester lead
to the diode mounting plate and the other tester lead to a diode terminal.
Note the reading and then reverse the tester leads and check each diode again. If a diode conducts
current in both directions, it is "shorted" and the complete Heat Sink Assembly with Diodes (Part No.
09653S) must be replaced.
On rare occasions a singl e fuse link may melt due to excessive heat. This can be caused by a loose
internal fuse connection. Check all three fuse connections inside the charger to be sure they are clean and
tight. The proper torque on the fuse connector nuts is 20 Inch-Pounds (23 Cm-Kg).
PART B - BOTH FUSE LINKS BLOW

This is normally caused by a reverse polarity connection between the charger DC output
connector and the battery connector. Check the battery pack and battery connector to be sure they are
wired in the correct polarity. If possible, check the voltage and polarity at the battery connector with a
DC voltmeter. Also, check the charger DC output connector for the correct polarity. The white wire
should be connected to the positive (+) contact, and the black wire to the negative (-) contact. If a r e v e r s e )
polarity connection is made between the charger and batteries, both fuse links will blow, regardless of
whether the power supply cord is connected to an outlet.
Another cause for both fuse links blowing is the short circuit failure of both diodes. Although this is rare,
it may occur as the result of a lightning strike at the charging location. Excessive heat due to a loose
connection may also cause both fuse links to melt. Refer to Part A - "Single Fuse Link Blows" for
troubleshooting procedures.
MANUAL 92350-002
JANUARY 1997
SIN X93597051
SECTION 3 - AMMETER READS 30 AMPS FOR MORE THAN 30 MINUTES
This high output condition is caused by misuse, connecting the charger to an incorrect battery
system which is lower than 24 volts. A common error is to install one or more of the 6 volt batteries in
a 24 volt battery pack reverse polarity. Using a suitable DC voltmeter, test to be sure all batteries in a
battery pack are correctly wired and also test the battery pack voltage at the charging connector. After
charging for 3 0 minutes at this excessive rate, the measured on charge voltage should rise to 22 to 26 volts
DC for a 24 volt system. Voltage measurements, while charging, lower than this indicate an incorrect
or failed battery pack that must be corrected before using the charger.
CAUTION
DO NOT connect the charger to battery packs which are not 24 volt
systems.This misuse will cause overheating and transformer burnout
will result.
SECTION 4 -
CHARGER OUTPUT IS LOW
The most probable cause oflow output is a single fuse link blowing as the result of a short circuit
failure of one diode. Refer to Section 2 - "Charger Fuse Blows" for troubleshooting procedures. On rare
occasions a short circuit failure of the transformer coils may cause the output to be low. Refer to section
7 - Transformer Short or Burn Out" for test procedures.
CAUTION
Do not use the charger if the output is low. Batteries will not reach
full charge, thereby increasing the possibility of a harmful deep
discharge during their next use.
SECTION 5 - CHARGER TURN OFF MALFUNCTIONS
The Electronic Timer Kit turns the charger off as well as on. Proper charge time is determined by
many factors, but the main elements are: (1) battery size, (2) depth of battery discharge and (3) finish
charge rate. Large severely discharged batteries require more time to reach full charge than do smaller
lightly discharged batteries.
The charge rate, as indicated by current flow in amperes on the panel meter, is controlled by the
batteries' rising voltage during charge. The higher the on charge voltage will rise, the lower the finish
charge will be before the Electronic Timer terminates charging.
The following timer malfunctions are occasionally due to factors other than the charger's
performance. To help isolate the problem, it is often necessary to use the charger on a different set of
batteries and the original set of batteries on another charger.
)
MANUAL 92350002
JANUARY 1997
SIN X935-97051
PART A -
CHARGER TURNS OFF TOO SOON
Check to be sure the power supply cord is securely connected to a live outlet. If the power s u p p l y , .
outlet is live, proceed with the next step.
)
To determine if the charger did shut off too soon, disconnect and reconnect the charger DC output
connector. This will restart the charger. Observe charger output on the ammeter.
1.
The ammeter needle jumps smartly to between 20 and 25 amps and then tapers below 14 amps
within 15 minutes. This indicates that the batteries were truly charged. The apparent short charging time
is in response to the batteries' ability to accept charge and the electronic timer is performing properly.
2.
The ammeter needle jumps smartly to between 20 and 25 amps, but does not taper below 14 amps
within 15 minutes. If the batteries have been properly maintained and charged regularly, this generally
indicates that the batteries were not fully charged. If possible, use a hydrometer to check the specific
gravity of several battery cells. If the specific gravity readings are more than 30 points (.030) lower than
normal full charge readings, the electronic timer has malfunctioned and the complete Electronic Timer
Kit must be replaced. Refer to Section 1, Part D - "Electronic Timer Kit Replacement" for correct
procedures.
If the batteries have not been used or charged regularly, they may be sulfated and will not produce
their full capacity. Repeated cycles (at least 5) of a light discharge followed by a full charge will generally
result in the recovery of most of the battery's capacity. Do not interpret this reduced battery capacity as
being caused by the charger turning off too soon. The charger is working properly if, after several charge
cycles, the battery capacity increases to near normal. Sulfation occurs most often when the batteries have
been stored without weekly charging. New batteries may also be sulfated due to extended shipment or
storage time prior to sale.
As batteries age, individual cells may weaken, causing a reduction in battery capacity. This
condition normally results in a finish charge higher than 10 Amps and less time is required to fully charge
the batteries. Do not interput this shorter charging time and reduced battery capacity as being caused by
the charger turning off too soon. The battery is aging naturally and the charger is working properly. When
the batteries will no longer perform as required, they should be replaced.
PART B -
CHARGER DOES NOT TURN OFF
New batteries with all good cells should rise to at least 2.5 volts per cell. This will allow the finish
charge rate to taper below 8 amperes. As batteries age, individual cells may weaken and these cells may
not reach 2.5 volts. This will result in finish charge rates greater than 8 amperes, and less time will be
required for the batteries to reach full charge. At a finish charge rate of 8 amperes or less the charge time
should not exceed 18 hours. At a finish charge rate greater than 8 amperes the charge time should not
exceed 14 hours.
If the chargerremains on longer than the specified maximum time, check to see if the charger turns
on immediately when the DC output cord is connected without the normal two to five second delay. If
the charger turns on instantly without the two to five second delay the Electronic Timer Kit has probably
failed. This type of malfunction generally results in the charger not turning off and the complete
Electronic Timer Kit must be replaced. Refer to Section 1, Part D - "Electronic Timer Kit Replacement"
for correct procedures.
MANUAL 92350002
JANUARY 1997
SIN X93597051
'
)
If the charger remains on longer than the maximum time specified and the two to five second delay
is present, verify that the green wire from the Electronic Timer Kit and the secondary transformer coil lead
are securely connected to the diode lead as shown. The charger will NOT turn offifthe green wire is loose
or disconnected. If the green wire is securely connected, the Electronic Timer has malfunctioned and the
complete Electronic Timer Kit must be replaced.
If a precision digital type DC voltmeter is available, a test to verify that the Electronic Timer has
malfunctioned can be made. Connect the charger to the batteries and allow to charge normally. After the
charge rate has tapered to its lowest point, measure the battery terminal voltage using a DC voltmeter
capable of reading in increments of. 00 1 volts. Continue charging and check the battery voltage reading
every hour. If the battery voltage increases less than. 0 12 volts, or if the battery voltage decreases between
successive hourly readings, the charger should turn off If the charger does not turn off, the Electronic
Timer has malfunctioned and the complete Electronic Timer Kit must be replaced.
PARTC-CHARGERRUNS TOO LONG BUT DOES TURN OFF

In the event of AC power interruption when the charger is on, the charger will automatically restart
when AC power is restored. This power outage can make the apparent charge time seem longer than the
actual charge time. To check for AC power interruptions, plug an electric clock into the same oudet to
which the AC cord is connected. Charge normally and note any time difference between the test clock
time and the actual time.
SECTION 6 - AC LINE FUSE OR CIRCUIT BREAKER BLOWS
If this occurs when the charger power supply cord is connected to an oudet, without the DC output
connector connected to the battery connector, the charger power supply cord may be shorted. Disconnect
the power supply cord from its oudet and the DC output connector from the battery connector, then check
to be sure the Electronic Timer Kit is NOT bypassed. With a suitable continuity tester, check the circuit
across the power supply cord prongs as shown. THE CIRCUIT SHOULD NOT BE COMPLETE. If the
circuit is complete, check the relay contacts to be sure they are open and have not welded closed. If the
relay contacts are open, the power supply cord is shorted and must be replaced. If the power supply checks
good, the transformer coils may be shorted. Refer to Section 7 - "Transformer Short or Burnout" for test
procedures.
SECTION 7 - TRANSFORMER SHORT OR BURNOUT

Failure of the transformer can be the result of natural aging, premature shorting of adj acent coil
turns or overheating damage. The most common cause oftransformer overheating and premature burnout
is the result of misuse, connecting the charger to a battery system of lower voltage than specified on the
charger (See Section 3). Darkening of all the transformer secondary coil windings is an indication of
possible overheating damage. A low or complete lack of output would be observed on the ammeter,
however, the transformer may hum or the AC line fuse or circuit breaker may blow when the charger is
turned on. To test the transformer, disconnect the power supply cored from its oudet and the DC output
connector from the battery connector. Then disconnect the transformer secondary coil leads #1 and #4
from the diode terminals and disconnect the transformer capacitor coil leads from the capacitor terminals.
Use care when disconnecting the capacitor lead so the wires do not break.
)
MANUAL 92350-002
JANUARY 1997
SIN X93S-970S1
DANGER
!)
HIGH VOLTAGE: With the charger operating, the charger capacitor voltage is
approximately 650 volts AC. Use extreme caution when worldng near the capacitor
terminals.
In order to apply AC power directly to the transformer primary coil, the Electronic Timer Kit must
be bypassed. Refer to Section 1, Part A for by-pass procedures. With the Electronic Timer Kit bypassed
take caution in connecting the power supply cord to an outlet. If the AC line fuse or circuit breaker blows,
the transformer is shorted internally and must be replaced. If this does not occur, check the transformer
secondary and capacitor coil voltages as shown in Figure 6, using a suitableAC voltmeter. Ifthe measured
voltages are substantially lower than those shown, the transformer is shorted internally and must be
replaced.
If the transformer secondary coil voltage and capacitor coil voltage check good, disconnect the
power supply cord from its outlet. Check the capacitor to be sure its rating is 6 Mfd. 660 volts AC, and
then carefully reconnect the capacitor coil leads to the capacitor terminals. Then, take caution when
reconnecting the power supply cord to an outlet and measure the transformer secondary voltage again.
The correct voltage reading is shown in Figure 7. Ifthe transformer secondary voltage reading is the same
as measured with the capacitor disconnected, from Figure 6, the capacitor may be open, the capacitor coil
may be open or the capacitor coil terminals may not be making proper electrical contact. Refer to Section
1, Part C, Item 2 for capacitor test procedures. If the voltage readings are correct, both the transformer
and capacitor are good, refer to Section 1, Part C, Item 1 for further tests of the DC circuit.
.)
If it should become necessary to replace a terminal on one of the transformer leads, the new
terminal must be crimped AND soldered. NOTE: Some transformer leads may be aluminum wire and
a solder must be used on these wires that is intended for use on aluminum, such as Alcoa #807 solder with
Alcoa #69 flux. If these materials are not available locally, contact the Lester factory.
)
MANUAL 92350-002
JANUARY 1997
SIN X935-97051
APPENDIXA
BOLT TORQUE CHART

BASIC STRESS
lENSILE STRENGTII (T) MIN
MAJOR AREA
PROOF LOAD (P)
SQ. IN
SAE GRADE (1951)
NOMINAL
DJA
lHREADS
INCH
GRADE 5
SAE GRADE 5
GRADES
CLAMP
ASSEMBL YTORQUE
R=.2OODRY
-.150LUB
SAE GRADE 8
CLAMP
ASSEMBL YTORQUE
4-40
.1120
.00604
120KSI 85KSI
150KSI
120KSI
LOAD
LBS.
380
8LB-IN
6LB-IN
LOAD
LBS.
540
12LB-IN
9LB-IN
4-4lS
.1120
.00661
120KSI
85KSI
150KSI
120KSI
420
9LB-IN
7LB-IN
600
13LB-IN
IOLB-IN
b-:H
.1380
..00909
120KSI
b-4U
.1380
.01015
R~.200DRY
R~.15OLUB
8SKSI
l50KSI
120KSI
580
16LB-IN
12LB-IN
820
23LB-IN
17LB-IN
120KSI 8SKSI
150KSI
120KSI
640
ISLB-IN
13LB-IN
920
25LB-IN
19LBIN
8-32
.1640
.01400
120KSI 85KSI
150KSI
120KSI
900
30LB-IN
22LB-IN
1260
41LB-IN
31LB-IN
lS-~b
;1640
.01474
120KSI 85KSI
150KSI
120KSI
940
31LB-IN
23LB-IN
1320
43LB-IN
32LB-IN
10-24
10-32
114-20
.1900
.01750
120KSI 8SKSI
150KSI
120KSI
1120
43LB-IN
32LB-IN
1580
6OLB-IN
45LB-IN
.1900
.0200
120KSI
8SKSI
150KSI
120KSI
1285
49LB-IN
36LB-IN
1800
68LB-IN
51LB-IN
.2500
.03180
120KSI
85KSI
l50KSI
120KSI
2020
8LB-FT
75LB-IN
2860
12LB-FT
9LB-FT
lI4-:llS
.2500
.03640
120KSI 85KSI
l50KSI
120KSI
2320
10LB-FT
86LB-IN
3280
14LB-FT
10LBFT
)/ Ib-llS
.3125
.05240
120KSI
150KSI
120KSI
3340
17LB-FT
13LB-FT
4720
25LB-FT
18LB-FT
.3125
.05800
120KSI 85KSI
l50KSI
120KSI
3700
19LB-FT
14LB-FT
5220
25LB-FT
20LB-FT
.3750
.07750
120KSI 8SKSI
150KSI
120KSI
4940
30LB-FT
23LB-FT
7000
45LB-FT
35LB-FT
5/16-24
3/8-16
3/8-24
7/17-14
7/16-20
112-13
112-20
9/16-12
9/16-18
85KSI
.3750
.08780
120KSI 8SKSI
150KSI
120KSI
5600
35LB-FT
25LB-FT
7900
50LB-FT
35LB-FT
.4375
.10630
120KSI
85KSI
150KSI
120KSI
6800
50LB-FT
35LB-FT
9550
70LB-FT
55LB-FT
.4375
.11670
120KSI 85KSI
150KSI
120KSI
7550
55LB-FT
4OLB-FT
10700
80LB-FT
6OLBFT
5000
.14190
120KSI
8SKSI
150KSI
120KSI
9050
75LB-FT
55LB-FT
12750
110LBFT
8OLBFT
5000
.15990
120KSI
8SKSI
150KSI
120KSI
10700
90LB-FT
65LB-FT
14400
120LB-FT
9OLB-FT
.5625
.18200
120KSI 8SKSI
150KSI
120KSI
11600
1l0LBFT
80LB-FT
16400
15OLBFT
110LB-FT
.5625
.20300
120KSI 8SKSI
150KSI
120KSI
12950
120LB-FT
90LB-FT
18250
170LB-FT
130LB-FT
;)flS-l1
.6250
.22600
120KSI 85KSI
150KSI
120KSI
14400
15OLB-FT
1l0LB-FT
20350
220LBFT
170LB-FT
5/8-18
3/4-10
3/4-1b
7/8-9
7/8-14
1-8
1-12
1 1/8-7
1118-12
11/4-7
1 1I4-12
13/8-6
13/8-12
1 1I2-6
1 112-12
.6250
.25600
120KSI
8SKSI
150KSI
120KSI
16950
18OLB-FT
13OLB-FT
23000
24OLB-FT
180LB-FT
.7500
.33400
120KSI 8SKSI
150KSI
120KSI
21300
260LB-FT
200LB-FT
30100
38OLB-FT
280LB-FT
.7500
.37300
120KSI
85KSI
150KSI
120KSI
23800
300LB-FT
220LB-FT
33600
420LB-FT
320LB-FT
.8750
.46200
120KSI
85KSI
150KSI
120KSI
29500
520LB-FT
390LB-FT
41600
600LB-FT
460LB-FT
.8750
50900
120KSI 85KSI
150KSI
120KSI
32400
570LB-FT
43OLB-FT
45800
660LB-FT
500LB-FT
1.000
.60600
120KSI 85KSI
150KSI
120KSI
38600
770LB-FT
58OLB-FT
54500
9OOLB-FT
680LB-FT
1.000
.66300
120KSI 8SKSI
150KSI
120KSI
42300
85OLB-FT
63OLB-FT
59700
l000LB-FT
740LB-FT
1.1250
.76300
10SKSI
74KSI
150KSI
120KSI
42300
800LBFT
6OOLBFT
68700
1280LB-FT
96OLB-FT
1.1250
.85600
IOSKSI
74KSI
150KSI
120KSI
47500
88OLB-FT
66OLB-FT
77000
1440LB-FT
108OLB-FT
12500
.96900
10SKSI 74KSI
150KSI
120KSI
53800
1120LB-FT
84OLB-FT
87200
1820LB-FT
1360LB-FT
1.2500
1.0730
105KSI
74KSI
150KSI
120KSI
59600
1248LB-FT
920LB-FT
96600
2000LB-FT
OOLB-FT
13750
1.1550
lOSKSI
74KSI
150KSI
120KSI
64100
1468LB-FT
1100LB-FT
104000
2380LB-FT
8OLB-FT
1.3750
13150
105KSI
74KSI
150KSI
120KSI
73000
1680LB-FT
1260LB-FT
118400
2720LB-FT
204OLB-FT
15000
1.4050
105KSI 74KSI
150KSI
120KSI
78000
1940LB-FT
1460LB-FT
126500
3160LB-FT
2360LB-FT
15000
1.5800
105KSI 74KSI
l50KSI
120KSI
87700
2200LB-FT
1640LB-FT
142200
3560LB-FT
2660LB-FT
N01ES:
l.1HIS CHART SHOWS RECOMMENDED BOLT TORQUES.

2. TORQUE = R X D X T
R = .150 FOR LUB CONDITIONS
R = .200 FOR DRY CONDmONS
TO ASSURE CONSISTENCY IN TORQUE, LUBRICATE FASTENERS WITH ENGINE OIL
(MAY BE USED OIL)
D = NOMINAL DIAMETER IN INCHES
T =DESIRED CLAMP LOAD IN POUNDS = 75% PROOFLOAD X STRESS AREA
MANUAL 92350-002
JANUARY 1997
SIN X935-97051
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
DIAMETER
DRY
LUBRICATED
THREADS THREADS
DRY
THREADS
LUBRICATED
THREADS
DRY
THREADS
LUBRICATED
THREADS
DRY
THREADS
LUBRICATED
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
MlO
39
23
42
25
53
32
73
44
M12
67
40
73
44
92
55
127
76
M14
107
64
116
69
146
89
203
122
M16
167
100
181
108
230
138
316
190
M20
325
195
352
211
449
269
617
370
M24
562
337
609
386
775
465
1066
640
M30
1117
670
1210
726
1540
924
2188
1271
MANUAL 92350-002
JANUARY 1997
SIN X93597051
SELF-PROPELLED

Serial Number X935-970S1
ILLUSTRATED PARTS MANUAL
SHIPPINGADDRESS
MAILING ADDRESS
TIME CONDOR
TIME CONDOR
8300 IMPERIAL DRIVE

WAco,TEXAS 76712
(254) 420-5200
P.O. Box 21447

(254) 420-5200
MANUAL92350-003
January 1997
SIN X935-97051
Parts Book Revised 1199
_--------
()
'-
'\
INTRODUCTION
The primary purpose ofthis manual is to provide the user with a thorough understanding of the
proper operating procedures necessary to comply with the intended use oftheCONDOR, and to
provide the information necessary to maintain and service theCONDOR.
THE OPERATOR'S MANUAL MUST BE RETAINED ON THE CONDOR AT ALL TIMES.
Do not attempt to operate or service the CONDOR until you have read
and understood all information provided in this manual. Familiarize yourself
with the functions and operations of the upper and lower controls. A good
understanding of the controls, their limitations, and their capabilities will
maximize operating efficiency. The various decals attached to this
CONDOR also contain vital operational instructions. Read the decals
It is YOUR RESPONSmILITY 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 RESPONSmILITY to understand and obey all federal, state, and local regulations
regarding the operation and use of aerial work platforms. A copy of the ANSI/SIA 92.6-1990 Manual
of Responsibilities is attached for your use.
TIME CONDOR 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 TIME CONDOR

Many of the parts used in the manufacture of theCONDOR have specific properties, and the
manufacturer recommends that replacement parts be purchased through TIME CONDOR in order to
ensure the original integrity of the product. Repairs and adjustments should only be made by trained
and qualified personnel. Please refer to the maintenance and parts sections of the Condor Operation,
Maintenance, & Parts Manual for information on service and maintenance oftheCONDOR.
NOTE:
Please refer to the Condor Parts section of the Operation, Maintenance, & Parts Manual
for information pertaining to your machine.
MANUAL 92350-003
Janwuy 1997
SIN X935-97051
II
1. If you need assistance or have any service or maintenance questions, TIME CONDOR service
and parts personnel are always available by phone or fax. The telephone numbers are:
(254) 420-5200 Telephone

(254) 420-5299 Voice Mail
(800) 443-5803 FAX
2.
There are numerous written Maintenance Procedures availabl e for this CONDO R.
Theseprocedures are available through the Condor Service Departmentto 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 servi ce or sales
persons for a schedule. Remember, training of mechanics is the responsibility oftheir
employer, but Condor Service Schools help youprovidethis 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-propell ed models;
and #92334 for truck-mountedmodels.
TIME CONDOR
)
8300 IMPERIAL DRIVE,
P.o. Box 21447, WACO, TEXAS 76702-1447<254-420-52005, 254666-4544 FAX
CONDOR MODEL V2033XL & V2033

ILLUSTRATED P ARTS MANUAL
TABLE OF CONTENTS
IN'fRODUCTION .................................................................................................................. i
SERVICE INFORMATION .............................................................................. ii
SERIAL NUMBER TO MODEL DESIGNATION ............................................. iii
TABLE OF CONTENTS............................................................................................... 1
FIGURE
DESCRIPTION
PAGE
A .................................................. SerialNumber Location ................................................... 2

B .................................................. RecommendedSpare Parts List ........................................ 3
C .................................................. Howto Order Parts ...................................................... 4,5
1.1 .................................................. FinalInstallation V2033XL ............................................... 6
1.2 .................................................. Final Installation V2033 .................................................... 8
2.1 .................................................. DecalInstallation ............................................................ 10
3.1 .................................................. Chassis Assembly V2033XL ............................................ 12

3.2 .................................................. Chassis Assembly V2033 ................................................ 14
3.3 .................................................. Hose Kit ....................................................................... 16
3.4 .................................................. Lift Cylinder ................................................................... 18
3.5 .................................................. Steer Cylinder ................................................................. 19
3.6 .................................................. BrakeCylinder ................................................................ 20
3.7 .................................................. HubMotorAssembly ..................................................... 21
3.8 .................................................. Hub Assembly ................................................................ 22
3.9 .................................................. Tube Kit ................. ,...................................................... 23
3.10 .................................................. BellyPanAssembly ......................................................... 24
3.11 .................................................. Motor & Pump Assembly .............................................. 28
3.12 .................................................. Pump Assembly ............................................................. 29
3.13 .................................................. Motor24VDCAssembly ............................................... 30
3.14 .................................................. Valve Installation ............................................................ 32
3.15 .................................................. Valve Assembly .............................................................. 34
3.16 .................................................. Charger 115V/25A ........................................................ 36
3.17 .................................................. Charger 115V/25AMod ................................................ 37
3.18 .................................................. Charger 115V/60HZ-25A124VDC ................................ 38
3.19 .................................................. Electrical Wiring ............................................................. 40
4.1 .................................................. Lower Control Box Assembly ........................................ 42
5.1 .................................................. ArmstackAssembly ........................................................ 50
5.2 .................................................. Armstack Cylinder .......................................................... 56
5.3 .................................................. ManifoldAssembly ......................................................... 58
5.4 .................................................. Manifold ........................................................................ 59
6.1 .................................................. Platform Assembly ......................................................... 60
6.2 .................................................. 110 Volt Extension To Platform ..................................... 63
6.3 .................................................. Upper Control Box Assemb ly ........................................ 64
n
\o"""b
(9'l
,)
7.1 .................................................. Travel Alarm (Option) ...................................................' 6

7.2 .................................................. Motion ~larm (Ol?tion) .................................................
.". "10
7.3 .................................................. StrobeLlght(Option) .................................................... 6 - 7 (
7.4 .................................................. DescendAlarm(C?ption) ................................................ 9 .,. '12"
7.5 .................................................. SlopeAlarm (Option). 1...,
S
7.6 .................................................. Hour Meter (XL-Option) .............................................. 1 ." 7 i.L
7.7 .................................................. BatteryConditionIndicator(XL-Option) .......................
... '7 T
7.8 .................................................. Low-Voltage Warning Interrupt (Xt-Option) .................
.,
7.9 .................................................. Larger Batteries IPOS (XL-Option) ...............................
- 7b
75
MANUAL 92350-003
January 1997
SIN X935-97051
FIGURE A-Serial Number Location
1
2
The CONDORModel V2033XL & V2033 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, at the rear between fork lift pockets.
The second place to find the serial number is at thefront steering knuckle kingpin.
......
. ..
"
..
;"to:
MANUAL 92350-003
Janwuyl997
SIN X935-97051
FIGURE B-Recommended Spare Parts List
CONDORMODEL V2033XL&V2033 (1 UNIT-l YEAR OPERATION)
PARTNUMBER
!)
DESCRIPTION
V2033XL
V2033
QTY
QTY
91029 ................................. Nut Lug 1/2" .................................................. 5 ............................. 5

55363-001 .......................... Stud Wheel 1/2"-20 x 13/4" ........................... 5 ............................. 5
54783 ................................. CableAssembly,EmergencyLowering ............. 1 ............................ 1
54798 ................................. Couple Nut, 10-32UNF .................................. 1 ............................. 1
55471 ................................. Plunger, Hand Retract Spring ............................ 3 ............................. 3
55241 ................................. Spring Loaded Pull-Up Latch ........................... 3 ............................. 3
54048 ................................. Latch Door ..................................................... 1 ............................. 1
67408 ................................. Element,HydraulicFilterP/N33430 ................ 5 ............................. 5
36085 ................................. Fitting, Swivel 900 Elbow 6-6 ........................... 2 ............................ 2
51036 ................................. Switch Limit Body Only ................................... 1 ........................... 1
51037 ................................. OffsetHeadLimitSwitch ................................. 1 ............................. 1
51039-002 ........................ LimitSwitch,ArmlShort ................................. 1 ........................... 1
54589 ................................. Controller, Drive/Steer .................................... 1 ..................... N/A
67939-015 .......................... Fuse, 15Amp ................................................... 1 ............................. 1
67940 ................................. FuseHolder ..................................................... 5 ............................. 5
52138 ................................ Solenoid24V ................................................... 1 ............................. 1
206-00001-00 ..................... Diode .............................................................. 9 ............................. 9
54438 ................................. Relay, 24V SPD T Bosch ................................... 1 ............................. 1
34547 ................................. Jumper ............................................................. 4 ...................... N/A
34542 ................................. Jumper ...................................................... N/A ............................. 1
55982-002 .......................... Decal Installation .............................................. 1 ...................... N/A
55982-102 .......................... Decal, V2033XLEssentiais ............................... 1 .......... ~ ............ N/A
55982-001 .......................... Decal Installation ........................................ N/A ............................. 1
55982-101 .......................... Decal, V2033 Essentials .............................. N/A ............................. 1
55469 ................................. HoseKit .......................................................... 1 ............................. 1
55243 ................................. Spring-DeckLatch ......................................... 1 ............................. 1
55333 ................................. Charger ........................................................... 1 ............................ 1
54910-102 .......................... Receptacle ................................ ~ ....................... 1 ............................. 1
54910-104 ......................... Mouming ......................................................... 1 ....................... N/A
51913 ................................. Operator,RedP-Pull ........................................ 1 ............................. 1
51914 ................................. Base, 1 NC Contact ......................................... 1 ............................ 1
52670 ................................. Operator, 3 PosRot ......................................... 1 ....................... N/A
34464 ................................ Base, NO/NC Contacts ................................... 1 ....................... N/A
52669 ................................. Operator,BlackP-Button ................................. 1 ....................... N/A
52672 ................................. Base, 1 NO Contact, ........................................ 1 ....................... N/A
69146 ................................. Operator, GreenP-Button ................................ 1 ....................... N/A
54913 ................................. Operator BlacklBlackDoubleP-Button ........... 1 ....................... N/A
52029 ................................. Base, 2 NO Contacts ........................................ 1 ............................. 1
50075 ................................. Switch ............................................................. 1 ............................. 1
67758 ................................. ToggleSwitch ............................................ N/A ............................. 1
52671 ................................. Operator, 3 Pos Key .................................. N/A ............................. 1
MANUAL 92350-003
JanuaIY 1997
SIN X935-97051
FIGURE C-How to Order Parts

1.
When ordering parts for yourCONDOR, 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
TIME CONDORParts 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 TIME CONDOR 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 TIME CONDOR Parts
Department. Credit will be authorized through the Service Department after a Warranty
Claim has been submitted to TIME CONDOR. A Warranty Claim is to be filed for any part
received as "defective". See Maintenance Manual for Warranty Procedures.
5.
TIME CONDOR will ship parts as per our customers' request at the time of the order-i.e.,
UPS, Federal Express, or preferred truck line. When shipping Federal Express, your customer account must be given at the time of the order.
6.
TIME CONDOR classifies its orders in the following ways:

Emergency
Stock
(unit out of service) - Top priority. Shipping deadline for emergency

orders to ship same day is 2.00 p.m. Central Standard Time. Any
emergency order received after 2.00 p.m. will be shipped the
following day.
Order to be shipped within 1 week.
7.
TIME CONDOR has a $25.00 Net Minimum Billing charge per order.
8.
All price quotations will be valid for 90 days.
9.
Parts shown as shipped on the TIME CONDOR packing list and subsequent invoice but not
received by the dealer/customer MUST be reported within 10 days after the date of shipment.
If the parts are still required, a NEW parts order must be submitted. Shortages and discrepancies will be reviewed on an individual basis by the Parts staff and adjustments will be made
accordingly.
10.
Invoice discrepancies regarding incorrect prices or discounts should be reported immediately

to the Parts Department. Report the Sales Order number, Purchase Order number, and
Invoice number. Your request will be reviewed and adjustments will be made accordingly.
)
MANUAL 92350003
JanuaI}' 1997
SIN X935-97051
TIME CONDOR PARTS DEPARTMENT

FAX ORDER FORM FAX NO. 800-443-5803
}CCOUNT#
I
NAME
N
F
ADDRESS
0
R
M
CITY
A
T
I
PHONE
0
( )
N
CUST. PURCHASE ORDER NO.
C
U
S
T
0
M
E
R
PURCHASER
SALES ORDER #
NAME
STATE
S
H
I
P
ZIP
FAX
(
I
ADDRESS
T
0
iPHONE
FAX
ORDER DATE
STATE
PTY
REQUEST DATE
ZIP
SPECIAL MARKS & NUMBERS
SHIPPING INSTRUCTIONS
PART NUMBER
QTY.
DESCRIPTION
FOR ORDER STATUS PLEASE CHECK

APPROPRIATE BOX BELOW
EMERGENCY
STOCK
MANUAL 92350-003
JanUlUY 1997
SIN X935-97051
NOTES
FIGURE 1.1: Final Installation
14
1-----1
15
3
12
13
/_)
MANUAL 92350-003
January 1997
SIN X935-97051
FIGURE 1.1: Final Installation

ITEM
Ref.
1
2
3
4
5
6
7
-8
-9
-10
11
12
13
14
15
-16
-17
-18
-19
-20
-21
-22
-23
-24
-25
-26
-27
-28
PARTNUMBER
DESCRIPTION
M-V2033XL-01 ........... Final Installation V2033/XL .................................................... Ref.

55441 .......................... Arm Stack Installation .................................................................. 1
55478 .......................... Platform Assembly ...................................................................... 1
55467 .......................... Chassis Assembly ........................................................................ 1
55468 ..~........................ BellyPan Assembly ..................................................................... 1
54918 .......................... 110VExt. To Platform Installation .............................................. 1
55315 .......................... WiringInstallation ........................................................................ 1
54783 .......................... CableAssembly,EmergencyLowering ........................................ 1
................................... Oil,HydraulicTellusT32 ........................................................ 8Gl.
[NotUsed] ....................................................................................................................... .
................................... Nameplate, ScissorIdent............................................................. 1
55482 .......................... Cover,LHSide ........................................................................... 1
55483 .......................... Cover, RH Side ........................................................................... 1
54048 .......................... Latch, Door ................................................................................ 2
55317 .......................... Box Assembly, Upper Control ................................................... 1
55489 .......................... Box Assembly, Lower Control .................................................... 1
55469 .......................... HoseKit ..................................................................................... 1
55982 .......................... Decal Installation ......................................................................... 1
67837-007 .................... Tie,Nylon7 1/ 2 Black ............................................................... 10
34354 .......................... Holder,SafetyManual-BlkCaps .................................................. 1
67793 .......................... Clamp, 2.75 Dia. Cable ............................................................... 2
BOW31401 .................. Washer,Flat.25 IDx.63"OD ..................................................... 2
BOW34272 .................. Nut,Hex.25-20UNCNylonLock .............................................. 2
92350-001 .................... Operator'sManual ...................................................................... 1
A630-V2033 ................ OplMaintIPrtsManual ............................................................... 1
55866 .......................... Elec. Schematic ........................................................................... 1
55309 .......................... Hyd.Schematic ........................................................................... 1
55486 .......................... Dwg. V2033 Final Assembly ....................................................... 1
55469 .......................... Dwg. V2033 Hose Kit ................................................................ 1
I
MANUAL 92350-003
1anuaIY 1997
SIN X935-97051
FIGURE 1.2: Final Installation V2033
20
12
.,1---.----7
21
14
2
13
)
MANUAL 92350-003
January 1997
SIN X935-97051
FIGURE 1.2: Final Installation V2033

ITEM
Ref.
1
2
-3
-4
-5
-6
7
-8
-9
-10
-11
12
13
14
-15
-16
17
18
19
20
21
-22
-23
-24
-25
-26
-27
-28
-29
-30
-31
-32
-33
-34
-35
-36
-37
-38
-39
PARTNUMBER
DESCRIPTION
QIY
M-V2033-01 ................ Final Installation V2033 ........................................................... Ref.

55955 .......................... Chassis Assembly V2033 ............................................................. 1
55958 .......................... BellyPanAssembly ..................................................................... 1
BOW30055 .................. Bolt,.38-16 UNCx 1.25 Hex ...................................................... 2
BOW30057 .................. Bolt,.38-16 UNCx 1.75 Hex ...................................................... 2
BOW36703 .................. Washer, .37 ID .81 OD Gr 8 SAE Flat ........................................ 4
BOW34274 .................. Nut, 3/8-16 UNC Hex Lock ...................................................... 4
55962 .......................... ArmstackInstallation ................................................................... 1
54616-009 ................... Pin, Arm 20.38" .......................................................................... 2
54701 ........................ Block,Armstack.Nylatron ........................................................... 2
54616-008 .................... Pin, Arm26.62" .......................................................................... 2
55279 .......................... Block,Slide ................................................................................. 2
55981 .......................... Platform Assembly ...................................................................... 1
55846 .......................... WrringInstallation ........................................................................ 1
54783-002 .................... Cable Assembly, EmergencyLowering ........................................ 1
................................... HydraulicOilTexacoHDZ32 ................................................ 8Gl
.................................. Nameplate,ScissorIdent............................................................ 1
55758 ......................... CoverWeldment,RHSide .......................................................... 1
55759 .......................... CoverWeldment,LHSide .......................................................... 1
54048 .......................... Latch, Door ................................................................................ 2
55850 .......................... Box Assembly, Upper Elec.......................................................... 1
55869-001 .................... Box Assembly, Lower Elec......................................................... 1
BOW39002 .................. Bolt, 1/4-20 x 3/4 Gr 8 Hex Hd ................................................ 4
BOW31401 .................. Washer,.25 ID x .63 OD Flat. ..................................................... 4
BOW34272 .................. Nut, 25-20UNC Nylon Lock ..................................................... 4
55469 .......................... HoseKit ..................................................................................... 1
55982 .......................... DecalInstallation ......................................................................... 1
67837-007 .................... Tie, 71/2" Black Nylon ............................................................ 10
34354 .......................... Holder Assembly,SafetyManual ................................................. 1
67793 .......................... Clamp, 2.75 DiaCable ................................................................ 2
BOW31401 .................. Washer,.25IDx.630DFlat. ....................................................... 2
BOW34272 .................. Nut, 25-20UNCNylonLock ..................................................... 2
92350-001 .................... Operator'sManual ...................................................................... 1
A630-V2033-1 ............. Manual,OplMaintlParts ............................................................ 1
55843 ......................... Schematic,Electric ....................................................................... 1
55309 ......................... Schematic,Hydraulic ................................................................... 1
55953 .......................... Dwg, M-V2033-01 Final Assembly .............................................. 1
55469-DWG ............... Drawing,HoseKit ...................................................................... 1
04-0175-57 .................. CONDORGreenGJ-5 .......................................................... 4G1.
04-0081-57 ................. Primer .................................................................................... 4GL
.)
MANUAL 92350-003
Januaxy 1997
SIN X935-970S1
FIGURE 2.1: Decal Insta11ation
21
)
PARTIAL SECTION A
APPLIES TO ALL MODELS
12
/0
r
!
ARM STAND
o
o
o
o
18
o
o
REF
0
0
0
0
0
-0
000 0
0
0
0
0
000 0
000 000
0
0
0 0
0
0
0
0
0
0
0
0
000
0
0
000
0
0
0
0
0
0
000 000 0
)
MANUAL 92350-003
January 1997
SIN X935-97051
FIGURE2.1:DecalInstallation
PART NUMBER
Ref
*1
*13
14
15
16
17
18
19
20
""21
55982 .......................... Decal Installation .................................................................... Ref.

55890 .......................... Decal V Upper Operator Instructions V2033 ............................... 1
55889 .......................... Decal VXL Upper Operator Intructions V2033 XL .................... 1
55894 .......................... Decal, V General Caution ........................................................... 1
54652-003 .................... Decal, GuardraiVChain Caution .................................................. 1
55963-800 .................... Decal, 250/800 Rated Load ........................................................ 2
55963-750 .................... Decal, 250/750 Rated Load ........................................................ 1
55944 .......................... Decal, 250RWL On Ext. XL ....................................................... 1
55480-002 .................... Decal, Lower Op Instruction ...................................................... 1
55480-001 .................... Decal,LowerControls ............................................................... 1
56303 .......................... Decal, U seArmstamd Caution .................................................... 1
54984-005 .................... Decal, Rear Bumper .................................................................... 1
66973 .......................... Decal, Elect. Hazard Keep Clear ................................................. 2
55871-001 .................... Decal,VUpperElectricaIBoxTop ............................................. 1
55856-001 .................... Decal, VXL Upper Control Box ................................................ 1
55871-002 .................... Decal, V Upper Electrical Box Front ........................................... 1
55856-002 .................... Decal, V XL Upper Electrecal Box Front .................................... 1
54984-007 .................... Decal, Hydraulic Fluid ................................................................. 1
55940-023 .................... Decal, CONDOR 3.45 x 23 ...................................................... 2
55984 .......................... Decal, V2033XL ......................................................................... 2
55941-017 .................... Decal, Condor "Bird" ................................................................. 2
53259 .......................... Tape, Non-Skid 6" Black ................................................... 1.50LF
66921 .......................... Coating,Non-SkidJetBlack ............................................... 025GL
55982-DWG ............... Dwg. V2033/XLDecalInstallation ............................................ 1
54984-006 .................... Decal, 110VExtention To Platform V2033XL ........................... 1
56302 .......................... Decal, Crushing Danger V2033XL .............................................. 1
31
51340 .......................... NameplateScissorsIndentification ........................................... Ref.
55982-102 .................... Decal Kit, V2033XLEssential ................................................. Ref.

55982-101 .................... Decal Kit, V2033 Essential ..................................................... Ref.
*2
*3
*4
~"5
*6
*7
*8
*9
""10
""11
*12
QTY
DESCRIPTION
ITEM

Included In Essential Decals
'~Indicates
[[REF
w r
2 1/4 MARGIN
NO NON-SLIP
COATING
)
PLANVIEW OF
MODEL V2033
PARTIAL REAR VIEW OF

MODELS V2033
MANUAL 92350-003
January 1997
SIN X935-97051
FIGURE 3.1: Chassis Assembly V2033XL
1-----1
1-----1
' I
,
' 3
, I
2 Pl
L__ ________ ~
I
----------~
NOTES:
1. BRAKE RELEASE HANDLES (ITEM 31) MUST SWING
FREELY. DO NOT TIGHTEN ITEMS 35, 36, &: 37
ANY MORE THAN SNUG fiT (2 PL).
2. FOR ITEMS IDENTifiED

FINAL ASSY.
SEE HOSE KIT IN
3. ITEM 33, 55924, INCLUDES SPINDLE 55921,

WHICH IS REOUIRED ON CHASSIS WLDMNT 55445.
2 PL
INCLUDES: NUT, WASHER.
COTTER PIN
(SEE NOTE 3)
2 PL
27
SEE NOTE 1
TOP ViEW OF AXLE
)
o
,------------------------1
! BHL Y PAN FRONl WALL
0
I
!,
81368-40-40
2 Pl REf
I
,,
I
o
TOP VIEW OF CHASSIS WELDMENT
2 PL
TOP VIEW OF STEERING COMPONENTS

1.
LOCTITE ITEM 8 INTO ITEMS 4 &: 5.
MANUAL 9235Q.O03
JanuaI)' 1997
SIN X935-97051
FIGURE 3.1: Chassis AssemblyV2033XL

ITEM
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
PART NUMBER
DESCRIPTION
QTY
55467 .......................... Assembly, Chassis V2033XL ................................................... Ref.

55445 .......................... Chassis Weldrnent ....................................................................... 1
34145 .......................... BushingR#81368 ....................................................................... 2
02219 .......................... Elbow, 90 M]04 F]04 ............................................................... 2
55496-003 .................... Knuckle Weldment,LHStr ......................................................... 1
55496-004 .................... Knuckle Weldment,RHStr ......................................................... 1
54776 .......................... ThrustWasher,Kingpin ............................................................... 2
55402 .......................... Retainer,Kingpin ........................................................................ 2
BOW39104 .................. Bolt, Hex Hd .50-13UNC x 1.00 Gr 8 ........................................ 2
54775 .......................... ConnectingArm,Steering ........................................................... 1
81368-01-08 ................ Bearing, .75"10 x 1.00"OD x .50"L ............................................ 4
BOW36708 .................. Washer,Flat.75 .......................................................................... 4
55111 .......................... Cylinder, 2.00"Dia./6/81 " Steer .................................................. 1
54035 .......................... Pin, Steering Cylinder .................................................................. 2
BOW36718-HD .......... Washer, Flat 3/4" SAE ................................................................. 2
BOW38230 .................. Pin, Cotter .125"Dia. x 1.25 ......................................................... 4
54644-001 .................... Motor, 11.9 Hyd. Wheel .............................................................. 2
BOW30109 .................. Bolt,Hex.50-13UNCx2.25 ....................................................... 8
BOW36605 .................. Nut, 1/r13 ................................................................................. 8
55302 .......................... HubAssembly,Drivew/Studs ................................................... 2
54779-Dwg ................. RearHubInstallationDrawing .................................................... 1
BOW38232 .................. Cotter Pin, .12 x 1.75L ................................................................ 2
54885-001 .................... Adapter, MOR08 FOR10 1.00 Lg ............................................... 1
54885-002 .................... Adapter, MOR08 FROiO 1.812Lg............................................. 1
54885-003 .................... Adapter, MOR08 FOR102.625 Lg............................................. 1
54885-004 .................... Adapter,MOR08FOR103.438Lg............................................. 1
36085 .......................... Fitting,Swivel900Elbow8-8 ..................................................... 4
54929 .......................... Tire&WheelAssembly(Tire&WhellNotSoldSeperately) ......... 4
91029 .......................... Nut,.50-20UNFWheelR#30288 ............................................. 10
54714 .......................... BrakeCylinder ............................................................................ 2
54796 .......................... Pin, Brake ................................................................................... 2
54795 .......................... Handle Weldment,BrakeRelease ................................................. 2
54779 .......................... Rear Hub Assembly .................................................................... 2
BOW30059 .................. Bolt, Hex .38-16UNC x 2.25 Gr 5 .............................................. 2
BOW30063 .................. Bolt,Hex.38-16UNCx3.25 ....................................................... 2
BOW36703 .................. Washer,Flat.38"lOx.81"OD .................................................... 4
BOW34274 .................. Nut,HexLock 3/ s-16UNC ........................................................ 4
02236 .......................... Elbow, 90 0M]04 M004 ............................................................. 6
55467-DWG ............... Chassis AssemblyD rawing .......................................................... 1
)
MANUAL 92350-003
January 1997
SIN X935-97051
8)
FIGURE 3.2: Chassis Assembly V2033
~S-:
2 PL-REf
SEE NOTE 3
30
2 PL
2 PL
27
REF
SEE NOTE 1
lOP VIEW DE AXl E
NOTES:
1. BRAKE RELEASE HANDLES (ITEM 31) MUST SI't1NG
FREELY. DO NOT TIGHTEN ITEMS 35. 36. & 37
ANY MORE THAN SNUG FIT (2 PL).
2. FOR ITEMS IDENTIFIED

fiNAL ASSY.
SEE HOSE KIT IN
3. SPINDLE ASSY INCLUDES SPINDLE. CASTLE NUT,

WASHER & COTlER PIN.
SPINDLE ASSY IS PART Of CHASSIS WELDMENT.
4. EACH HUB ASSY INCLUDES FIVE LUG NUTS.
BELLY PAN
FR~cNHT~~~ArL_L ~L-~-+____
81368-40-40
2 PL REF
__
L
2
2 PL
TOP VIEW OF CHASSIS WELDMENT
10 PL
2 PL
)
TOP VIEW OF STEERING COMPONENTS
NOTES:
,.
LOCTiTE ITEM 8 INTO ITEMS 4 &: 5.
MANUAL 92350-003
January 1997
SIN X935-97051
FIGURE 3.2: Chassis Assembly V2033 . ,
QTY
PART NUMBER
Ref.
55955 ......................... Assembly, Chassis V2033 ........................................................ Ref.

55956 .......................... ChassisWeldInent ....................................................................... 1
34145 .......................... BushingR#81368 ....................................................................... 2
02219 .......................... Elbow, 90 M}04 F}04 ............................................................... 2
55496-003 .................... Knuckle Weldment,LHStr ........................................................ 1
55496-004 .................... KnuckleWeldment,RHStr ......................................................... 1
54776 .......................... ThrustWasher,Kingpin ............................................................ 2
55402 .......................... Retainer,Kingpin ....................................................................... 2
BOW39104 .................. Bolt, Hex Hd.50-13UNCx 1.00 Gr8 ........................................ 2
54775 .......................... ConnectingArm,Steering ........................................................... 1
81368-01-08 ................ Bearing, .75"ID x 1.00"OD x .50"L ........................................... 4
BOW36708 .................. Washer,Flat.75 .......................................................................... 4
55111 .......................... Cylinder,2.00"Dia./6/81" Steer .................................................. 1
54035 ......................... Pin, Steering Cylinder .................................................................. 2
66110-075 .................... Washer, Flat 314 " SAE ................................................................. 2
BOW38230 .................. Pin, Cotter .125 "Dia. x 1.25 ......................................................... 4
54644-001 .................... Motor, 11.9 Hyd. Wheel .............................................................. 2
BOW30109 .................. Bolt,Hex.50-13UNCx2.25 ....................................................... 8
BOW36605 .................. Nut, l/r13 ................................................................................. 8
55302 .......................... HubAssembly,Drivew/Studs ................................................... 2
54779-Dwg ................. RearHubInstallationDrawing .................................................... 1
BOW38232 .................. Cotter Pin,.12x 1.75L ................................................................ 2
54885-001 .................... Adapter, MOR08 FOR10 1.00Lg ............................................... 1
54885-002 .................... Adapter,MOR08FR0101.812Lg............................................. 1
54885-003 .................... Adapter,MOR08FOR102.625Lg............................................. 1
54885-004 .................... Adapter,MOR08FOR10 3.438 Lg............................................. 1
36085 .......................... Fitting,SwiveI900Elbow8-8 ..................................................... 4
54929 .......................... Tire&Whee1Assembly(fire&WhellNotSoldSeperately) ......... 4
91029 .......................... Nut,.50-20UNFWheelR#30288 ............................................. 10
54714 .......................... Brake Cylinder ............................................................................ 2
54796 .......................... Pin, Brake ................................................................................... 2
54795 .......................... Handle We1dment,BrakeRelease ................................................. 2
54779 .......................... RearHubAssembly .................................................................... 2
BOW30059 .................. Bolt, Hex.38-16UNCx 2.25 Gr 5 .............................................. 2
BOW30063 .................. Bolt,Hex.38-16UNCx3.25 ....................................................... 2
BOW36703 .................. Washer,Flat.38"IDx.81"OD .................................................... 4
BOW34274 .................. Nut,HexLock 3/ s-16UNC ........................................................ 4
02236 .......................... Elbow, 90 0M}04 M004 ............................................................. 6
55955-DWG ............... Chassis AssemblyDrawing .......................................................... 1
1
2
3
4
5
6
7
8
9
DESCRIPTION
ITEM
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
MANUAL 92350-003
January 1997
SIN X935-97051
FIGURE 3.3: Hose Kit
f-----l
:
I
~-----l
L _____ ~
BELLY PAN
BACK WALL
C--)
--
LIFT CYLINDER
r;:;:;----------I TOP
/\
, ,
,
I
I,
,
BELLY PAN
: FRONT WALL
I,
,
~~T~M
=====J
12
RIGHT MOTOR
LEFT MOTOR
STEER
----------------------------~
P1
VALVE ASSY
HYDRAULIC TANK
.3
)
ELECTRIC MOTOR
MANUAL 92350-003
Jarwary 1997
SIN X935-97051 .
FIGURE3.3:HoseKit
DESCRIPTION
ITEM
PARTNUMBER
Ref.
55469 .......................... Hose Kit V2033 ...................................................................... Ref.

66698-119.00 ............... Hose Assembly, #06 66645 J37 ST-ST ....................................... 1
66044-151.00 .............. Hose Assembly, #0467685J37ST-ST ........................................ 1
66702-019.00 ............... Hose Assembly, #1066137 J37 ST-ST ........................................ 1
66698-020.00 ............... Hose Assembly, #06 66645 J37 ST-ST ........................................ 1
66698-017.00 ............... Hose Assembly, #06 66645 J37 ST-ST ........................................ 1
66696-012.5 ................. Hose Assembly, #04 66646 J37 ST-ST ........................................ 1
66696-012.5 ................. Hose Assembly,#0466646J37ST-ST ........................................ 1
66700-026.00 .............. Hose Assembly, #0666645 J37 ST-STJ ....................................... 1
66700-024.00 ............... Hose Assembly, #06 66645 J37 ST-STJ ....................................... 1
66043-028.00 ............... Hose Assembly, #0367684 J37 STJ-STJ ..................................... 1
66043-019.50 ............... Hose Assembly, #03 67684J37STJ-STJ ..................................... 1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
-)
)
MANUAL 92350-003
Janwuyl997
SIN X935-97051
QTY
FIGURE 3.4: Lift Cylinder
I")
~~
r-
00
l=!w
UO
~w
~~
X
w
~w
~'I
r<)i'.
'<tCX)
N
n
1O:=
ITEM
PART NUMBER
Ref.
54705-001 .................... Cylinder,Lift .......................................................................... Ref.

54705-100 .................... Seal Kit ....................................................................................... 1
54705-101 .................... Castle Nut .................................................................................. 1
54705-102 .................... CastIronRing ............................................................................ 1
54705-103 .................... Piston (Steel) ............................................................................... 1
54705-104 .................... WearRing .................................................................................. 1
.................................... PolyPack (Included in Seal Kit 54705-100) ................................... 1
.................................... O-Ring (Included in Seal Kit 54705-100) ...................................... 1
.................................... Stop Tube (Included in Seal Kit 54705-100) ................................. 1
54706-105 .................... Jacket Assembly .......................................................................... 1
54705-106 .................... Piston Rod ................................................................................. 1
.................................... Polypack(IncludedinSealKit54705-100) ................................... 1
.................................... O-Ring (Included in Seal Kit 54705-100) ...................................... 1
54705-107 .................... GlandNut .................................................................................. 1
.................................... Rod Wiper (Included in Seal Kit 54705-100) ................................ 1
55221 .......................... FlowControlValve .................................................................... 1
1
2
3
4
5
6
7
8
9
10
11
12
13
-14
DESCRIPTION

MANUAL 92350-003
lanU3I)' 1997
SIN X935-97051
QTY
FIGURE 3.5: Steer Cylinder
')
00
NZ
wo
uo
I- W
tbrrl-Q:'
0::>-
~_
0
"'-...0
i'-,
0...
o::w
1-
1-1-
"--'
WX
IYW
I"")t[)
(Jli'-
rrjo
~N
PARTNUMBER
Ref.
55111 .......................... Cylinder,Steer ........................................................................ Ref.

55111-100 .................... Seal Kit ....................................................................................... 1
55111-101 .................... LockNut .................................................................................. 1
................................... Polypak (Included in Seal Kit 55111-100) ..................................... 2
................................... O'Ring(IncludedinSealKit55111-100) ...................................... 1
55111-102 .................... Piston(Alum) ............................................................................. 1
55111-103 .................... JacketAssembly .......................................................................... 1
55111-104 .................... Piston Rod ................................................................................. 1
................................... Polypak(TypeB) (Included in Seal Kit 55111-100) ....................... 1
................................... O'Ring(IncludedinSealKit55111-100) ...................................... 1
55111-105 .................... GlandNut .................................................................................. 1
................................... Rod Wiper (Included in Seal Kit 55111-100) ................................ 1
BOW32287 .................. Jam Nut 5/8-18 ......................................................................... 1
55111-106 .................... RodEnd .................................................................................... 1
1
2
3
4
5
6
7
8
9
10
11
12
DESCRIPTION
QTY
ITEM
Revised January 1998

MANUAL 92350-003
January 1997
SIN X935-97051
FIGURE 3.6: Cylinder, Brake
EB
I
7/16-20 O-RING
PORT TYP
)
tJ-_ _ _ _ _ _ _ _ _ _ _ _ _ _
11-_4===~~~~_3._06_
10.18 EXTENDED _ _ _ _ _
9.31 RETRACTED
QTY
ITEM
PARTNUMBER
Ref.
54714 .......................... Cylinder, 1.75Bx 1.13Rx.88 Stroke ........................................ Ref.

54714-100 .................... Seal Kit ....................................................................................... 1
54714-101 .................... Jacket Assembly .......................................................................... 1
54714-102 .................... Piston Rod ................................................................................. 1
54714-103 .................... Spring ........................................................................................ 1
.................................... Teflon Backup (Included in Seal Kit 54714-100) ........................... 1
.................................... Polypak (Included in Seal Kit 54714-100) .................................... 1
54714-104 .................... Piston(Alum) ............................................................................. 1
.................................... O'Ring(IncludedinSealKit54714-100) ...................................... 1
.................................... Polypak(Type 'B') (Included in Seal Kit 54714-100) ..................... 1
.................................... O'Ring(IncludedinSealKit54714-100) ...................................... 1
54714-105 .................... GlandNut .................................................................................. 1
.................................... Rod Wiper (Included in Seal Kit 54714-100) ................................ 1
1
2
3
4
5
6
7
8
9
10
11
DESCRIPTION
-_-_-_-_-_-_---1-1:

MANUAL 92350-003
lanwuyl997
SIN X935-97051
FIGURE 3.7: Hub Motor Assembly . ,
10
1
6
1
17
10
11
DESCRIPTION
QTY
ITEM
PARTNUMBER
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
54644-001 .................... Motor, 11.9 Hydraulic Wheel ................................................... Ref.

54644-100 .................... Seal Kit For Wheel Motor ........................................................... 1
54644-101.................... Housing, Bearing ........................................................................ 1
54644-102 .................... Shaft & Bearing Kit (11/4in Tapered) ......................................... 4
54644-103 .................... Key (For TaperedShaft) ............................................................. 1
54644-104 .................... Nut, Hex (For Tapered Shaft) .................................................... 1
54644-105 .................... Plate, Wear ................................................................................. 1
54644-106 .................... Drive ......................................................................................... 1
54644-107 .................... Geroler ...................................................................................... 1
54644-108 .................... Drive, Valve ............................................................................... 1
54644-109 .................... PlateDrive ................................................................................. 1
54644-110 .................... Valve .......................................................................................... 1
54644-111 .................... Balance Ring ............................................................................... 1
54644-112 .................... Pin ............................................................................................. 2
54644-113 .................... Spring ........................................................................................ 2
54644-114 .................... Bolt ............................................................................................ 4
54644-115 .................... Housing, Valve f /8-14 Staggered Ports) ...................................... 1
54644-116 .................... Plug Assembly 7 /16-20UNF ......................................................... 1
)
MANUAL 92350-003
January 1997
SIN X935-97051
FIGURE 3.8: Hub Assembly, Rear

Chassis Weldment
Ref.
5
6
7
-)
11
12
10
ITEM
PARTNUMBER
Ref.
1
2
3
4
5
6
54779 .......................... Hub Assembly ........................................................................ Ref.

54779-109 .................... Hub ........................................................................................... 1
54779-101 .................... InnerCup ................................................................................... 1
54779-102 .................... InnerCone ................................................................................. 1
54779-106 .................... Seal ............................................................................................ 1
54779-103 .................... OuterCup .................................................................................. 1
54779-104 .................... Outer Cone ................................................................................ 1
BOW36718-fII) .......... Washer ....................................................................................... 1
BOW1802 ................... SlottedNut, 3/4"-16UNF ............................................................ 1
BOW38233 .................. CotterPin,.125"x2.00" ............................................................. 1
54779-105 .................... Dust Cap ................................................................................... 1
54779-107 .................... Stud ........................................................................................... 5
54779-108 .................... StudNut .................................................................................... 5
8
9
10
11
12
DESCRIPTION

MANUAL 92350-003
January 1997
SIN X935-97051
QTY
FIGURE3.9:TubeKit
ITEM
PARTNUMBER
Ref.
-1
-2
-3
-4
55397
55072
55067
55047
55050
55048
55324
55051
55298
55076
55064
55063
-5
-6
-7
-8
-9
-10
-11
DESCRIPTION
QTY
.......................... TubeKit ................................................................................ Ref.

.......................... TubeAssembly,M2 .................................................................... 1
.......................... TubeAssembly,M1 .................................................................... 1
.......................... Tube Assembly, M3 Bulkhead ..................................................... 1
.......................... TubeAssembly,M3 .................................................................... 1
.......................... TubeAssembly,CylVenttoT .................................................... 1
.......................... TubeAssembly,B ....................................................................... 1
.......................... Tube Assembly, Brakes to T ........................................................ 1
.......................... Tube Assembly, TtoFilter ........................................................... 1
.......................... TubeAssembly,S2 ..................................................................... 1
.......................... TubeAssembly,Sl ..................................................................... 1
.......................... TubeAssembly,L ....................................................................... 1
)
MANUAL 92350-003
Januaty 1997
SIN X935-97051
",
--.-'~
NOTES:
1. REFER TO SHEET 2 FOR HYDRAULIC ASSEMBLY
INFORMA TION.
SEE HOSE KIT IN
FINAL ASSY.
SEE TUBE KIT.
F'L
4. FOR ITEMS IDEN TIFIED

5. EST. WT.~ 706 Ibs.
E9
E9
2 PL
4 PL
SEE CABLE KIT.
SOd
CHARGER
BA TTERY
RED
CK
SOd
Szt-l
SZl-l
NVrO~:I1
NVrOdl
CK
BLK
CK
~3N
CK
CK
TROJAN
TROJAN
T-125
T-125
POS
PL
CK
6
~K SEE NOTE 4
POS
FIGURE 3.10: Belly Pan Assembly . ,

PARTNUMBER
Ref.
55468 .......................... BellyPan Assembly V2033XL ................................................. Ref.

55958 .......................... Belly Pan Assembly V2033 ...................................................... Ref.
55481 .......................... BellyPanWeidmentV2033XL .................................................... 1
55786 .......................... Belly Pan Weldment V2033 ......................................................... 1
54989 .......................... MotorlPumpAssembly .............................................................. 1
55379 .......................... ValveInstallation ......................................................................... 1
55297 .......................... TankWeldment,Hyd.................................................................. 1
50316 .......................... BreatherFiller ............................................................................ 1
52049 .......................... Gauge,FluidLevel ...................................................................... 1
04699-08 ..................... Plug,SocketHex.50NPT ...................................................... ~ ... 1
02806 .......................... Straight,MJ10MP12 ................................................................. 1
33430 .......................... Ftlter ......................................................................................... 1
67408 .......................... -Filter Element ........................................................................... 1
00324 .......................... Elbow, 90 MJ08 MP12 ............................................................. 1
02430 .......................... Straight,MJ04MB04 .................................................................. 3
02431 .......................... Fitting, Straight MJ06 MB06 ........................................................ 2
02303 .......................... Elbow, 90 0 MJ06MB06 .............................................................. 2
00345 .......................... Tee,MJ06MJ06MB06 ............................................................... 1
00334 .......................... Nut,Bulkhead04 ........................................................................ 5
00336 .......................... Nut, Bulkhead 06 ........................................................................ 5
02662 .......................... Elbow, 90 MJ06 M006 ............................................................ 2
55398 .......................... Cable Kit (See Note 4) ................................................................ 1
04674 .......................... Elbow, 90 MJ10M008 L ......................................................... 1
02407 .......................... Tee,MJ04MJ04MP)4 ................................................................ 1
55333 .......................... Charger Mod.115V/25A ............................................................ 1
52138 .......................... Soienoid24V .............................................................................. 1
55334 .......................... Jumper Assembly, 12LG Wire ................................................... 1
52627 .......................... Battery,6VTrojan Tl25-WT ....................................................... 4
55505 .......................... Angle, Battery Tie Down 22" ...................................................... 2
55506 .......................... J-Bolt, Battery Hold Down ......................................................... 2
BOW36726 .................. Washer,.31IDSplitLock ............................................................ 3
BOW30055 .................. Bolt,Hex.38-16UNCx 1.25 ....................................................... 3
BOW30057 .................. Bolt,Hex.38-16UNCx1.75 ....................................................... 2
BOW31433 .................. Washer, .38 x .81"OD Flat SAE Gr 5 .......................................... 5
BOW34274 .................. Nut,HexLock 3/ g "-16UNC ....................................................... 5
BOW30037 .................. Bolt,Hex.31-18UNCx3.00 ....................................................... 3
BOW30029 .................. Bolt, Hex.31-18UNC x 1.00 ....................................................... 4
BOW34273 .................. Nut,LockHex 5/16"-18UNC ...................................................... 4
BOW30003 .................. Bolt,Hex.25-20UNCx.875 ....................................................... 4
55397 .......................... Tube Kit (See Note 3) ................................................................. 1
04185 .......................... Fitting,BulkheadTee .................................................................. 2
BOW34323 .................. Nut,.25-20UNCWing .............................................................. 2
1
2
3
-4
5
6
7
8
9
( _)
10
11
12
13
14
15
16
17
-18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
-39
40
41
DESCRIPTION
QTY
ITEM
MANUAL 92350-003
Janlllll)'l997
SIN X935-97051
TK
9
LEFT
BACK
SIDE
PI
r-___~
S"ILD~E~L______________~'-______________
~3
SI
'---+~S2
GI
MI
M2
~K SEE NOTE 3
-~:':---+~~~t--rs~-L~~__~__
3 PL
TK
HK
TANK
BELL Y PAN
BELLY PAN FRONT WALL
2 PL
FIGURE 3.10: Be11yPanAssembly
ITEM
PARTNUMBER
Ref.
55468 .......................... Belly Pan Assembly V2033XI.. ................................................. Ref.

55958 .......................... Belly Pan Assembly V2033 .................................................. Ref.
55481 .......................... BellyPanWeldmentV2033XI.. .................................................. 1
55786 .......................... Belly Pan Weldment V2033 ......................................................... 1
54989 .......................... MotorlPumpAssembly .............................................................. 1
55379 .......................... ValveInstallation ........................................................................ 1
55297 .......................... TankWeldment,Hyci.................................................................. 1
50316 ......................... BreatherFiller ............................................................................. 1
52049 .......................... Gauge,FluidLevel ..................................................................... 1
04699-08 ..................... Plug,SocketHex.50NPT .......................................................... 1
02806 .......................... Straight,MJ10MP12 .................................................................. 1
33430 .......................... Filter .......................................................................................... 1
67408 .......................... -Filter Element ........................................................................... 1
00324 .......................... Elbow, 90 MJ08 MP12 ............................................................ 1
02430 .......................... Straight,MJ04MB04 ................................................................ 3
02431 .......................... Fitting,StraightMJ06MB06 ....................................................... 2
02303 .......................... Elbow, 90 0 MJ06 MB06 .............................................................. 2
00345 .......................... Tee, MJ06 MJ06 MB06 ............................................................... 1
00334 .......................... Nut,Bulkhead04 ........................................................................ 5
00336 .......................... Nut, Bulkhead 06 ....................................................................... 5
02662 .......................... Elbow, 90 MJ06 M006 ............................................................ 2
55398 .......................... Cable Kit (See Note 4) ................................................................ 1
04674 .......................... Elbow, 90 MJ10M008 L ......................................................... 1
02407 .......................... Tee, MJ04 MJ04MP)4 ................................................................ 1
55333 .......................... ChargerMod.115V/25A ............................................................ 1
52138 .......................... Soienoid24V .............................................................................. 1
55334 ........................ ;. Jumper Assembly, 12LG Wire ................................................... 1
52627 ......................... Battery, 6VTrojan T125-WT ...................................................... 4
55505 .......................... Angle, Battery Tie Down 22" ...................................................... 2
55506 .......................... J-Bolt, BatteryHoldDown ......................................................... 2
BOW36726 .................. Washer,.31IDSplitLock ............................................................ 3
BOW30055 .................. Bolt, Hex.38-16UNC x 1.25 ....................................................... 3
BOW30057 .................. Bolt, Hex .38-16UNC x 1.75 ...................................................... 2
BOW31433 .................. Washer, .38 x .81"OD Flat SAE Gr 5 .......................................... 5
BOW34274 .................. Nut,HexLock 3/ s "-16UNC ....................................................... 5
BOW30037 .................. Bolt,Hex.31-18UNCx3.00 ....................................................... 3
BOW30029 .................. Bolt, Hex.31-18UNC x 1.00 ....................................................... 4
BOW34273 .................. Nut, Lock Hex 5116"-18UNC ................................................. 4
BOW30003 .................. Bolt,Hex.25-20UNCx.875 ....................................................... 4
55397 .......................... Tube Kit (See Note 3) ................................................................. 1
04185 .......................... Fitting,BulkheadTee .................................................................. 2
BOW34323 .................. Nut,.25-20UNCWing .............................................................. 2
1
2
3
-4
5
6
7
8
9
10
11
12
13
14
15
16
17
-18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
-39
40
41
DESCRIPTION
MANUAL 92350-003
lanllllI)'l997
SIN )(935-97051
QTY
. , FIGURE 3.11: Motor & Pump Assembly
IlIl
000000000
000000000
000000000
000000000
'0 0 0 0 0 0 0 0 0
000000000
O~O~O~O
PART NUMBER
Ref.
1
54989 .......................... Motor/PumpAssembly .......................................................... Ref.

54761 .......................... Duplex Pump & Parts (See Page 45) ........................................... 1
54761-101 .................... Seal Kit (pump) .......................................................................... 1
BOW30029 .................. Bolt,Hex.31"-18UNCx 1.00" ................................................... 4
.................................... Tag Nails .................................................................................... .
BOW31444 .................. Washer,Flat S/16" 4
54759 .......................... 24 Volt Motor (See Page 46) ...................................................... 1
54989-100 .................... Gasket ........................................................................................ 1
54760 .......................... ReplacementCoupling ................................................................ 1
[NotUsed] ...................................................................................................................... 1
2
3
4
5
6
7
8
DESCRIPTION
QTY
ITEM
)
MANUAL 92350-003
January 1997
SIN X935-97051
FIGURE 3.12: Pump Assembly
SECTION A-A
9
10
18
17
13
12
HYDRAULIC SCHEMATIC
8
INLET PORT 16
3/4-16 SAE
-)
ITEM
PARTNUMBER
Ref.
24
23
11
OUTLEr PORTS
9/16-18 SAE
DESCRIPTION
20
QTY
54761 .......................... DuplexPump & Parts ............................................................ Ref.

54761-100 .................... Seal Kit ....................................................................................... 1
54761-103 .................... Gear Housing ............................................................................. 1
.........................................................................................................................................
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
........................................................................................................................................ .
54761-108 .................... DrivePin .................................................................................... 1
........................................................................................................................................ .
................................... Oil Seal (in seal kit) ...................................................................... 1
54761-112 .................... DriveShaft ................................................................................. 1
................................... LeePlug ..................................................................................... 1
54761-107 .................... 375 Gear Face ............................................................................ 1
................................... Gasket (in seal kit) ....................................................................... 1
54761-102 .................... Needle Bearing ........................................................................... 1
54761-101 .................... IdlerShaft .................................................................................. 1
54761-105 .................... Stator ......................................................................................... 1
54761-106 .................... Screw ......................................................................................... 8
54761-109 .................... Shear Pin .................................................................................... 1
................................... Plastic Plug ................................................................................. 1
... ........................ ........ Gasket (in seal kit) ....................................................................... 1
54761-111 .................... Woodruff Key ............................................................................ 1
........................................................................................................................................ .
................................... Plastic Plug ................................................................................. 1
........................................................................................................................................ .
22
.........................................................................................................................................
23
54761-110 .................... CreascentRing ............................................................................ 1
24
54761-104 .................... Gear Housing ............................................................................. 1
MANUAL 92350-003
Janu<uy 1997
SIN X935-97051
FIGURE 3.13: Motor 24VDC Assembly
-l-----NAMEPLATE
15
)
MANUAL 92350-003
January 1997
SIN X935-97051
FIGURE 3.13: Motor 24VDC Assembly
QTY
PARTNUMBER
Ref.
1
54759 .......................... Motor, 24VDCAssembly ....................................................... Ref.

................................... Complete Stator Assembly .......................................................... 1
NSS ............................. Complete Terminal Assembly ..................................................... 2
................................... Screw Hex fill Cap 3/g"-16 ....................................................... 2
................................... Jam Nut, Hex 3/g"-16 ................................................................. 2
................................... Jam Nut, Hex 3/g"-16 ................................................................. 2
............................. ...... Insulator ..................................................................................... 4
...................... ............. Insulator ..................................................................................... 2
................................... Lock Washer,Split 3/ g" ............................................................... 2
................................... Lock Washer, Ext. TTH3/g" ....................................................... 4
................................... Field Coil Assembly .................................................................... 1
................................... FieldPole ................................................................................... 4
................................... Screw, BTTN fill Socket, 3/g"-16 x 5/g" ..................................... 8
................................... Field Coil Terminal ..................................................................... 1
................................... Loctite,222 .................................................................................. .
................................... PulleyCover ............................................................................... 1
................................... Screw, Socket fill #10-32 x1.00" ............................................... 4
54759-117 .................... CompleteArmatureAssembly .................................................... 1
54759-118 .................... Fan ............................................................................................. 1
54759-119 .................... Bearing,Pulley ............................................................................ 1
54759-120 .................... Bearing,Comm .......................................................................... 1
................................... Complete Comm Cover Assembly ............................................. 1
54759-122 .................... Complete Brush Ring Assembly .................................................. 1
54759-123 .................... Brush Spring ............................................................................... 8
54759-124 .................... BrushAssembly .......................................................................... 2
................................... Screw, RH Slotted #10-32 x 3// ................................................. 4
................................... Nut, Hex #10-32 ........................................................................ 4
................................... Washer Bearing Spring ................................................................ 1
................................... Screw, Hex fill #10-32 x 2.00" .................................................. 4
54759-129 .................... Brush Inspection Cover ............................................................... 1
................................... Screw, PH fill #10-32 x 1_3// .................................................. 1
................................... Nut, Square #10-32 .................................................................... 1
........................... ........ Insulator ..................................................................................... 1
................................... Screw, RH Slotted 1//-20 x 3/g" ................................................. 2
................................... Lock Washer, Ext. TTHI// ....................................................... 2
54760 .......................... Coupling Assembly .................................................................. Ref
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
DESCRIPTION
ITEM
22
23
24
25
26
27
28
29
30
31
32
33
34
35
NSS -Not Sold Separately

)
MANUAL 92350-003
JanU3I}' 1997
SIN X935-97051
FIGURE 3.14: Valve Installation
REAR VIEW
)
LEFT END VIEW
MANUAL 92350-003
January 1997
SIN X935-97051
FIGURE 3.14: Valve Installation
')
G2
CREEP
o
o
o
)
RIGHT END VIEW
ITEM
PART NUMBER
Ref.
1
2
3
4
5
6
7
8
55379
55296
54892
02525
02448
00458
04579
04682
04003
DESCRIPTION
QTY
.......................... Valve Installation ..................................................................... Ref.

.......................... Valve Assembly .......................................................................... 1
.......................... Valve,LoadControl ................................................................... 2
.......................... Straight,M]04M004 ................................................................. 3
.......................... Straight,M]06M006 ................................................................. 5
.......................... Straight,M]08M008 ................................................................. 1
.......................... Elbow, 90 M]06 M006 LL ...................................................... 1
.......................... Tee,M]04M004M]04 .............................................................. 1
.......................... Nut, Cap #04 ............................................................................. 2
MANUAL 92350-003
JanUaIY 1997
SIN X935-97051
FIGURE 3.15: Valve Assembly
fit
12
RIGHT END VIEW
FRONT VIEW
=
=
=
c
LEFT END VIEW A- A
BACK VIEW 8-B
SERVICE PARTS:
l
J
55296-100 REXROTH QUAD RING KIT.

4 RINGS PER KIT.
55296-101 COIL
NOTES:
1. SEAL ALL OPENINGS WITH THREADED PLUGS.
REF: 7/16-204 PL; 9/16-186 PL: 3/4-16 1 PL
MANUAL 92350-003
JanuaI)'1997
SIN )(935-97051
FIGURE 3.15: Valve Assembly . ,
QTY
ITEM
PARTNUMBER
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
55296 .......................... Valve Assembly ...................................................................... Ref.

55337-001 .................... Manifold,Valve .......................................................................... 1
54646-004 .................... Valve,Drive ............................................................................... 1
54646-001 .................... Valve, Steer ................................................................................. 1
54646-005 .................... Valve,Select ................................................................................ 1
54639 .......................... Cartridge, 2 Way No Spool Valve ............................................... 2
54852-052 .................... Orifice, 0.052 DiaHF 10 ............................................................ 1
54641 .......................... Cartridge,4WayNoSpoolValve ............................................... 1
54634 .......................... Cartridge,FlowDividerValve .................................................... 1
54890 .......................... Cartridge,Dir.ActReliefValve ................................................... 2
54640 . ... ....... ......... ..... Cartridge, Check Valve ............................................................... 1
54889 .......................... Cartridge, Flow Control Valve .................................................... 1
54622 .......................... Cartridge, Needle Valve .............................................................. 1
54638 .......................... Cartridge, Sequence Valve ........................................................... 1
DESCRIPTION
.)
MANUAL 923S0-003
JanU3IY 1997
SIN X93S-970S1
FIGURE 3.16: Charger115V125AMod.
11
BlK
BA TTERY
CHARGER
~--RRmED----__~
- - 24
DESCRIPTION
QTY
ITEM
PART NUMBER
Ref.
1
2
55333 .......................... Charger, 115V125AMod. ...................................................... Ref.

54908 .......................... Charger,115V160HZ-25A/24VDC ........................................... 1
BOW23065 .................. Ring Terminal, 12Ga. 3/8 Stud ................................................... 2
)
MANUAL 923S0-003
Janruuy 1997
SIN X93S-970S1
FIGURE 3.17: Charger 115V/25A Mod.
14
BU<
BATTERY
CHARGER
22 1/2 _
RED
EB
-J
ITEM
PART NUMBER
Ref.
1
2
55901 .......................... Charger, 115V125AMod . ...................................................... Ref.

54908 .......................... Charger, 115V/60HZ-25A/24VDC ........................................... 1
BOW23065 .................. Ring Terminal, 12Ga. 3/8 Stud ................................................... 2
DESCRIPTION
)
MANUAL 92350-003
Januaxy 1997
SIN X93S-970S1
QTY
. , FIGURE 3.18: Charger 115V160HZ-25A124VDC
I~====::::"
~~H
11'1YlLll.'\1
~'ii'1I ~~rrnr
Wlo.'ii'
II?~
.1
~v-Electrlcal825 W.4tASt. Lincoln. NE 68522 USA

ACYOLTS
IlERn
MODEl
[iliJ
[!QJ
1179701
ACAMPS
PHASE
SERIAL NO.
IT]
IT]
DCVOlTS
IHJLi\IFl@ll:1i'l
IU\'i"i'imfC&'PCri"if
"CELLS.RIE.COHNECTEO
l..EAM~~~~~:'':Tr~~'1.
U,$.'AT.NO.'.7i4,$05
c::EJ
M.8R.I"AT.NO.',Al14,t5S
[KJ
W. GR.PAT.NO.2.a51,ne
.lA-rAN PAT. NO.S3U3I1n,
DCAMI"S
'''.PAT.NO.2,203,1U
)
RING
10
I
I
I
I
I
#12 AWG,
2 PL
~o
III
.281 X .625 SLOT

MOUNTING HOLES
4 PLCS.
(IN BASE LEG)
~I
AMMETER, 0-30 AMP
]
V
~I@
II
II
I
I
I
I
I
I
~
~
~
~
~
~
~
~
~
~
~
~
MANUAL 92350-003
Januruy 1997
SIN X935-97051
~
~
c::==::::J
c::==::::J c::==::::J
c::==::::J ~
c::==::::J c::==::::J
~ c::==::::J
c::==::::J c::==::::J
~ c::==::::J
~ c::==::::J
~ c::==::::J
~ c::==::::J
c::==::::J c::==::::J
I
I
\~
I
I
\E
VENTILATION LOUVERS
ON BACK SIDE
FIGURE 3.18: Charger 115V160HZ-25A124VDC . ,
ELECTRIC nMER
BLACK
RED
GREEN
TRANSFORMER
FAN
RED or WHITE
+
TO SA TTERIES
BLACK
BLACK
FAN
WHITE
.GREEN WIRE NO T USED

ON SOME MODELS.
QTY
ITEM
PART NUMBER
DESCRIPTION
Ref.
54908 ..........................
54908-101 ....................
54908-102 ....................
54098-103 ....................
54908-104 ....................
54908-105 ....................
54908-106 ....................
54908-107 ....................
54908-108 ....................
54908-109 ....................
54908-110 ....................
Charger,115V/60HZ-25A/24VDC ....................................... Ref.

Transformer Assembly
HeatsinkAssembly, with Diodes
Ammeter
Electronic Timer Assembly
Capacitor,6.0MFD,660VAC
Fuse Assembly
Case Assembly
Bushing, 7W-2, Insulator For Cordset
Cordset,DC,75",NoPlug
ACReceptacle
)
MANUAL 92350-003
JanuaIY 1997
SIN X93S-970S1
CABLE FROM LOWER CONTROL

BOX TO UPPER CONTROL BOX
CABLE FROM LOWER CONTROL

BOX TO HYDRAULIC VAL YES
,.-V-V--
COLOR
GRN
BlU
BlU BlK
ORN
ORN/alK
WHT
alK
WHT/BlK
BLK WHT
GRN BlK
REO BlK
REO
#
I
2
[,- 6
[,- 7
[,- 8
V-- IDA
V-- 80
V-- IIA
V-- 12
16
r-
[,-
CIRCUIT DESCRIPTION
GROUNO
rORWARD
DRIVE VALVE
REVERSE
RIGHT
STEER VALVE
lEn
uP PLArrORM
SElEC T VALVE
rAST ORIVE SPEEO
DECElERA TlON VALVE
CREEP DRIVE SPEED VALVE
POSITRAcnON VALVE
SIGNAL HORN
OPTION
SPARE
19
,---- 6
ill:
Q~~I'N"H
4$P~~t.t
bS~TEIIIoI
#8C=Y.1",H MOTION
HSD=WHT TRAVEL
H9=WH T DESCEND
~--.j.,p;.-F--~II
I'=GRN
WELD ON
STUD AT
CHASSIS
11=GRN
OPTIONAL
16GA/2C
67295-035
'----'--T<.:.::='-----' STROBE LIGHT OPTION
'-'-_---''-!L::9_=-''WH''-'...T_ _--' VALVE ON CYL
~[
rJ iJ rGkfl'PL
@ @
DRIVE
@ @
SELECT
@@
~[J [j
18D=WHT/BlK
~J
CABLE FROM
lOWER CON TROl BOX
rv
r-~~
r-
II=GRN
SENSOR
opnON
a=
SIGN l
l=G N
l=ORN
GROUND
GROUND
=8LK
58=alU
III--,"m
CONTACTOR
POWER
POWER
fl0A-BLK
opnONAl 16GA/8C 67295-024 CABLE
rROM lOWER CON TROL BOX, RErtR
TO STANDARD CABLE SHOWN BELOW
'7=ORNIBLK
HllA=BlK/WHT
SPARE-RED
116=REO/BLK
OPMN l
SIGNAL HORN
SIGNAL
HI6=RED/BlK
#i=GRN
Ie
SIGNAL HORN OP TlON
I=GRN
GROUND
5B-BlK
POWER
2 PL
IS
"
18
,.
21
19
18
20 2Pc
CONNECTOR & CABLE

SUB-ASSV IS INCLUDED
IN ARM INSf.
5' SLOPE
.PL
16 19 20
20
:-h
'( :t-LtJ
f/4=BLU/BLK
:- -,
STEER
@@
9
10
11
12
ClRCUI T DESCRIP TlON

GROUND-SPARE, Ir NO OPnONS
FORWARD DRIVE
POWER TO UPPER CONTROLS
REVERSE DRIVE
OPTION
BA TTER V GAGE
lEn STEER
RIGHT STEER
UP PLATI'ORM
DOWN PlA rrORM
r AST DRIVE SPEED
CREEP DRIVE SPEED
POSITRAcnON
BELOW ARE LISTED CONDUCTORS IN CABLE

THAT IS PART or CERTAIN opnONS.
(REr opnONAL 16GA/16C 67295-003)
, . - - 13
GRN WHT
SLOPE ALARM
OPTION
,.-OVERRIDE LOW VOLT
OPTION
RED WHT
,--- 15
"
INDICA TE lOW VOL T
BLU/WHT
OPTION
, . - - 16
BLK RED
SIGNAL HORN
OPTION
L f..J
[SiSiD
r-
ALARM
OPTIONS
7
8
L I--'~
2J
1\)
.8=WHT
12=BlU
CID
,---,---,---,.-,.-,.--
"-
#I=GRN
16-0RN
1\ POS (+)
"
----=,--,..Jj
I. 20 21 2 PL
112=GRN/BlK
COLOR
GRN
BLU
RED
BlU/BlK
REO BlK
ORN
ORNIBLK
\\!-iT
\\!-iT Blk
BlK
BlK/\\!-iT
GRN/BLK
,---- 3
,---,---- 5
,)
0
r-- I
10
CONTACTOR
STANDARD CABLE rROM

LOWER CON TROl BOX
NOTES:
I. SEE: 5'918-DWG rOR IIOV EXT
2. THIS DWG SUPERCEDES 54916.
FIGURE3.19WiringInstallation . ,
PART NUMBER
Ref.
1
2
3
55315 ......................... WiringInstallation ................................................................. Ref.

55331 .......................... Jumper Assembly 3" LgWire ...................................................... 6
55330-001 .................... Jumper Assembly21 1/ 2" Lg Wire ............................................... 1
55330-002 ................... JumperAssembly24" LgWire .................................................... 1
55330-003 .................... Jumper Assembly14 1/ 2 " Lg Wire ............................................... 1
55328 ......................... Switch Assembly, Chassis Limit ................................................. 1
67295-037 ................... -Cable, 16Ga.l4 Conductor SJO ..................................... 1.85LF
51036 .......................... -SwitchLimitBodyOnly ........................................................... 1
51037 .......................... -Offset Head Limit Switch ........................................................ 1
51039-002 ................... -Limit Switch Arm, Short ............................................................ 1
67114-003 .................... -Strain Relief 1/2"NPT .37/.5 ................................................. 1
55868 .......................... Spacer, .5"OD x #10 ID x .5L Nylon ......................................... 2
BOW31148 .................. Screw, Round Hd #lO-32UNF x 2 ............................................. 2
BOW31233 .................. Nut, Hex Keps #10-32 ............................................................... 2
67837-006 .................... Tie, Nylon 6" Black ..................................................................... 1
55222 .......................... Cover, Chassis Elec. Terminal ..................................................... 1
34552-008 .................... TerminalStrip ........................................................................... 1
BOW31130 .................. Bolt, Round Hd #8-32UNC 1/2 " 2
BOW31232 .................. Nut, Hex Keps #8-32UNC ........................................................ 2
54952 .......................... Support Weldment, Cable .......................................................... 1
BOW34980 .................. Pin, Roll.125 x 1.250 .................................................................. 1
BOW34575 .................. Bolt, Carriage .25-20UNC x .75L ............................................... 2
54926 .......................... Tray, Extension Cable ................................................................. 1
BOW30002 .................. Bolt,Hex.25-20UNCx.75 ........................................................ 3
BOW31444 .................. Washer,Flat.25"IDx.63"OD .................................................. 12
BOW32606 .................. Clamp, Wire Loom 1" Dia ........................................................ 3
67281-005 .................... Wrapping, 3/4" Black/Spiral ................................................. 66LF.
55329 .......................... Cylinder Harness Assembly ......................................................... 1
7
8
9
QTY
ITEM
10
11
12
13
14
15
16
17
18
19
20
21
22
23
DESCRIPTION
)
MANUAL 92350-003
Jamruyl997
SIN )(93597051
FIGURE 4.1: Box Assembly-Lower Control
I
I
I
I
I
I
III
III
111
ill
~I
fUSE
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
LL ___________ J
I
I
I
I
I
I
I
I
I
I
I
L ___ _
)
MANUAL 92350-003
January 1997
SIN X935-97051
FIGURE 4.1: Box Assembly-Lower Control
P ART NUMBER
Ref.
1
2
3
55489 ........................ BoxAssembly-LowerControl ............................................. Ref.

55488 .......................... Box,Mach.LowerControl ......................................................... 1
55029 .......................... Decal, Box Elec. T ags ................................................................. 1
51913 .......................... Operator,RedP-Pull ................................................................. 1
51914 .......................... Base + lNCContact .............................. ,,~:: ........................... 1
52670 .......................... Operator, 3 Pos. Rot (Key Switch 52671) .. ~ .. 8..~Q.~9..I~ .. 1
52029 .......................... Base + 2 NO Contacts ............................................................... 1
50075 .......................... Switch, (R.efPIN 67760) .......................................................... 1
54438 .......................... Relay, 24V SPDTBosch ............................................................. 1
206-00001-00 ............... Diode ....................................................................................... 9
67114-013 ................... StrainRelieflNPT.62/.75 ........................................................ 1
67114-008 ... ...... .......... Connector, Strain Relief...... ........ .............. ............ ............ ...... ..... 1
67114-009 .................... StrainRelief,3/4"NPT.62/.75 .................................................... 2
67124-003 .................... Locknut,l"NPT ........................................................................ 1
67124-002 .................... Locknut,3/4NPTConduit ......................................................... 3
67123-003 .................... Seal, Connector Elect 1" ............................................................ 1
67123-002 .................... Seal, Connector Elect. 3/4" ............................. ~ ............................ 3
34542 .......................... Jumper ....................................................................................... 4
67837-006 ................... Tie, Nylon 6" Black ..................................................................... 8
BOW31430 .................. Washer,Flat#10ID ................................................................... 1
BOW31129 .................. Screw,SlotRoundHd8-32UNCx 3/g " 1
BOW31232 .................. Nut, Hex Keps#8-32UNC ........................................................ 1
BOW31124 .................. Screw, Round Hd #6-32 x 1/2"Lg ............................................... 4
BOW31231 .................. Nut, Hex Keps #6-32 ................................................................. 4
BOW31428 .................. Washer,Flat#6 ...................................... ~ ................................... 4
67295-024 .................... Cable,8 Cond.16AWG Type SO ..................................... 9.50LF.
67295-004 .................... Cable, 12 Conductor 16Ga .................................................... 5LF.
34552-016 .................... Termina1Strip ............................................................................. 2
67295-022 .................... Cable, 3 Conductor 12AWG ........................................... 5.50LF.
67940 .......................... Holder,Fuse ............................................................................... 1
67939-015 .................... Fuse, 15Ga 1/4" x 1-1/ 4".............................................................. 1
58282 .......................... Wire, 12 GaBlack ................................................................. 4LF.
58300 .......................... Wire, 16 Ga Black .................................................................. lLF.
66720-001 .................... Disconnect, STA-KON Female ................................................... 6
BOW23087 .................. Terminal,FemalePush-On.250W ............................................... 3
67960-006 .................... Terminal,Ringl016-14AWG ..................................................... 2
BOW23024 .................. Ring, Tongue 16-14 Ga 1/4Stud ................................................. 1
BOW23025 .................. Terminal,RingTongue 16-14Ga ................................................ 1
BOW18578 .................. Terminal,PiggybackR67963 ...................................................... 1
BOW23087-2 .............. Terminal,FemalePush-On.250W ............................................... 2
55489 .......................... Dwg.BoxAssembly,LowerControl ...................................... Ref.
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
51
52
53
A626-2633 ...................
A309-2633 ...................
A310-2633 ...................
67295-003 ....................
DESCRIPTION
QTY
ITEM
Low Volt AlarmlInterrupt ..................................................... Ref.

MotionAlarm ........................................................................ Ref.
StrobeLight ........................................................................... Ref.
XL Models 16ga/16cond ...................................... ~ ................ Ref.

MANUAL 92350-003
Jarnwy 1997
SIN X93597051
FIGURE 4.1: BoxAssembly-LowerControl
i---------------------------------r-------------d:-----l
I
50
1
"DOWN"
5G
@o
"UP"
12 GA
'"
SG
9
9 PL
12 GA
0&
12 GA
72 PL
58
224 PL
_______ j ________
234 PL
L-----
244 PL
3 _ 9 __O
_________
TO MOTOR
CONT.iTOR"-SEE SHEEr 113
. - - - - - - - - - - - - - - -- - - - - - - - - - - - - -
SEE SHEET 63
- --
- - - - ----- ---,
NOTES:
1. THIS SHEET SHOWS "STANDARD", SEE SHEET 3 FOR 0
2. CONNECT "RED/BLK" TO SPARE, AS SMWN .
.3. ALL WIRING TO BE 16 GA. EXCEPT CIRCUlfS .3,5, 8( 5[
4. SEE WIRING DRAWING FOR COLOR TO CIRCUIT NUMBER
L ________________________________ J
i:~=--~~~~~~h'~hl~~--0NEtI_.w:,,11IQIB"
BOX ASSY.
)
MANUAL 92350-003
lanuaIy 1997
SIN X935-97051
ITEM
PART NUMBER
DESCRIPTION
QTY
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
55489 .......................... Box Assembly- Lower Control .............................................. Ref.

55029 .......................... Decal, Box Elec. Tags ................................................................. 1
51913 .......................... Operator, Red P-Pu 11 .. 1
51914 .......................... Base + iNC Contact ................................................................. 1
52670 .......................... Operator,3 Pos. Rot (KeySwitch52671) ..................................... 1
52029 .......................... Base + 2NO Contacts ............................................................... 1
50075 .......................... Switch, (RefP /N 67760) ............................................................ 1
54438 .......................... Relay,24VSPDTBosch .............................................................. 1
206-00001-00 ............... Diode ........................................................................................ 9
67114-013 .................... StrainRelieflNPT.62/.75 ......................................................... 1
67114-008 .................... Connector,StrainRelief............................................................... 1
67114-009 .................... Strain Relief, 3/4NPT .62/.75 ...................................................... 2
67124-003 .................... Locknut, 1" NPT ........................................................................ 1
67124-002 .................... Locknut, 3/4NPT Conduit .......................................................... 3
67123-003 .................... Seal, Connector Elect 1" .............................................................. 1
67123-002 .................... Seal, Connector Elect. 3/ / 3
34542 .......................... Jumper ....................................................................................... 4
67837-006 .................... Tie,Nylon6"Black ..................................................................... 8
BOW31430 .................. Washer, Flat #10 ID ................................................................... 1
BOW31129 .................. Screw,SlotRoundHd8-32UNCx 3 /g" ...................................... 1
BOW31124 .................. Screw, Round Hd #6-32 x 1/2Lg ................................................ 4
BOW31231 .................. Nut, Hex Keps #6-32 ................................................................. 4
BOW31428 .................. Washer,Flat#6 .......................................................................... 4
67295-024 .................... Cable, 8 Condo 16AWG Type SO ..................................... 9.50LF.
34552-016 .................... TerminalStrip ............................................................................. 2
67295-022 .................... Cable, 3 Conductor 12AWG ........................................... 5.50LF.
67940 .......................... Holder,Fuse ............................................................................... 1
67939-015 .................... Fuse, 15Ga 1// x 1-1/4" .............................................................. 1
58282 .......................... Wire, 12GaBlack .................................................................. 4LF.
58300 .......................... Wire, 16 GaBlack .................................................................. 1LF.
66720-001 .................... Disconnect,STA-KONFemale ................................................... 6
BOW23087 .................. Terminal, FemalePush-On.250W ............................................... 3
67960-006 .................... Terminal, Ring 10 16-14AWG ..................................................... 2
BOW23024 .................. Ring, Tongue 16-14 Ga 1/4 Stud .................................................. 1
BOW23025 .................. Terminal, Ring Tongue 16-14 Ga ................................................ 1
BOW23087-2 .............. Terminal, FemalePush-On.250W ............................................... 2
51
52
53
A626-2633 ................... LowVoltAlarmlInterrupt ..................................................... Ref.

A309-2633 ................... MotionAlarm ........................................................................ Ref.
A310-2633 ................... StrobeLight ........................................................................... Ref.
67295-003 .................... XL Models 16ga/16cond ....................................................... Ref.

MANUAL 92350-003
January 1997
SIN X935-97051
fit
,Ill
:j :
I
20"
BOX
INSIDE
BOX
2 PL
fcl~
END OF STRAIN REiJEF TY?
38"
CABLE
SHEATH
CABLE 16GA/8C (REF)

TO MOTOR CONTACTOR/
5" SLOPE SENSOR OPTION
(REF)
67964-002
5" SLOPE
OPTION
(REF)
67964-002
5" SLOPE
OPTION
(REF)
(REF)
67960-006
5" SLOPE
OPTION
MANUAL 92350-003
JanuaIY 1997
SIN 'X935-97051
BOW23025
(REF)
5" SLOPE
OPTION
67964-002
5" SLOPE
OPTION
PARTNUMBER
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
2425
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
55489 .......................... BoxAssembly-LowerControl .............................................. Ref.

55029 .......................... Decal, Box Elec. Tags ................................................................. 1
51913 .......................... Operator,RedP-Pull ................................................................. 1
51914 .......................... Base + lNCContact ................................................................. 1
52670 .......................... Operator, 3 Pos. Rot (Key Switch 52671) ................................... 1
52029 .......................... Base + 2 NO Contacts ............................................................... 1
50075 .......................... Switch, (R.efP/N 67760) ............................................................ 1
54438 .......................... Relay, 24VSPDTBosch .............................................................. 1
206-00001-00 .............. Diode ....................................................................................... 9
67114-013 .................... Strain Relief 1 NPT .62/.75 ......................................................... 1
67114-008 .................... Connector,StrainRelief............................................................... 1
67114-009 .................... Strain Relief, 3/..NPT .62/.75 ...................................................... 2
67124-003 .................... Locknut,l"NPT ....................................................................... 1
67124-002 .. ,. ................ Locknut,3/.. "NPTConduit ........................................................ 3
67123-003 .................... Seal, Connector Elect 1" ............................................................. 1
67123-002 .................... Seal,ConnectorElect. 31/ .......................................................... 3
34542 .......................... Jumper ....................................................................................... 4
67837-006 .................... Tie, Nylon 6" Black ..................................................................... 8
BOW31430 .................. Washer,Flat#10ID ................................................................... 1
BOW31129 .................. Screw, Slot RoundHd 8-32UNCx 3/g" ..... 1
BOW31124 .................. Screw, RoundHd #6-32 x II/Lg ............................................... 4
BOW31231 .................. Nut, Hex Keps #6-32 ................................................................. 4
BOW31428 .................. Washer,Flat#6 .......................................................................... 4
67295-024 .................... Cable,8 Cond.16AWG Type SO ..................................... 9.50LF.
67295-004 .................... Cable, 12 Conductor 16Ga ............................................... ,.,.. 5LF.
34552-016 .................... TerminalStrip ............................................................................. 2
67295-022 .................... Cable, 3 Conductor 12AWG ,.,.,.,.,.,.,. .. ,. ...... ,. ............ ,. ... 5.50LF.
67940 .. ,.,. ... ,..,.,. .......... Holder,Fuse ,.,..,. ........... ,. .. ,. .... ,. .... ,. ....... ,. .. ,. .. ,..,..,. ..... ,.,..,. .... ,. .. 1
67939-015,. ...... ,.,. .. ,.,.,. Fuse, 15Ga II.." x 1-1/4" ,.,.,.,. ...... ,. ............. ,.,.,.,.,. .... ,. ... ,. .. ,. .... ,. .. 1
58282 ,.,.,.,.,. ........ ,. .... ,. Wire, 12 Ga Black .......... ,. .............................. ,.,. .... ,.,.,.,.,.,. .... 4LF.
58300 ... ,.,. .. ,.,.,.,. .... ,.,.. Wire, 16 Ga Black .......... ,.,. .. ,. .............................. ,. ....... ,. ....... lLF.
66720-001 ,.,. .... ,. .. ,.,. .... Disconnect,STA-KONFemale ................................................... 6
BOW23087 .................. Terminal,FemalePush-On.250W .................. ,. .. ,. .............. ,.,. ..... 3
67960-006 .. ,. ........... ,. ... Terminal, Ring 10 16-14AWG ...... ,. .... ,. .......... ,.,. .. ,. .......... ,. ... ,. .... 2
BOW23024 ............ ,. .... Ring, Tongue 16-14 Ga II.... Stud ..,.,. .... ,.,. .............. ,. ........ ,. ........ 1
BOW23025,. ........... ,. ... Terminal, Ring Tongue 16-14 Ga ...... ,.,. .. ,. .. ,.,.,.,. .. ,.,.,. ................ 1
BOW18578 ........ ,. ........ Terminal,PiggybackR67963 ............. ,. ............. ,.,. .... ,. ................ 1
BOW23087-2 .............. Terminal,FemalePush-On.250W .................. ,.,.,. .............. ,. ....... 2
55489 .. ,. .......... ,.,. ........ Dwg.BoxAssembly,LowerControl ........ ,. ............................ Ref.
51
52
53
A626-2633 ...................
A309-2633 ..... ,.,. .. ,.,. .. ,.
A310-2633 .. ,. ...............
67295-003 ................ ,. ..
DESCRIPTION
QTY
ITEM
Low Volt AlarmlInterrupt .. ,. .... ,. .... ,. .. ,. .... ,. ........................ ,.. Ref.

MotionAlarm ....... ,. ... ,..,. .. ,. ..... ,. ..... ,. ...... ,..,. .. ,. ...... ,.,.,. .......... Ref.
StrobeLight ....................................... ,. ...... ,. .......................... Ref.
XL Models 16gal16cond ............ ,. ................ ,. ........ ,.,. ........... Ref.

MANUAL 92350-003
JanuaI)' 1997
SIN Xl/35-97051
FIGURE 4.1: Box Assembly- Lower Control
i---------------------------------r--------------5
t~cJf\b
12GA
,odf'l
5D
-----l
IZ GA
"OOWN"
5G
"uP"
~::-,2GA
12 GA
5G
5E
5E
N2:,
!
'-b-------~Jr---------~,------~-5-8--;5B
234 Pl
244 PL
_ _ _ _ _ _ _ _ _ -----1 _ _ _ _ _ _ _ _ _ _ _ _ _
I--------r---- 1-------- f - - - -
SEE SHEET #3
1----
!.1
LOW VOLT oPTION
5.3
STROBE LIGHT QPnON
,~,'c<i'-,G"A----)
i2~ ~:~
ETC.
16 GA
SO
L.?_
50
""'---~==ilt~cn~
16
~---
(~~O!~~ __ _
~CONTACTOR
VALVES
SEE SHEET #3
38 39
O _________
(REF) 1 EA. BOW18578

(REF) 1 EA. 80W2.3087
5' SLOPE OPTION
SEE SHEET #3
---------------------------1
I
NOTES:
1. THIS 5HEE T SHOWS ALL OPTIONS. SEE SHEEr 2 FOR "STANDARD",
2. CONNECT "RED/BLK~ TO SPARE, AS SHOW, IF NO ALARM OPnON.

CONNECT "RED/BLK" TO CIRCUIT 8e FOR MonON ALARM OPTION.
CONNECT "RED/BLK TO CIRCUIT 9 FOR DESCEND ALARM OPTION.
CONNECT "RED/BLK~ TO CIRCUIT 80 FOR TRAVEL ALARM OP"TION.
3. ALL WIRING TO BE 1E. GA. EXCEPT CIRCUITS ,3,5, &: 50 A;5 MARI\ED.
4. IF LOW VOLT OPTION IS USED, THEN 00 NOT USE JUMPER BETWEN
8A AND 88
N
5. SEE Vv1RtNG ORAW1NG FOR COLOR TO CIRCUIT NUMBER TABLE.
51
LOW VOLTAGE
BATTERY
PROTECTION
opnON
RESET
GROUND
L _____________ : ::: ________________ ~
MANUAL 92350-003
Januatyl997
SIN X935-97051
FIGURE 4.1 Box Assembly- Lower Control
ITEM
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
51
52
53
PART NUMBER
DESCRIPTION
QTY
55489 .......................... BoxAssembly-LowerControl .............................................. Ref.

55488 .......................... Box, Mach. Lower Control ......................................................... 1
55029 .......................... Decal, Box Elec. T ags ................................................................. 1
51913 .......................... Operator ,RedP-Pull .................................................................. 1
51914 .......................... Base + 1 NCContact ................................................................. 1
52670 .......................... Operator, 3 Pos. Rot (Key Switch 52671) ................................... 1
52029 .......................... Base + 2 NO Contacts ............................................................... 1
50075 .......................... Switch, (RefP/N 67760) ............................................................ 1
54438 .......................... Relay,24VSPDTBosch .............................................................. 1
206-00001-00 ............... Diode ........................................................................................ 9
67114-013 .................... Strain Relief 1 NPT .62/.75 ......................................................... 1
67114-008 .................... Connector,StrainRelief ............................................................... 1
67114-009 .................... StrainRelief,3//NPT.62/.75 .................................................... 2
67124-003 .................... Locknut, 1" NPT ........................................................................ 1
67124-002 .................... Locknut, 3// NPT Conduit ........................................................ 3
67123-003 .................... Seal, Connector Elect 1" .............................................................. 1
67123-002 .................... Seal, Connector Elect. 3// .......................................................... 3
34542 .......................... Jumper ....................................................................................... 4
67837-006 .................... Tie, Nylon 6" Black ..................................................................... 8
BOW31430 .................. Washer, Flat#10ID ................................................................... 1
BOW31129 .................. Screw, Slot RoundHd 8-32UNC x 3/g" 1
BOW31232 .................. Nut, HexKeps#8-32UNC ........................................................ 1
BOW31124 .................. Screw, Round Hd #6-32 x 1/2"Lg ............................................... 4
BOW31231 .................. Nut, Hex Keps #6-32 ................................................................. 4
BOW31428 .................. Washer, Flat #6 .......................................................................... 4
67295-024 .................... Cable, 8 Cond.16AWG Type SO ..................................... 9.50LF.
34552-016 .................... TerrninalStrip ............................................................................. 2
67295-022 .................... Cable, 3 Conductor 12AWG ........................................... 5.s0LF.
67940 .......................... Holder,Fuse ............................................................................... 1
67939-015 .................... Fuse, 15Ga 1// x 1-1/4" .............................................................. 1
58282 .......................... Wire, 12 GaBlack .................................................................. 4LF.
58300 .......................... Wire, 16GaBlack .................................................................. lLF.
66720-001 .................... Disconnect,STA-KONFemale ................................................... 6
BOW23087 .................. Terminal,FemalePush-On.250W ............................................... 3
67960-006 .................... Terminal, RingJO 16-14AWG ..................................................... 2
BOW23024 .................. Ring, Tongue 16-14 Ga 1// Stud ................................................ 1
BOW23025 .................. Terminal, Ring Tongue 16-14Ga ................................................ 1
BOW23087-2 .............. Terminal,FemalePush-On.250W ............................................... 2
A626-2633 ...................
A309-2633 ...................
A310-2633 ...................
67295-003 ....................
Low Volt AlarmlInterrupt ..................................................... Ref.

MotionAlarm ........................................................................ Ref.
Strobe Light ........................................................................... Ref.
XL Models 16ga/16cond ....................................................... Ref.

MANUAL 92350-003
Iammy 1997
SIN X935-97051
8)
. , FIGURES.l:ArmstackAssembly
~~.,~~--~--~=~.,
~-
_____ - - - - - - - - - - - - - - - ___
14 15
-----
--___
SEE NOTE 2
~3
--___ ----r-- - -----<:::::"'-_ .... ___ .~
---------~_--
--
___ -
SEENOTE2~3~::~ ----
___ -
----
--______
F\\
~-----
'
,-
~-./(
14 15
2 PL
- -..::::::::.- -
---, ---- --
14 15
- - ___
14 15
---~:.----..:::::::---
--- ------------- ----
-":::::::::':.-
--- ----- ----- ----- ----- ------
- - - - - - -13
-~
-....-:::::.....--_
____ - - - - - - - - -
----
--- -------- -
-::----
---:>::-
- --- - -
---~--
- -
----- --- ----- ---- ---- --- ---
2 PL
- - _____~19
30 2PL
NOTES:
1.
TOTAL EST. WT.= 1090 LBS.
2.
ITEM 13 TO BE ON UPHILL SIDE OF

ROUND TUBE. ITEMS 14 & 15 TO BE
ON DOWNHILL SIDE OF ROUND TUBE.
3.
THIS OWG SUPERCEDES 55282.
)
MANUAL 92350-003
Janwnyl997
SIN X935-97051
FIGURE5.1:ArmstackAssembly
ITEM
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
PART NUMBER
DESCRIPTION
QTY
55441 .......................... ArmstackAssembly ................................................................ Ref.

55418 .......................... Armstack Weldment + Brg/Pin .................................................. 1
55418-001 .................... Arm Weldment, Lower Outer ..................................................... 1
55418-002 .................... Arm Weldment, Lower Inner ...................................................... 1
55418-003 .................... Arm Weldment, Left Middle Outer ............................................ 1
55418-004 .................... Arm Weldment, Right Middle Outer ........................................... 1
55418-005 .................... Arm Weldment,Middle Inner ..................................................... 1
55418-006 .................... Arm Weldment, Upper Outer ..................................................... 1
55418-007 .................... Arm Weldment, Upper Inner ...................................................... 1
81368-007 .................... Bearing, 1.50"ID x 2.50"L x 1/8 W ........................................... 14
54616-002 .................... Shaft, Arm Pivot 6 3//Lg ........................................................... 4
54616-001 .................... Shaft, Arm Pivot 18" Lg ............................................................. 5
67281-005 .................... Wrapping, 3// Black/Spiral .............................................. 2.83LF.
66388-001 .................... Collar, 1 1/ 2 " Shaft .................................................................... 14
BOW30037 .................. Bolt,Hex.31-18UNCx3.00 ..................................................... 11
BOW34273 .................. Nut,LockHex 5/16"-18UNC .................................................... 15
55327 .......................... Harness, Main Control ................................................................ 1
67295-017 .................... Cable, 3 Conductor 12 Ga ................................................... 39LF.
67998-001 .................... Screw, Thread Frmng.. 38-16 x 1.0 Lg ........................................ 2
BOW32606 .................. Clamp, Wire Loom 1"Dia .......................................................... 9
BOW9977 ................... O-Ring, .375"ID x .50"OD ......................................................... 1
BOW30000 .................. Bolt,Hex.25-20UNCx.50 ........................................................ 2
BOW30035 .................. Bolt,Hex.31-18UNCx2.50 ....................................................... 2
BOW30036 .................. Bolt,Hex.31-18UNCx2.75 ....................................................... 4
55083 .......................... ManifoldAssembly, Lift Cylinder ................................................ 1
54569 .......................... Cable Bracket, Holding Valve ...................................................... 1
54798 .......................... Nut, 10-32UNF Coupling ........................................................... 1
54705 .......................... Cylinder,ArmstackLift ............................................................... 1
34145 .......................... Bushing, (R#81368) .................................................................... 4
54616-004 .................... Shaft, ArmPivot6.50"Lg............................................................ 1
55027 .......................... Pin Weldment, Lift Cylinder ........................................................ 1
55279 .......................... Block,HDPESlide ..................................................................... 2
54616-009 .................... Shaft,ArmPivot20.38"Lg.......................................................... 2
54701 .......................... Block,ArmstackNylatron ........................................................... 2
54582 .......................... Block, UHMWPEBearing .......................................................... 2
02236 .......................... Elbow, 90 MJ04 M004 ............................................................ 1
02662 .......................... Elbow, 90 MJ06 M006 ............................................................ 1
)
MANUAL 92350-003
January 1997
SIN X935-97051
, J
4 PL
115 1/2
~
132
.1
e
'"r.I
~
GJ
!":'"
~
~
5 PL
RIGHT SIDE VIEW
m
cr
FIGURES.l:AnnstackAssembly
QTY
ITEM
PARTNUMBER
Ref.
55441 .......................... ArrnstackAssembly ................................................................ Ref.

55418 .......................... Arrnstack Weldment + Brg/Pin .................................................. 1
55418-001 .................... Arm Weldment,Lower Outer ..................................................... 1
55418-002 .................... ArmWeldment,LowerInner ...................................................... 1
55418-004 .................... Arm Weldment, Right Middle Outer ........................................... 1
55418-005 .................... Arm Weldment,MiddleInner ..................................................... 1
55418-006 .................... ArmWeldment,UpperOuter ..................................................... 1
55418-007 .................... Arm Weldment, Upper Inner ...................................................... 1
81368-007 .................... Bearing, 1.50"ID x 2.50"L x 1/8 W ........................................... 14
54616-002 .................... Shaft, Arm Pivot 6 3/ /Lg ........................................................... 4
67281-005 .................... Wrapping, 3// Black/Spiral ............................................. , 2.83LF.
66388-001 .................... Collar, 1 1/ 2 " Shaft .................................................................... 14
BOW30037 .................. Bolt,Hex.31-18UNCx3.00 ..................................................... 11
BOW34273 .................. Nut,LockHex s/16"-18UNC .................................................... 15
55327 .......................... Harness, Main Control ................................................................ 1
67998-001.. .................. Screw, Thread Frmng.. 38-16x 1.0Lg ........................................ 2
BOW32606 .................. Clamp, Wire Loom l"Dia .......................................................... 9
BOW9977 ................... O-Ring, .375"ID x .50"OD ......................................................... 1
BOW30000 .................. Bolt, Hex .25-20UNC x .50 ........................................................ 2
BOW30035 .................. Bolt,Hex.31-18UNCx2.50 ....................................................... 2
BOW30036 .................. Bolt,Hex.31-18UNCx2.75 ....................................................... 4
55083 .......................... ManifoldAssembly,LiftCylinder ................................................ 1
54798 .......................... Nut, 10-32UNF Coupling ........................................................... 1
34145 .......................... Bushing, (R#81368) .................................................................... 4
54616-004 .................... Shaft, ArmPivot6.50"Lg............................................................ 1
55027 .......................... Pin Weldment,LiftCylinder ........................................................ 1
55279 .......................... Block,IIDPESlide ..................................................................... 2
54701 ........... :.............. Block,ArmstackNylatron ........................................................... 2
54616-008 .................... Shaft,ArmPivQt26.62"Lg.......................................................... 2
54582 .......................... Block, lJI-IMWPEBearing .......................................................... 2
02236 .......................... Elbow, 90 M]04 M004 ............................................................. 1
02662 .......................... Elbow, 90 M]06 M006 ............................................................ 1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
DESCRIPTION
)
MANUAL 92350-003
January 1997
SIN X935-97051
. , FIGURE 5.1: ArmstackAssembly
4 PL
5 PL
10
-----------~-----------~
10 PL
12
SEE NOTE #1
SECTION C-C
Scale= 1:3
2 PL
SEE
SECTION 8-8
Scole= 1: 3
2 PL
2 PL 12
SEE NOTE #1
SECTION A-A
Scale= 1: 3
MANUAL 923 50-003

January 1997
SIN X935-97051
FIGURE 5.1: ArmstackAssembly

ITEM
PART NUMBER
Ref.
55441 .......................... Annstack.Assembly ................................................................ Ref.

55418 .......................... Annstack Welchnent + Brg/Pin .................................................. 1
55418-001 .................... Arm Weldment, Lower Outer ..................................................... 1
55418-002 .................... ArmWelchnent, Lower Inn er ...................................................... 1
55418-004 .................... Ann Weldment, Right Middle Outer ........................................... 1
55418-005 .................... ArmWeldment,MiddleInner ..................................................... 1
55418-006 .................... Arm Welchnent, Upper Outer ..................................................... 1
55418-007 .................... Arm Welchnent, Upper Inner ..................................................... 1
81368-007 .................... Bearing, 1.50"ID x2.50"L x 1/8 W ........................................... 14
54616-002 .................... Shaft, Arm Pivot 6 3/ 4"Lg .......................................................... 4
67281-005 .................... Wrapping,3/4 "Black/Spiral .............................................. 2.83LF.
66388-001 .................... Collar, 1 1/ 2" Shaft .................................................................... 14
BOW30037 .................. Bolt,Hex.31-18UNCx3.00 .................................................... 11
BOW34273 ................. Nut,LockHex 5/ 16-18UNC ..................................................... 15
55327 .......................... Harness, Main Control ............................................................... 1
67998-001 .................... Screw, Thread Frmng..38-16 x 1.0 Lg ....................................... 2
BOW32606 .................. Clamp,WireLooml"Dia .......................................................... 9
BOW9977 ................... O-Ring,.375"IDx.50"OD ......................................................... 1
BOW30000 .................. Bolt,Hex.25-20UNCx.50 ........................................................ 2
BOW31401 .................. Washer,Flat .25"IDx.63"OD .................................................... 2
BOW30035 .................. Bolt,Hex.31-18UNCx2.50 ....................................................... 2
BOW30036 .................. Bolt,Hex.31-18UNCx2.75 ...................................................... 4
55083 .......................... ManifoldAssembly,LiftCylinder ................................................ 1
54798 .......................... Nut, 10-32UNF Coupling ........................................................... 1
34145 .......................... Bushing, (R#81368) .................................................................... 4
54616-004 .................... Shaft, Arm Pivot 6.50"Lg............................................................ 1
55027 .......................... Pin Welchnent, Lift Cylinder ........................................................ 1
55279 .......................... Block,lIDPESlide ..................................................................... 2
54616-009 .................... Shaft, ArmPivot20.38"Lg.......................................................... 2
54701 .......................... Block,ArmstackNylatron ........................................................... 2
54616-008 .................... Shaft,ArmPivot26.62"Lg......................................................... 2
54582 .......................... Block, lJ1-Th1WPEBearing .......................................................... 2
02236 .......................... Elbow, 90 M]04M004 ............................................................ 1
02662 .......................... Elbow, 90 M}06M006 ............................................................ 1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
DESCRIPTION
)
MANUAL 92350-003
Janwuyl997
SIN X935-9705\
QTY
G
~
.....
CJ
U1
~
p;-
a-:
()
ft;:t>
CAVITY FOR PARKER

FVIOIS VALVE CARTRIDGE
REF. CONDOR #55221
en
REF FOUR BUSHIN(, 34145
g
CJ
o::c=
~
~----------------------r--i
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -+--
I __ I
_______________________ L
~
FIGURE 5.2: ArmstackLift Cylinder Assembly
ITEM
PARTNUMBER
DESCRIPTION
Ref.
54705 .......................... ArrnstackLiftCylinder Assembly ............................................ Ref.

54705-100 .................... Seal Kit ........................................................................................
54705-101 .................... CastleNut ...................................................................................
54705-102 .................... Cast Iron Ring ............................................................................. .
54705-103 .................... Piston (Steel) ................................................................................ .
54705-104 ............. ... .... Wear ring .................................................................................... .
54705-105 .................... Jacket Assembly ........................................................................... .
54705-106 .................... Piston Rod .................................................................................. .
54705-107 .................... GlandNut ................................................................................... .
55221 .......................... FlowControlValve,LiftCylinder ................................................
QTY
)
MANUAL 92350-003
JanU3l}' 1997
SIN )(935-97051
----'-,-'
CD FIGURE 5.3: Manifold Assembly

c=--=r==-,
[QJ
JL
11
II
---\;T
I
I
-'Zf;" '
)
ITEM
PARTNUMBER
DESCRIPTION
Ref.
1
2
-3
55083 .......................... Manifold Assembly ................................................................ Ref.

54596-001 .................... Manifold, Lift Cylinder ............................................................... 1
54635-001 .................... Valve, 2WNCSPCL Cartridge ................................................... 1
00417 .......................... Plug,M004 ................................................................................ 1
QTY
)
MANUAL 92350003
Janruuy 1997
SIN X935-97051
SECTION A-A
SAE-6 a-RING PORT
SAE-4 a-RING PORT
VALVE CAVITY PER CHART
LINE PORT
GAUGE PORT
..JB
FROM CAVllY SPOTFACE
~
O-RING DETAIL
SEE 0- RING DE' AlL

CYLINDER PORT
. , FIGURE 6.1: Platform Installation
o
o
o
)
10
)
MANUAL 92350-003
Janwuyl997
SIN X935-97051
FIGURE 6.1: Platform Installation . ,
PARTNUMBER
Ref.
55478 .......................... Platform Installation ................................................................ Ref.

54598 .......................... Platform Weldment .................................................................... 1
55474-001 .................... ToeboardWeldmentLH ............................................................ 1
55474-002 .................... ToeboardWeldmentRH ............................................................ 1
54682 .......................... MountWeldment,Ext.DeckRoller ............................................ 4
54689 .......................... Roller, Ext. Deck ........................................................................ 4
55476 .......................... DeckWeldment,Ext.................................................................. 1
55267 .......................... HandraiIWeldment,Ext.Deck .................................................... 1
55241 .......................... LatchAssembly,.62-11UNCMount ........................................... 1
55473 .......................... Handrail W eldment, Side ............................................................. 2
55470 .......................... Gate, Lift Up ............................................................................. 1
55471 .......................... Plunger, Latch ............................................................................. 2
55243 .......................... Spring,DeckLatch ..................................................................... 2
55244 .......................... Finger Ring,DeckLatch .............................................................. 2
BOW36702-HD .......... Washer, .313, .813 "OD x .344"ID x .10 ...................................... 8
BOW2548 ................... S-Hook ...................................................................................... 1
164-00013-00 ............... Chain2l0 ......................................................................... 2.50LF.
50286 .......................... ChainSnap ................................................................................. 1
BOW34273 .................. Nut,LockHex 5/16"-18UNC .................................................... 34
BOW36718-HD .......... Washer, Flat 3// SAE ................................................................. 4
BOW30002 .................. Bolt,Hex.25-20UNCx.750 ..................................................... 12
BOW30008 .................. Bolt,Hex.25-20UNCx2.00 ....................................................... 6
BOW36780 .................. Nut,Hex.25-20UNCNylonLock ............................................ 18
BOW30027 .................. Bolt,Hex.31-18UNCx.75 ...................................................... 18
BOW34602 .................. Bolt, Carr .31-18UNC x 1.25 .................................................... 16
55207 .......................... Plug,Dome ................................................................................ 2
55563 .......................... BracketWeldment,LockMount .................................................. 1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
QTY
ITEM
22
23
24
25
26
27
28
DESCRIPTION
~
~
~'"
0
0
c6
MANUAL 92350-003
January 1997
SIN X935-97051
0
0
oooorr
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
o~ ::!
This page intentionally left blank
)
MANUAL 92350-003
January 1997
SIN X935-97051
FIGURE 6.2: 110 Volt Extension To Platform
GRE N
-LOCA TED AT RIGHT REAR
WHITE
OF PLATFORM-NOT ILLUSTRATED
BLACK
:3 PL -LOCA TED
UNDER
PLATFORM
REF. CABLE IS INCLUDED

IN ARMSTACK
AT CHASSIS
12
REF. LEFT
GOLD SCREW
FRONT OF CHASSIS
GREEN SCREW
11
SILVER SCREW
PARTNUMBER
Ref.
54918 .......................... 110VoltExtensionToPlatform{Option) ............................... Ref.
1
2
3
4
5
6
7
8
9
-)
10
11
12
13
66357 ..........................
55019 ..........................
66358 ..........................
67114-003 ....................
67124-001 ....................
67123-001 ....................
BOW31105..................
BOW31233 ..................
BOW32603 ..................
52710 ..........................
55036-001.. ..................
BOW34272 ..................
DESCRIPTION
QTY
ITEM
Receptacle, Ground Fault ............................................................ 1

OutletBox,Platform .................................................................. 1
Cover, Weatherproof .................................................................. 1
Strain Relief1/2"NPT .371.5 ........................................................ 1
Locknut, 1/2"NPTStrainRelief .................................................... 1
Seal, Connector Elect. 1/2" 1
10-32 x .75 Slotted Pan Head, Machine Screw.............................. 2
Nut, Hex Keps #10-32 ............................................................... 2
Clamp, WireLoom.50 ............................................................... 4
Plug,110Volt ............................................................................. 1
Grommet, 1/2" II) 1/4 X 13 / 16" Dia. Grv ..................................... 1
Nut,HexLock.25"-20UNC ....................................................... 4

MANUAL 923S0'()03
Janwuyl997
SIN X93S-970S1
. , FIGURE 6.3: Upper Control Box Assembly
17
35 REF'
I
I
""
LOWER
II
"I I
II
"
"
~~-----------------rl~'
I
I
I
:
L_U ____'I
I",
I' I,
l ___________________________ l
)
MANUAL 92350003
Janrnuyl997
SIN )(93597051
FIGURE 6.3: Upper Control Box Assembly
PARTNUMBER
Ref.
1
2
55317 .......................... Upper Control Box Assembly ................................................ Ref.

54587 ......................... Box, Upper Control .................................................................. 1
5~ .. 5.19.7.g.~.......... Contr.BMS4RM9071 W/RG5 + Lever ...................................... 1
54589-100 .................... -Boot ......................................................................................... 1
51913 ......................... Operator-Push Pull ..................................................................... 1
51914 .......................... Contact BlockNC ...................................................................... 1
52670 .......................... OperatorSelector ..................................................................... 1
34464 .......................... ContactBlockNO-NC .............................................................. 1
52669 .......................... Operator Black Pushbutton ........................................................ 1
52672 ......................... Contact Block 1 NO .................................................................. 2
69146 ......................... Operator, Green Pushbutton ....................................................... 1
54913 .......................... Operator-BlacklBlackD\JaISwitch ........................................... 1
52029 .......................... BlockContact2NOw/Base ...................................................... 1
54910-104 .................... MountingBase-AGPanel .......................................................... 1
54910-102 .................... Recep. Screw Term. #1-16 ......................................................... 1
67837-006 .................... Tie, Nylon 6.00" Black ................................................................ 5
BOW31125 .................. Screw, SlottedPan#06-32UNF x .62" ........................................ 4
BOW31231 .................. Nut,'Hex Keps #6-32 ................................................................. 4
55012 .......................... Insert, Control Box Plastic .......................................................... 2
58300 .......................... Wire, 16GaBlack ................................................................... 8LF.
54976-001 .................... Decal, UpperControIBox .......................................................... 1
54976-002 .................... Decal, Upper Control Box .......................................................... 1
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
31
32
33
34
35
36
37
DESCRIPTION
QTY
ITEM
A620-2633 ................... BatteryConditionIndicator(Option) ....................................... Ref.

A353-2633 ................... Slope Alarm (Option) ............................................................. Ref.
A626-2633 ................... Low Volt AlarmlInterrupt (Option) ....................................... Ref.
A304-2633 ................... Signal Horn (Option) .............................................................. Ref.
)
MANUAL 92350-003
Janwuyl997
SIN X935-97051
,-----------------,
I
OPTIONAL
SLOPE
ALARM
...
Z
511I
13
SEE
NOTE I
...
18
I
r-- ---- --- --- --- ---- --- -l-- - - - - - - - - -Jl - - - - - - - - - - - - - LID (FLIPPED OPEN)
----i
LEFT SIDE
OPTIONAL
BATTIERY
INDICATOR
OPTIONAL
LOW VOLTAGE
OVERRIDE SIIHCH
o><
"'I
JA
~,
glg,
I
I
16
---1---------------- .
I
L...-- __ - - - - - - - -
JB
---j
~--~
-J
8
DRIVE SPEED
~I
wi
"'I
L ____________________ ~
VIEW OF INSIDE OF BOX
L _________________ ~
PllOPlH:t.t,R1''''0IN~11014
1-+----I---+-I~'4T.:iI~~~
NOTES:
1. CONNECT CIRCUIT" AS REOUIRED BY OPTIONS.
2. CIRCUITS 1, 5, 13, 14, 15, & 16 ARE FOR OPTIONS.
=:::.\II~lIItoCl
'-'-
JQ..~~CUOll::::.'I'r.ii. ~
1.171.E.CJtItO.
-
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""1'1\._
B.SEf'CI( 10/301'5
6&61
I( 0
t'"I:5;;l__
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5Co\,I.
WACO, TEXAS
BOX ASSY MDD263.3

UPPER CNTRL
lIft.t
55317
I:I.~
,.
C
2 Or:' 2
FIGURE 6.3: Upper Control Box Assembly
PARTNUMBER
Ref.
1
2
55317 .......................... UpperControlBoxAssembly ................................................. Ref.

54587 .......................... Box, Upper Control ................................................................... 1
54589 .......................... Contr.BMS4RM9071 W IRG5 + Lever ...................................... 1
54589-100 .................... -Boot ......................................................................................... 1
51913 .......................... Operator-PushPull ..................................................................... 1
51914 .......................... Contact BlockNC ...................................................................... 1
52670 .......................... OperatorSelector ....................................................................... 1
34464 .......................... ContactBlockNO-NC .............................................................. 1
52669 .......................... Operator Black Pushbutton ......................................................... 1
52672 .......................... Contact Block 1 NO .................................................................. 2
69146 .......................... Operator, Green Pushbutton ....................................................... 1
54913 .......................... Operator-BlacklBlackDualSwitch ........................................... 1
52029 .......................... BlockContact2NOw/Base ...................................................... 1
54910-104 .................... MountingBase-AGPanel. ......................................................... 1
54910-102 .................... Recep. Screw Term. #1-16 ......................................................... 1
67837-006 .................... Tie, Nylon 6.00" Black ................................................................ 5
BOW31125 .................. Screw, SlottedPan#06-32UNF x .62" ........................................ 4
BOW31231 .................. Nut, Hex Keps #6-32 ................................................................. 4
55012 .......................... Insert, ControlBoxPlastic ........................................................... 2
58300 .......................... Wire, 16Ga Black ................................................................... 8LF.
54976-001 .................... Decal, Upper Control Box .......................................................... 1
54976-002 .................... Decal, UpperControIBox .......................................................... 1
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
31
32
33
34
35
36
37
DESCRIPTION
QTY
ITEM
A620-2633 ................... BatteryConditionIndicator(Option) ....................................... Ref.

A353-2633 ................... Slope Alarm (Option) ............................................................. Ref.
A626-2633 ................... Low Volt AlarmlInterrupt (Option) ....................................... Re
A304-2633 ................... Signal Hom (Option) .............................................................. Ref.
MANUAL 92350-003
Januaxyl997
SIN X93597051
FIGURE 7.1: Travel Alarm (Option)
QTY
ITEM
PART NUMBER
DESCRIPTION
Ref.
-1
-2
-3
-4
A301-2633 ...................
80188-024 ....................
67295-035 ....................
BOW23027 ..................
55036-001 ....................
TravelAlarm .......................................................................... Ref.

WobbulatorandSpeaker ............................................................. 1
Cable, 16Ga.l2 Conductor S]O ............................................. 2LF
Terminal 6 Stud 16/14Ga. Spade ............................................... 4
Grommet, 1/2"ID 1// x 13/16 "Dia. Grv ...................................... 1
)
MANUAL 92350-003
Januruy 1997
SIN X935-97051
FIGURE 7.2: MotionAlarm (Option)
QTY
ITEM
PART NUMBER
Ref.
A309-2633 ................... MotionAlarm ........................................................................ Ref.

80188-024 .................... WobbulatorandSpeaker ............................................................. 1
67295-035 .................... Cable, 16Ga.l2Conductor SJO ............................................. 2LF
BOW23027 .................. Terminal 6 Stud 16/14Ga. Spade ............................................... 4
55036-001. ................... Grommet, 1/2"ID 1// x 13/16"Dia. Grv ...................................... 1
206-00001-00 ............... Diode ........................................................................................ 2
-1
-2
-3
-4
-5
DESCRIPTION
)
MANVAL92350-003
lanuaIy 1997
SIN X935-97051
FIGURE 7.3: Strobe Light (Option)
REF. RIGHT SIDE VIEW

OF PLATFORM
4
3 PL
ITEM
PARTNUMBER
Ref.
1
2
3
4
5
6
7
8
9
10
A310-2633 ................... Strobe Light ........................................................................... Ref.

58395 .......................... Light Amber Strobe 12-72 VDC ............................................... 1
BOW31400 .................. Washer,Flat #10 ....................................................................... 3
BOW31144 .................. Screw, Slot Rnd. #10-32UNF x .50 ............................................ 3
55400 .......................... Mount -Strobe Light 14" .......................................................... 1
BOW34001 .................. Bolt, Hex .25-20UNC x 1.00 ..................................................... 2
BOW31432 .................. Washer, Flat .31 ID x .68 OD .................................................... 2
BOW36780 .................. Nut,Hex .25-20UNCNylonLock ............................................. 2
67295-035 .................... Cable, 16Ga.l2 Conductor SJO .......................................... 50LF
52672 .......................... Base + 1 NO Contact ZB2BZ101 ............................................. 2
58259 .......................... Wire, 18Ga. Black-Bulk .......................................................... 1LF
DESCRIPTION
QTY
MANUAL 92350-003
January 1997
SIN X935-97051
FIGURE7.4DescendAlarm(Option)
ITEM
PARTNUMBER
Ref.
A312-2633 ................... DescendAlarm ....................................................................... Ref.

80188-024 .................... WobbulatorandSpeaker 24V .................................................... 1
67295-035 .................... Cable, 16Ga.l2 Conductor 5JO ............................................ 2LF
BOW23027 .................. Terminal 6 Stud 16/14Ga. Spade ............................................... 4
55036-001 .................... Grommet, 1/2"ID 1// x 13/16 "Dia .............................................. 1
34542 .......................... Jumper ....................................................................................... 1
-1
-2
-3
-4
-5
DESCRIPTION
MANUAL 92350-003
January 1997
SIN X935-97051
QTY
FIGURE 7.5: Slope Alarm (Option)
QTY
ITEM
PART NUMBER
Ref.
-1
A353-2633 ................... Slope Alarm ........................................................................... Ref.

32002 .......................... Slope Sensor 2-Axis ................................................................... 1
BOW30002 .................. Bolt, Hex .25-20UNC x .750 ..................................................... 2
BOW31432 .................. Washer, Flat .31 ID x .68 OD .................................................... 2
67295-024 .................... Cable, 8 Conductor 16AWG Type SO .................................. 7LF
BOW23003 .................. Terminal Ring #6796022-18 #10 Stud ...................................... 2
34644 .......................... Alarm ......................................................................................... 1
58259 .......................... Wire, 18Ga.Black-Bulk .......................................................... 2LF
-2
-3
-4
-5
-6
-7
DESCRIPTION
)
MANUAL 92350-003
J anuaI)' 1997
SIN X935-97051
FIGURE 7.6: Hour Meter (XL-Option) . ,
2 PL
88=WHT
#1 =8LK
#1 =8LK
88=WHT
REFERENCE
MOTOR CONTACTOR
QTY
ITEM
PARTNUMBER
Ref.
-1
-2
-3
-4
-5
-6
-7
-8
-9
A619-2633 ................... Hour Meter ............................................................................ Ref.

80027 .......................... Meter, Hour 4/40VDC ............................................................ 1
67840-001 .................... Bracket, Gage Mounting ............................................................. 1
BOW30003 .................. Bolt,Hex .25-20UNCx.875 ...................................................... 2
BOW31401. ................. Washer, Flat .25 ID x .63 OD .................................................... 4
BOW36780 .................. Nut,Hex .25-20UNCNylonLock ............................................. 2
67295-035 .................... Cable, 16Ga.l2 Conductor SJO ............................................ 6LF
BOW23087 .................. Coupler - R#67963 16-14 Female ............................................... 2
67960-006 .................... Terminal Ring - 16-14 #10 Stud ................................................. 2
67837-004 .................... Tie,Nylon-4"Black ..................................................................... 4
DESCRIPTION
MANUAL 92350-003
JanuaIY 1997
SIN X935-97051
FIGURE 7.7: Battery Condition Indicator (XL-Option)
ITEM
PART NUMBER
Ref.
A620-2633 ................... BatteryConditonIndicator ...................................................... Ref.

37716 .......................... Meter, 24VBattery ..................................................................... 1
37993 .......................... MeterGuard .............................................................................. 1
58300 .......................... Wire, 16Ga.-Black .................................................................. 2LF
67963-001 .................... Coupler - 22-18 Male ................................................................. 2
-1
-2
-3
-4
DESCRIPTION
QTY
)
MANUAL 92350-003
JanUllI)'l997
SIN X935-97051
FIGURE 7.8: Low-Voltage Warning Interrupt (XL-Option)
-)
QTY
ITEM
PART NUMBER
Ref.
A626-2633 .................. Low-Voltage Warning Interrupt .............................................. Ref.

54169 .......................... LowVoltageInterrupt 24V ......................................................... 1
54967-104 .................... Operator,BluelliumPushbutton ................................................. 1
55902 .......................... Base + NO/NCContactw!24VBulb ....................................... 1
58259 .......................... Wire, 18Ga. Black-Bulk .......................................................... 6LF
54935 .......................... Decal-LowVoltWarning/Override .......................................... 1
BOW31141 .................. Screw, SlottedRnd. #10-24 x 2.00 ............................................ 2
BOW31288 .................. Nut, Hex #10-32 ....................................................................... 2
BOW31430 .................. Washer, Flat #10 ID .................................................................. 4
-1
-2
-3
-4
-5
-6
-7
-8
DESCRIPTION
)
MANUAL 92350-003
JanwuyJ997
SIN X935-970SJ
FIGURE 7.9: Larger BatteriesIPOS (XL-Option)
)
MANUAL 92350-003
Jamruyl997
SIN X935-97051
SELF-PROPELLED

Serial Number X935-97051
VENDOR SECTION
SHIPPING ADDRESS
MAILING ADDRESS
TIME CONDOR
TIME CONDOR
8300 IMPERIAL DRIVE

WACO, TEXAS 76712
(254) 420-5200
P.O. Box 21447

(254) 420-5200
)
MANUAL 92350003
January 1997
SIN X93597051
CONDOR MODEL V2033XL, V2033

VENDOR SECTION
TABLE OF CONTENTS
CONTROLLER .................................................................................................. OEM CONTROLS

CHARGER ................................................................................................ LESTER ELECTRICAL
OPEN CIRCUIT TRANSFORMER TEST ....................................................................................... .
2000 SERIES MOTOR ............................................................................................... CHAR-LYNN
--
- --.-----------;;W-;-;IR~E:-;:CH:7A:-;:R~r:-----------.,----------.-----------------,
REVISIDNS
lill. COLUR
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-4-
'tELLO'll
GREI="N
"5
-- 6
7
_~_
. '}
=____
GAUGE
FROM
LENGTH
TO
- "~--
j~O A\lG
\tHf IRED
WH TIYEl
WHT IGRN
WHlIlllU
WHTlBlK
20 AvG
14'
nF2
Sl-HO
S1-C
20 AVG
22 A\lG
12'
52-NU
ROCKR-C
22 AWG
22 A\lG
12'
12"
ROCKER-NO
22 AWG
22 AWG
2 112'
S2-C
TB-3
TB-l
TB--4
TB-5
R(JCI<ER-C
P. B
po. B t B - 6
PER PERC rORM .33
BurIO"
MICRO (LErT)
{r\Q
b
MI CROSY ITCH
, I
rvp. 2 PlACES
1--
L-j
'-----r
--1,---.
nIJ~V"EPCN/434
I
J,/
TYP, 2 Pll\CES
lUP MICRO
<RJGHT)
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N~lf
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L P,B
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LEVER
---0
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,-
fl
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lC
2/1/95
ROTATED l.B.
SEPARATED MICRO'S MTD

DOC
IN ~G HANDLE fUR
D EASIER WIRING
pI 19195
RDCI<ER-tlJ
12
"'f
DD
II(jtalrTlIIII
lIP.
-t~2~O~AII~G4.:::.6__.;.;/,.!:2--I--.,!S~I..::c-C;...__1_....;l!..!iB~-.!.I_l
001
<D
(AUX)
<REV)
'---:I{:~(DClD
00
(FUD)-
~-
- STAMP
D1D
(LEFT>
'----'1"'----4lt(DCID
(RtGHf>
'------Himml
<24V)
t----1'------/l'----HK
~.~J
STAMP
\
-
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,. J lH H't utI I N',ERT
OWNERS MANUAL
24 Volt
Fully Automatic
Battery
Charger
Model 17970
Specifications:
ACSupply
DC Output
Battery Specifications
120 Volts
8 Amps
60 Hertz
Single-Phase
24 Volts
25 Amps Tapering
to 8 amps
Use only on 24 volt. 12 cell.

series connected wet lead
acid systems. 180-305
ampere-hour (20 hr. rate)
oIkteiv-1v-ElectriCa!
625 West A St.
Lincoln, NE 68522
USA
)
F01532 A
SAVE THESE IMPORTANT INSTRUCTIONS

READ AND FAMILIARIZE YOURSELF WITH THIS ENTIBE MANUAL BEFORE INSTALUNG OR OPERATING THE
-~C.HARGER. FOLLOW ALL INSTRUCTIONS ON THE BATTERY CHARGER, AND BATTERY POWERED EQUIp
pENT. THIS MANUAL CONTAINS IMPORTANT SAFETY AND OPERATING INSTRUCTIONS FOR THIS BATTERY
. CHARGER.
LOOK FOR THIS SYMBOL TO POINT OUT SAFETY PRECAUTIONS. IT MEANS BECOME ALERT YOUR
SAFETY IS INVOLVED. IF YOU DO NOT FOLLOW THESE SAFETY INSTRUCTION, PERSONAL INJURY OR
PROPERTY DAMAGE CAN OCCUR. SAVE THESE IMPORTANT INSTRUCTIONS.
to ensure superior battery performance and life. A patented
electronic circuit turns the charger on and off automatically.
When the battery has reached its maximum state of charge,
the circuitry will turn the charger off.
IMPORTANT SAFETY INSTRUCTIONS

1. SAVE THESE INSTRUCTIONS This manual contains
important safety and operating instructions for battery charger
Model 17970.
2. Before using battery charger. read all instructions and
cautionary markings on (1) battery charger. (2) battery, and
(3) product using battery.
CAUTION: TO REDUCE RISK OF INJURY, CHARGE ONLY
LIQUID ELECTROLYTE (WET) LEAD ACID RECHARGE
ABLE BATTERIES. OTHER TYPES OF BATTERIES MAY
BURST CAUSING PERSONAL INJURY AND DAMAGE.
RECEIVING AND INSTALLATION

When the charger is received, check for possible in transit
damage. If any damage is found, it should be reported as a claim
to the carrier.
Proper installation of the charger is important in order to

achieve good charger performance and to prevent damage
to the charger and batteries. The charger should be located
in a clean. cool. dry, and well ventilated area To permit free
air flow for convection cooling, allow three inches minimum
between the charger and any wall and six inches between
the charger and other equipment. Position the charger on a
foundation of stone, brick, concrete or grounded metal.
DANGER: TO REDUCE THE RISK OF FIRE. DO NOT USE
THE CHARGER NEAR FLAMMABLE MATERIALS OR
VAPORS.
3. Do not expose charger to rain or snow.

4. Use ot an attachment not recommended or sold by the
battery charger manufacturer may result in a risk of fire,
electric shock, or injury to persons.
S. To reduce risk of damage to electric plug and cord, pull by
plug rather than cord when disconnecting charger.
Make sure cord is located so that it will not be stepped on,
tripped over, or otherwise subjected to damage or stress.
An extension cord should not be used unless absolutely
necessary. Use of improper extension cord could result in a
risk of fire and electric shock. If extension cord must be
used, make sure:
a. Pins on plug of extension cord are the same number,
size, and shape as those of plug on charger
b. Extension cord is properly wired and in good electrical
condition.
c. Wire size is large enough for ac ampere rating of charger.
S. Do not operate charger with damaged cord or plug - replace
it immediately.
9. Do not operate charger if it has received a sharp blow. been
dropped, or otherwise damaged in any way; take it to a
qualified service center.
10. Do not disassemble charger; take it to a qualified service
center when service or repair is required. Incorrect
reassembly may result in a risk cif electric shock or fire.
11. To reduce risk of electric shock, unplug charger from a live
outlet or disconnect AC power to the outlet betore
attempting any maintenance or cleaning. Turning off
controls will not reduce this risk.
j ".
AC INPUT AND GROUNDING INSTRUCTIONS
A CAUTION: TO REDUCE RISK OF ELECTRIC SHOCK
OR FIRE, DISCONNECT POWER TO RECEPTACLE

BEFORE INSTALLING OR REMOVING UNIT.
This battery charger must be connected to a 120 Vac. 60
hertz, 1 phase AC power source which is properly
installed and grounded in accordance with the National
Electrical Code (U.S.) and all local codes and ordinances.
GROUNDING INSTRUCTIONS Charger should be

grounded to reduce risk of electric shock. Charger is
equipped with an electric cord having an
equipment-grounding conductor. The installed plug must be
plugged into an outlet that is properly installed and grounded
in accordance with all local codes and ordinances.
DANGER: NEVER AlTER AC CORD OR PLUG IF IT

WILL NOT FIT OUTLET. HAVE A PROPER OUTLET
INSTAlleD BY A QUAUFIED ELECTRICIAN. IMPROPER CONNECTION CAN RESULT IN A RISK OF
AN ELECTRIC SHOCK.
-A-
INTRODUCTION
COIIeROF~~
"-
This battery charger is a self-regulating charger with a minimum

of moving parts, designed for long, trouble free service. Built-in
,ne voltage compensation produces a consistent output when
~e AC supply voltage varies by as much a 10% from nominal.
. Convection cooling maximizes the reliability and minimizes any
maintenance costs. ONLY LIQUID ELECTROLYTE (WET)
LEAD ACID BATTERIES should be recharged with this charger
-2-
-C-
-8-
j(i)"l
ADAPTER
6:1 ~
~~I~"'~. 'i' l~i~

'Zl
GROUND
GROUNDING
IoIEAHS
OF CIROUNOED
0U1l.ET BOX
lII.ADe GADUNDED
oun.ET
NOTE: Use of an adapter shown in figures B and C is not

permitted in Canada.
This banery charger is for use on a nommai 120 volt circuit and
has a grounding plug, which looks like the adapter Iilustrated in
figure A. A temporary adapter, which looks like the adapter
illustrated in figures Band C. may be used to connect this piug
~l a two-pole receptacle as shown in figure B if a properly
. grounded outlet is not available. The temporary adapter should
be used only until a properly grounded outlet can be installed by
a qualified electrician.
4. Monitor the ammeter for correct charge current. The

initial charge current should range between
approximately 25 amps. If the batteries have not been
discharged. or the AC supply voltage is lower than 120
volts. the initial charge rate may be less. If the batteries
have been excessively discharged, or AC supply
voltage is higher than 120 volts. the initial charge rate
may be more than 25 amps.
5. Charge current will gradually taper to approximately 8
amps depending on the age and condition of the
batteries. Charger turns off automatically and the
"CHARGE COMPLETEff light will glow when battery is
fully charged. Charge time varies with battery size and
depth of discharge. Allow 12-14 hours for normal
charging. Severely discharged batteries may require
more time to be properly charged and equalized.
6. After the charger has turned off. disconnect the DC
output plug from the battery (if required) and the AC
supply cord from outlet.
A DANGER: BEFORE USING ADAPTER AS ILLUSTRATED.

BE CERTAIN THE CENTER SCREW OF OUTLET PANEL
PLATE IS GROUNDED.
The green-colored rigid ear or lug extending from adapter must
be connected to a properly grounded outlet. If necessary, replace
original outlet cover plate screw with a longer screw that will
secure adapter ear or lug to outlet cover plate and make ground
connection to grounded outlet.
EXTENSION CORD REQUIREMENTS

Always use a three conductor No. 14 AWG (1.5mm) heavy duty
cord with ground, properly wired, in good electrical condition and
keep it as short as possible. Make sure the pins on the plug of
the extension cord are the same number. size and shape as the
AC plug of the battery charger. The use of an improper extension
cord could result in a risk of fire or electric shock. Locate all cords
so they will not be stepped on, tripped over or otherwise
subjected to damage or stress.
MAINTENANCE INSTRUCTIONS
The battery charger requires minimal maintenance. It should
be kept clean and all connections are to be tightly secured.
In the event of intermittent operation, examine and tighten. if
necessary. all connections. BE SURE THE CHASSIS IS
SECURELY GROUNDED. If any problems cannot be
resolved consult a qualified service center.
DC OUTPUT
This battery charger is designed to produce a 24 volt dc output
'with an initial charge current of 25 amps. ONLY 24 VOLT. 12
);ELL. SERIES CONNECTED. 180 TO 305 AMP-HOUR,
LIQUID-ELECTROLYTE (WET) LEAD-ACID BATTERIES
SHOULD BE USED. The charge current will decrease gradually
to about 8 amps as the battery reaches full charge and will remain
there until the charger turns off. As the battery ages the charge
current may no longer decrease to the 8 amp finish current. Liquid
electrolyte batteries will normally be charged to 2.5 volts per cell.
OPERATING INSTRUCTIONS
1. Connect AC supply cord to a properly grounded 120 volt, 60
hertz. single phase outlet.
2. Connect the DC output plug to batteries (if required). The
black wire must be connected to battery negative (-). and
the red or white wire to battery positive (+). Make sure all
connections are clean and tight.
3. The charger will start after a short delay as indicated by the
"CHARGING" light. transformer hum and the ammeter
movement.
WARNING: LEAD ACID BATTERIES GENERATE GASES
WHICH CAN BE EXPLOSIVE. CHARGE ONLY IN WELL VEN
TlLATED AREAS. DO NOT DISCONNECT CHARGER DC OUT
PUT TERMINALS FROM BATTERY WHEN CHARGER IS ON.
THE RESULTING ARCING AND BURNING COULD CAUSE
THE BATTERY TO EXPLODE. KEEP SPARKS, FLAME, AND
SMOKING MATERIALS AWAY FROM BATTERY.
If the charger must be stopped. always disconnect the AC

supply cord from its outlet before disconnecting the DC output
terminals from the battery.
-3-
Observe the following battery maintenance procedures to

obtain good performance and maximum cycle life.
1. Always observe the following personal safety
precautions when working with lead acid batteries:
a. Someone should be within range of your voice or
close enough to come to your aid when you work
near a battery.
b. Have plenty of fresh water and soap nearby in case
battery acid contacts skin. clothing or eyes.
c. Wear complete eye protection and clothing
protection. Avoid touching eyes while working near
battery.
d. If battery acid contacts skin or clothing. wash
immediately with soap and water. If acid enters eye.
immediately flood eye with running cold water for at
least ten minutes and get medical attention.
e. NEVER smoke or allow a spark or flame in the
vicinity of batteries.
f. Be extra cautious to reduce risk of dropping a metal
tool onto battery. It might spark or short-circuit battery
or other electrical part that may cause explosion.
g. Remove personal metal items such as rings.
bracelets. necklaces, and watches when working with
a lead acid battery. A lead acid battery can produce a
short-circuit current high enough to weld a ring or the
like to metal, causing a severe burn.
h. NEVER charge a frozen battery.
DANGER: TO REDUCE RISK OF ELECTRIC SHOCK,

ALWAYS DISCONNECT THE AC SUPPLY CORD FROM
ITS OUTLET AND THE DC OUTPUT CORD FROM THE
BATTERY BEFORE ATTEMPTING ANY MAINTENANCE
(CHANGING FUSES, ETC.) OR CLEANING OF THE BAT
TERY OR BATTERY CHARGER.
2. New batteries should be given a full charge before their

first use because it is difficult to know how long batteries
have been stored.
3. Limit use of new batteries for first five cycles. New batteries
are not capable of their rated output until they have been
discharged a number of times.
not excessively discharge batteries. Excessive
discharge can cause polarity reversal of individual cells
, resulting in complete failure shortly thereafter. Limited use
of new batteries will minimize the chance of cell reversal.
5. CHECK THE LEVEL OF THE ELECTROLYTE IN
CONVENTIONAL LIQUID ELECTROLYTE LEAD ACID
BAITERIES MONTHLY. MAINTAIN THE PROPER
ELECTROLYTE LEVEL BY ADDING DISTILLED OR
PURIFIED WATER WHEN NECESSARY. Electrolyte levels
lower during discharge and rise during charge. Therefore. it
is mandatory that water be added to cells ONLY when they
are fully charged - do not overfill. Old batteries require more
frequent additions of water than new batteries.
6. Keep tops of batteries clean and dry to prevent excessive
self discharge. Keep battery terminals reasonably tight.
clDO
4.
5.
6.
TROUBLE SHOOTING
7.
FOR SAFE AND EFFICIENT TROUBLE SHOOTING. READ

THIS TROUBLE SHOOTING GUIDE COMPLETELY BEFORE
BEGINNING ANY TESTS.
Ii.
CAUTION: DO NOT OPERATE THE CHARGER IF IT IS

DAMAGED OR APPEARS TO BE MALFUNCTIONING.
PERSONAL INJURY OR DAMAGE TO THE CHARGER OR
BATTERIES MAY RESULT. DO NOT DISASSEMBLE THE
CHARGER. TAKE IT TO A QUAUFJED SERVICE AGENT
WHEN SERVICE OR REPAIR IS REQUIRED. INCOR
RECT REASSEMBLY MAY RESULT IN A RISK OF ELEC
\
TRIC SHOCK OR FIRE.
~ determine if a charger malfunction eXists, eliminate the
problems not associated with the charger in the sections below.
If the problem can not be resolved, contact a qualified service
center.
1. CHARGER D0ES NOT TURN ON
a. Battery is not connected to charger.
b. Charger is not plugged into a live AC outlet.
WARNING: IF THE AC OR DC PLUG OR RECEPTACLE IS
BROKEN, TWISTED, BENT OR LOOSE AND DOES NOT
MAKE GOOD ELECTRICAL CONTACT, HAVE IT RE
PLACED BY QUAUFIED SERVICE PERSONNEL IMMEDIATEL Y. DO NOT USE THIS CHARGER IN THIS
CONDITION AS FIRE OR PERSONAL INJURY CAN RESULT_
Ii.
c. DC fuses blown.
2. CHARGER REMAINS AT HIGH RATE
a. The charger is connected to a battery pack with a system
voltage lower than specified.
b. Battery amp-hour capacity is greater than specified for
charger.
c. One or more of the batteries in the battery pack has
reversed polarity.
3. CHARGER TURNS OFF EARLY
a. The DC cord was accidentally disconnected from the
battery during charge.
b. The battery has been allowed to sulfate. Charge the
battery at least once every three days when the
)
equipment is lightly utilized. Once sulfation is allowed to
take place it may be partially reduced by returning,
temporarily, to daily charging.
-4-
c. AC circuit is not live (power outage or circuit breaKer

blownl.
CHARGER DOES NOT TURN OFF
a. The charger is connected to a battery with an
amp-hour capacity greater than specified.
b. The charger is connected to a battery pack with a
system voltage higher or lower than specified.
c. New batteries (5 cycles or less), cold batteries or over
discharged batteries may require an extended charge
time to achieve full charge.
CHARGER FUSE BLOWS (OR CIRCUIT BREAKER)
a. AC fuse blows when wrong AC power supply is used.
BUILDING AC LINE CIRCUIT BREAKER OR FUSE
BLOWS
a. A "weak" fuse or circuit breaker is protecting the
circuit. Connect the charger to another outlet on a
different circuit. If the charger operates properly, have
a qualified electrician inspect and test the Original
circuit.
b. The circuit is overloaded. Connect the charger to
another outlet on a different circuit.
EQUIPMENT RANGE DECREASING
a. The electrolyte level in conventional liquid electrolyte
lead-acid batteries was allowed to drop below the too
of the battery plates. Add distilled water to JUST
.
COVER THE TOPS OF THE PLATES immediately
upon discovery and fill to the proper level with
distilled water at the completion of the very next
charge cycle. Battery capacity lost in this manner is
permanent and is not recovered with additional
charge cycles.
b. Use of the equipment before the batteries have been
fully charged and the charger turns off. This shortens
battery life and hastens the onset of reduced daily
range. Battery capacity lost in this manner is
permanent and is not recovered with additional
charge cycles.
c. This is the normal wear out process for all types of
deep-cycle motive power batteries.
WIRING DIAGRAM
ELECTRONIC TIMER
block
red
green-
TRANSFORMER
red or
white
~----~--~~--~~
147
TO
BATTERIES
block
2
AMMETER
block
DIODE
ton
white
,120 Voc
INPUT
CAPACITOR
*Green wire not used

1~~_________-___o_n__s_o_m__e__m_o_d_e_ls___________________________________________________
PARTS LIST FOR LESTRONIC II CHARGER

MODEL 17970 TYPE 24LC2S-SET
120 VAC 60 Hz
PART NO,
DESCRIPTION
232788
161058
16354S
163698
183208
023908
020288
232828
08776S
043288
CA8E A88EMBLY
TRANSFORMER ASSEMBLY
HEATSINKASSEMBLY, WITH DIODES
AMMETER
ELECTRONIC TIMER ASSEMBLY
CAPACITOR, 6.0 MFD, 660 VAC
BUSHING, 7W-2, IN8ULATOR FOR CORDSET
CORDSET, DC, 75", NO PLUG
FUSE ASEMBLY
AC RECEPTACLE
)
-5-
Limited Warrantv
.
Lester Electrical warrants each new Lester Battery Charger for defects in material and workmanship for a period
of two years from the date of manufacture of the complete unit. Repairs can be made at the Lester factory. To
do so send the defective unit with transportation charges prepaid to:
Lester Electrical
625 West "An Street
Lincoln, NE 68522 U.S.A.
Attention: Repair Department
For repairs made at other than the Lester factory, Lester will provide only the replacement parts. Defective parts
should be sent with transportation charges prepaid to the Lester factory at the previously mentioned address.
If the"unit or parts are found in the reasonable judgment of Lester to be defective in material or workmanship,
repair, or replacement will be made by Lester without charge for parts or labor. Repair or replacement will be
at the discretion of Lester, with replacements being made using current models or parts performing the equivalent
function. Labor charges other than those incurred at the Lester factory are not covered under this warranty. All
expenses associated with delivering defective items to the Lester factory and the expense of returning repaired
or replaced items from the Lester factory to the owner will be paid for by the owner. All warranty work
accomplished at the Lester factory will be completed within a reasonable time after receipt of defective items.
This warranty does not cover any semiconductor parts, such as diodes, which are vulnerable to electrical
overloads beyond the control of Lester. Warranty on parts not manufactured by Lester, which include, but are
not limited to, timers and ammeters is limited to the period specified in the original manufacturer's warranty.
This warranty does not cover any charger that has been subject to misuse, neglect, negligence, or accident, or
operated in any way contrary to instructions speCified on the charger case and in the owner's manual. No claim
of breach of warranty shall be cause for cancellation of the contract of sale of any Lester charger. Lester
assumes no responsibility for loss of time, inconvenience, or other damage, consequential or otherwise, resulting
from a defective charger. All implied warranties (including merchantability) are limited in duration to the two
years from date of manufacture warranty period.
Some states do not allow the exclusion or limitation of incidental or consequential damages: or limitations on
how long an implied warranty lasts, so the above limitations may not apply to you. This warranty gives you
specific legal rights, and you may also have other rights which vary from state to state.
Lester's obligation under this warranty is strictly and exclusively limited to the repair or replacement of defective
items. Lester issues this warranty in good faith and with full confidence in the workmanship and quality of Lester
products.
-6-
c~
OPEN CIRCUIT TRANSFORMER TEST

Failure of the transformer can be the result of natural aqinq
)
. premature shorting of adjacent coil turns or overheating damage. The most
common cause of transformer overheating and premature burn-out is the
result of misuse. connecting the charger to a battery system of lower
voltage than specified on the charger. Darkening of all the transformer
secondary coil windings is an indication of possible overheating damage.
! DANGER
HIGH VOLTAGE; With the charger operating, the charger capacitor

voltage can be as high as 660 Volts AC. Use extreme caution
when working near the capacitor terminals.
To test transformers used in chargers of different output voltages

than 36 Volt as covered in manual, Form 00910, the transformer coil AC
voltages are:
Charger
Nameplate
Vol t,:!qe
VDC
Number of
Lead-Acid
Battery Cells
in Series
VN
-)
No Load Open Circuit

Transformer Secondary Coil
e~_I~i_~Qli~g~~
Resonant
Capacitor
Connected
...,...,.
______________________ _
Resonant
Capacitor
Disconnected
'.)2 = '.)1 X 2/3
-'-'
~~
17 to ....._.
12
54 to 66
36 to 44
36
18
83 to 97
55 to 65
48
24
110 to 130
73 to 97
12
24
..:.,/
to
...,~
Use the equations to calculate approximate test voltages for other

systems.
The readings are approximate and transformer failure is indicated
when measured voltages are significantly lower than those calculated in
the table. DC voltages measured at the charging leads are about 1/2 the
transformer test voltage amounts.
Transformer secondary voltage measurements made with the resonant
capacitor connected can occasionally result in noticeably higher readings
than expected. No-load transformer instabilities and peculiar wave shapes
can increase these voltage readings. This is particularly true when using
digital meters, as several models get confused with other than pure sine
wave AC or pure ripple-~ree DC.
PROPER CARE OF MOTIVE POWER BATTERIES

Motive power battenes are suclectea to severe deep
cycte duty on a dally basIs. Althougn these oattenes are
designed to Withstand SUCr1 duty the following precautions must be observed to cctaln 0000 certormance ana'
maximum cycle life.
A CAUTION: Always wear protective eye shields and
clothing when working with batteries.
Batteries contain acids which can cause
bodily harm. Do not put wrenches or
other metal objects across the battery
terminal or battery top. ArCing or explosion of the battery can result.
,. When installing new batteries be sure the polarity of
each battery and overall oatterl paCK is correc:. Due
to the electrlcai cl1arac!enstics at this charger it is
possible to improperiy hook uo the batteries and not
blow the fuse wnen charging. 8attery ana/or charger
damage can result
2. New batteries should be given a full charge before
their first use because it is difficult to know how long
the batteries have been stereo.
3. Umit the use at new batteries for the first 20 cycles.
New batteries and oleer battenes that have been in
storage are not cacable aT their rated outcut until they
have been discharged ana chargeo a number oltimes.
5.
6.
7.
8.
4. Sulfation results when batteries in storage are not
maintained in a charged ac:ive state. Internal self discharge can bring about the start at thIS condition in as
little as three days in warm temperatures. Batteries
9.
atlowea to Sit unmatnralned in storage selt discharge.

suttate to vanous degrees ana lose caoaclty.
Reoeatea charging 'Hlil generally result in the recovery oi most oi the oatterys capaCity. though some
permanent loss can be exCected.
DO NOT EXCESSiVELY OISC;;ARGE THE BATTE;='IES. Excessive disc~arge can cause polarity reversai
of individual cells resuiting 10 complete failure shortly
thereatter. Heavily discharging (Over 60%) new batteries before they have been broken in (approximately 20
cycles) can cause permanent cell damage. resulting in
reduced energy capacity and shortened life.
Maintain the proper electrolyte level by adding water
when necessary. Never allow the electrolyte level to
fall below the top of the battery plates. Electrolyte levels fall during discnarge and rise during charge.
Therefore. to prevent the overilow of electrOlyte when
charging. it is mancatory that water be added to cells
AFTE;=' they have been fully charged. DO NOT OVERFILL Old batteries reouire more frequent additions of
water than dO new batteries.
When the temperature falls below 65 degrees F. the
battenes should be piaced on charge as soon atter
use as pOSSible. Cold battenes require more time to
fully recnarge.
The toes of the battenes and battery hold-downs must
be kept clean ana cr'.' at all times to orevent excessive
self discharge ana :Iow of current between the battery
posts ana frame.
Follow all operatinc instructions. cautions. and warnings as specified in ~hjs manual. on the charger. and
in your vehicle owners manual.
TROUBLE SHOOTING GUIDE

TO BE ABLE TO USE THE TROUBLE SHOOTING GUIDE SAFELY AND EFFECTIVELY IT IS IMPORTANT TO READ THIS
GUICE COMPLETELY BEFORE BEGINNING ANY TESTS.
~ CAUTION: REPAIRS BY QUALIFIED PERSONNEL
A DANGER: HIGH VOLTAGE - With the charger on.

the internal charger capacitor voltage is
ONLY. NOTE: Modifying this charger for
approximately 650 volts.
use other than that tor which it was
intended. repairs by persons not qualified, or not using original equipment
A CAUTION: ALWAYS UNPLUG THE ELECTRICAL
replacement parts will void the warranty
CORDS FROM THE AC OUTLET AND
and Lester liability.
THE BATTERIES BEFORE ATTEMPTING
ANY REPAIRS TO THE CHARGER.
~ CAUTION: DO NOT DISASSEMBLE THE CHARGER.
TAKE IT TO A QUALIFIED SERVICEMAN
WHEN SERVICE OR REPAIR IS
AWARNING: Do not operate the charger if it is malREQUIRED. Incorrect assembly may
functioning. Personal injury or property
result in a risk of electric shock or fire.
damage could result.
The Lestronic II battery charger is a reliable. automatic charger designed for long, trouble-free service. If a malfunction
should develop. identify the symptom and follow the associated test procedures.
MALFUNCTION SYMPTOM
SECTION
CHARGER DOES NOi iURN ON
A. Relay does not Close. No Tra:1sformer
Hum and Ammeter Does Not Register.
B. Relay Closes But No Transformer Hum
and Ammeter Does Not Register.
C. Relay Closes and Transformer Hums
But Ammeter Does Not Register.
D. E!ectronic iimer Kit Replacement
Instructions.
CHARGER FUSE BLOWS

A. Single Fuse Link Blows
B. Both Fuse Links Blow
SECTION
3
AMMETER i1EADS 30 AMPS FOR MORE
THAN 30 MINUTES
4
CHARGER OUTPUT IS LOW
CHARGER TURN OFF MALFUNCTIONS

A. Charger Turns Off Too Soon.
B. Charger Does Not Turn Off.
C. Charger Runs Too Long But Does Turn
Off.
AC LINE FUSE OR CIRCUIT BREAKER

BLOWS
TRANSFORMER SHORT OR BURN-OUT
SECTION 1 -
CHARGER DOES NOT TURN ON

~~arge!" CC OUIcut connecter
must ce ::,,::ec::-:: to :r.e :::atter!es !n crcer to turn tne
charger cn ...!. :Ime -:e!ay oi 2 :a 5 seconas is crovlded to
ailow acec:.;a:e :ir.":e :0 maKe 3 sec:.;re connection ceiore
the c~ar;er :L;r~s ~n. ;".i~er tnlS ame ae!ay the power
relay c:cses 3::: an 3Lc:::::e c::c:< should be heara.
When :r.e re!ay ::oses. ;"C ccwer IS s<.Jcciied to the transformer :::r:r..c,! c:::::. !f cceratlng :::r-:ceriy tt1e transformer
snoulc ~t..~ 3::: :t:e 5mr."!e!er sr.cwc Inclcate rne charge
rate. If :~e :.-2.,;::: ::::es ~c: ::..;rr: cn oroceny reier to Part
A. a or C rer seec::lc :es, or:::cec:Jres.
:n normal -:cerar::n :r:e
PART A -
RELAY DOES NOT CLOSE. NO TRANSFORMER HUM AND AMMETER DOES NOT
REGISTER.
CheCK to ce sure !he oower sueeiy cord is securely connec~ec to a iive oL;tlet CheCK the DC auteut connector
ana the batter! c::::lnec~or tor damage. dirt or corrosion
that wouid prevent a gooo e!ec!rlcal connection.
WARNING: 11 the plug or receptacle is broken.

twisted. bent or loose and does not
make good electrical contact. have it
replar:ed by a qualified serviceman
immediately. DO NOT USE THIS
CHARGER IN THIS CONDITION AS
FiRE OR PERSONAL INJURY CAN
RESULT.
Then cisocnnec::ne Dower sueciv cord from its outlet.
With tlie DC .Jutcet connec~or stl1I connec~ed to the battery connecter. measure the vOltage at the battery connec:or uSing a suitaoie DC voitmeter as snown in Figure 1.
The Eiectronlc Timer Kit may be bypassed in order to

veriiy that a malfunction eXists. First disconnect the
cnarger cower SUCCIY cord from its outlet ana the DC
output connector irom the batter! connector. Place a
Jumper wire oetween terminals #1 and #3 to bypass the
E:ec:ronlc Ti~er Kit as snown In Figure 2 and Figures 6
and 7.
The power sucety cord is now connected directly to the
primary transl0rmer coil ana the transformer should hum
when the power sueeiy cord is connected to a live outlet.
The charger oeeration may be checked by first connec~
ing the DC outout connec~or to the battery connector. anc
then connec:mg the power supply cord to an outlet If
normal cnarging current is indicated on the ammeter the
ElectrOniC Timer Kit :s detective and must be replaced.
CAUTION: DO NOT charge batteries with the Electronic Timer Kit bypassed. The charger
will remain on as long as the power
supply cord is connected to an outlet.
Severe overcharging and eventual damage to batteries will result.
If the transformer does not hum and the ammeter still
does not register with the Electronic Timer Kit bypassea.
a continuity cneck of the cnarger AC circuit is necessary.
Disconnect me power suoeiy cora from Its outlet and the
DC output connec:or irom the battery connector and.
With a sUltaole continUity tester. cneck the circuit across
the power sueeiy cord prongs as snown in Figure 2.
With the Elec~onic Timer Kit bypassed. the CIRCUIT
SHOULD BE COMPLETE.. If the Circuit is not comolete.
Individually check the continuity of the power SUPPlY
cord. primary transformer coil and all connections.
PART B -
FIGURE 1
Battery DC Voltage Test
RELAY CLOSES BUT NO TRANSFORMER

HUM AND AMMETER DOES NOT REGISTER
Check to be sure the power supply cord is securely connected to a live AC outlet. When three-prong to twoprong adapters are used. they tend to work loose resulting in a poor connection. Check the AC line fuse or
circuit breaker and. if possible. measure the AC line voltage at the outlet to be sure AC power is present. If
necessary connect a functioning c!1arger. utility light. or
other electrical appliance to the outlet to verify the presence of AC power.
If AC power is present. disconnect the power supply
cord from its outlet and the DC output connector from
tne battery connector. Bypass the Electrontc Timer Kit as
described in Section 1. Part A. and with a suitable continuity tester check the circuit across the power supply
cord prongs as shown in Figure 2. With the Electronic
The voltage reading shOuld be the same as the battery

terminal voltage and must be between 24 and 50 volts DC
in order to c:ose the relay. If the DC voltage is within the
above limits. remove the charger cover and verify thatthe
charger is properly wired and you read the same voltage
(24 to 50 Vec: insJ(:;e the charger wnere the white and
black wires of ~he DC core attacn. (Fig. 4 and wiring
diagram Fig. 8.; If the battery DC voltage measured inside
the charger is now below the above limits or not present
the DC plug or corcset has an internal break and must be
replaced. If the c:larger is wired correctly and a satisfactory battery DC voltage is measured inside the charger. a
malfunction in the Electronic Timer Kit has probably
occurred. Due to its complexity. do not attempt to make
field repairs to any part of the E!ectronic Timer Kit If a
malfunction eXists. simaiv remove-the entire Electronic
Timer Kit and repiace it 'with a new one. Refer to Part
D-"E!ectronlc Timer Kit Replacement"-for correct
procedure.
FIGURE 2
Charger AC Circuit Continuity Test
(Transformer removed for clarity)
-)
Timer Kit bvoasseo. the CIRCUIT SHOUl!) BE CC:"l?LET2. if the Circuit IS comCle,e. re!er to :ne wlrlnc =Iagram In Figure a. ana c~ec:-< :r.e relay wiring ane all
connections. If tne ClrCUlt is net comOle!e. cnecl< tne wiring ot the cower suooiy core. trans:ormer pnmarf cOil
leaas ana the EiectronJc Timer r<it. if the cnarger IS wlrea
correC:ly. inaivldually cneci< :r:e c::~~nUlty oi the cewer
sue ply cord. transformer primary COil and relay.
connector. ana checl< the charger fuse. If a fuse link is

Olown. reier to SectIon 2 - "Charger Fuse Slows" for
:urtner tests. If tt1e fuse cnecks gooo. use a low voltage
continUity tester to penorm the following tests:
1. Connect the tester leads to the Charger DC output
connector as snown in Figure 3. and note the reaaIng. Reverse the tester leads and check the output
connector again. The circuit should be complete In
oniy one direction. If the circuit does not conduct in
t!!lher cirection ana the fuse is good. individuaily
cneCK the continUIty of the DC output cord. ammeter.
diOdes. and ail connections. If the circuit conducts in
beth direc!lons. a "short" exists in the Charger DC
CirCUIt First Check the DC output cord tor a "short"
between the two wires. It is more likely ttlat one or
both diodes have "shorted." Refer to Section 2 "Charger Fuse Slows' for continuity test at diodes.
PART C -
RELAY CLOSES AND TRANSFORMER HUMS

BUT AMMETER DCES NOT REGISTER
If the relav c!oses ana the transiormer nums. the cnarcer
AC cirCUit and E:ectronlc Timer Kit are functioning prcoeny. If the ammeter does ne: regiSter. a fault in the
charger DC cirCUit eXists ane a continUity cnecl< must Oe
performea. Disconnect the power suepty core trom Its
Qutle! ana the DC output co~nec:or from the bar:ery
2. If the charger DC circuit test is good. a check of the

capacitor is necessary. Disconnect the power supply
cord from its outlet ana the DC output connector trom
the battery connector. Then disconnect both transformer coil leads from the capacitor terminals. Use
care when disconnecting the capacItor leads so the
wires dO not breal<. Using an ohmmeter. set the scale
to R X 10K ohms and test the capacitor as follows:
GOOD CAPACITOR-When the ohmmeter leacs
are connected to the capacitor terminals. the meter
needle jumps to mid-scaie
and rapidly moves to high
resistance (x).
FIGURE 3
Charger DC C.jntinuity Test
)
CAPAcrroR COIl.
(SecONOAAY COlI.
PRIMARY COIl.
UNDERNE.O.THI
SLACK WIRE --~

OF DC CORD
__l-~~~~~~~~~1.
~"r.:>"-
FIGURE 4
Electronic TImer. Kit Wiring
.~...:.. KIT
OPEN CAPAC:TOR-When me onmme!er leads

are cennec!eO to the capacitor terminals. the meter
neeole does not move ana
stays at nlgn resistance (xl.
A bulge In the toe of the
capac:ter may be visible if
the cacacltor has failed
"Open'"
SHORTED CAPAClTOR-When tl1e ohmmeter leads
are connected to the capacitor terminals. the meter
neeale jumps immediately
to zero ohms and remains
there.
If the capacitor is "Open" or "Shorted" it must be
reolaced.
C~UTION: Use only a 6 Mfd. 660 volt AC rated
capaCitor for replacement (Part No.

02390S1. The use of a different value
capaCitor may result in improper charging, capacitor failure. transformer burnout. and/or battery damage.
3. If ~he charger DC circuit and capacitor check good. a
test of the transformer is necessary. Refer to Section
i - "Transtormer Short or Burn-Out" for test proceat.:res.
PART D - ELECTRONIC TIMER KIT REPLACEMENT

The E:ectronlc Timer Kit should alwavs be replaced as a
complete assemcly. The tools reauired are a Phillips
head screwdriver. 3/8" and" 132" wrenches. and pliers. No soldering is required. To replace the kit follow the
step-by-step procedures listea below.
.
1. Disconnect the charger power sucply cord from its
outlet and the DC output connector from the battery
connector. and remove the charger cover.
2. Disconnect the green. black. and red wires of the
Electronic TImer Kit as shown in Figure 4. Then
remove the black and white leads of the power
supply cord and both primary transformer coil leads
from the Eiec:ronic Timer Kit terminal tabs. The Kit
can be removed by removing the three mounting
screws on the Charger front panel. Save ail hardware
for reassemcly.
3. Install the replacement Electronic Timer Kit by reversing the disassembly procedures described in Step 2.
When reconnecting the wires to the Electronic TImer
Kit terminal tabs support the terminal board to prevent damage to the electronic circuit board. Connect
FIGURE 5
Diode Continuity Test
either transformer ;Jrimarv lead to terminal #2. ar.a

the remaining ;Jnmary iead to terminal #3.
Connect :he OlacK leaa of the oower sue Ply cord te
termInal ~, on the ::ectrenic Timer Kit and the whIte
leac of the power sucely cord to terminal #2.
Connec! tl1e red wire of the E!ectronic Timer Kit along
With tl1e wnlte leac of the DC cora to the Heat SinK
Assemelv. Connec: the black wire at the Eiectronlc
Timer Kit along With the black leaa of the DC cord :0
the ammeter post. 00 not allow the ammeter post to
turn when tigntenmg the nut. Reconnect the green
wire of the Electronic Timer Kit along with the transformer seconcary !ead to the diode lead terminal.
A CAUTION: Be sure all connections are clean and
tight. Also check to be sure all wires and
terminals are positioned so they do not
short together or to the charger case.
4. Reelace the charger cover and cneck the Electronic
Timer Kit for proper operation as follows:
a. With the DC outout connector disconnected from
the battery connector. insert the power suecly
cord intO an outlet. The relav on the ElectrOnic
Timer Kit shouid not close. A DC voltmeter c:::nnec:ed across the DC output connector Should
indicate zero VOltS.
b. Disconnect tne power sueply cord from its outlet
ana connect the DC outeut connecter to the battery connector. The relay on the Electronic Timer
Kit shouid close with an audible "click" after a twO
to five second delay.
c. If the Electronic Timer Kit does not ocerate as (a)
and (b) above. reter to the wiring diagram in Figure
8 and check to be sure the charger is wired correctly. If the Electronic Timer Kit operates property.
the charger is ready for use. Always monitor the
first charge cycle to verify that the charger is turning off properly.
SECTION 2 - CHARGER FUSE BLOWS
The charger fuse ass em ely consists of a dual element fuse
link under a transparent cover mounted on the charger front
panel. Each fuse element is electrically connected in series
with a recnfier diode to provide protection for the transformer
in the event of a diode faiiure. Visually inpsect and electncaily
test the fuse to determine it one or both fuse links are blown
and refer to Pan A or Pan 8 for test procedures. LOCATE
AND CORRECT CAUSE OF TROUBLE BEFORE REPLACING BLOWN FUSE. DO NOT attempt to repair the fuse link
as inadequate protection wiil result
PART A - SINGLE FUSE LINK BLOWS
This condition is normaily caused by a shan circuit failure of one diode. The fuse link wiil blow when the
charger DC output connector is connected to the battery
connector. regardless of whether the power supply cord
is connected to an outlet To check the diodes. disconnect the power supply cord from its outlet and the DC
output connector from the battery connector. and then
disconnect one transformer secondary coil lead tram the
diode terminal. Using a low voltage continuity tester.
connect one tester lead to the diode mounting plate and
the other tester lead to a diode terminal as shown in
Figure 5.
Note the reading and then reverse the tester leads and
check each diode again. If a diode conducts current in
both directions. it is "shorted" and the complete Heat
Sink Assembly with Diodes (Part No. 096535) must be
replaced.
On rare occasions a slngie fuse linK mav melt due to

excessive neat. This can oe causea bv a ioose Internal
fuse connection. ChecK all :hree iuse connections Inside.
:he charger to be sure they are Clean and tight. The
proper torque on the fuse connector nuts is 20 InchPounas (23 Cm-Kg).
PART B - BOTH FUSE LINKS BLOW

This is normally caused l:ly a reverse oolarlty connection
between tne c!1arger DC cutout connector and the battery connector. ChecK the oatter/ pack anc oattery connector to be sure they are wired In the correct polarity. If
possible checK the voltage and polanty at the battery
connector with a DC voltmeter. Also. check the cnarger
DC outout connector for the correct polarity. The white
wire ShOUld be connected to the pOSitive (-+oj contact. and
the black wire to the negative H contact. If a reverse
pOlarity connection is mace between the charger ana
battenes. both fuse linKs wlil blow regardless of whether
the power supply cora is connectea to an outlet
AnOther cause for both fuse links blowing is the short
ClrC:.!lt failure of both diodes. Although this is rare. it may
occ:.!r as the result of a lightning stnke at the charging
location. ExceSSive heat due to a loose connectlon may
also cause both fuse links to melt. Refer to Part A "Single Fuse LlOk Blows" for trouole-shOoting procedures.
SECTION 3 - AMMETER READS 30 AMPS FOR MORE
THAN 30 MINUTES
This high outout condition is caused by misuse. connecting
the charger to an incorree: battery system whiCh is lower than
36 vOits. A common error is to instail one or more of the 6 volt
batteries in a 36 volt battery paCK reverse polarity. Using a
suitaole DC voltmeter test to be sure all batteries in a battery
pack are correctly wired. and also test the battery pack voltage at the charging connector. After charging for 30 minutes
at this excessive rate the measured on charge voltage should
rise to 34 to 38 volts DC for a 36 voit system. Voltage measurements_ while Charging, lower than this indicate an incorrect
or failed battery paCK that must be corrected betore using the
charger.
& CAUTION: DO NOT connect the charger to battery
packs which are not 36 volt systems_ This
misuse will cause overheating and transformer bum-out will result.
SECTION 4 - CHARGER OUTPUT IS LOW
The most probable cause of low output is a single fuse
link blowing as the result of a short circuit failure of one
diode. Refer to Section 2 - "Charger Fuse Blows" for
trouble-shooting procedures. On rare occasions a short
circuit failure of the transformer coils may cause the output to be low. Refer to Section 7 - "Transformer Short or
Burn-Out" for test procedures.
& CAUTION: Do not use Ihe charger if the output is

low. Batteries will not reach full charge.
thereby increasing the possibility of a
harmful deep discharge during their next
use.
SECTION 5 -
CHARGER TURN OFF MALFUNCTIONS
The Electronic Timer Kit turns the charger off as well as

on. Proper charge time is determined by many factors,
but the main elements are: (1) Battery size. (2) Depth of
battery discharge. and (3) Finish charge rate. Large
severely discharged batteries require more time to reach
full charge than do smaller lightly discharged batteries.
The charge rate. as indicated by current flow in amperes
on the panel meter. is controlled by the batteries' riSing
voltage during charge. The higher the on charge voltage
wlil rise. the lower the iinlsh charge rate wlil be beiore
the Electronic Timer terminates cnarglng.
The following timer malfunctions are occasionally due
to factors other than the charger's pertormance. To heip
isolate the problem it is often necessary to use Ihe
charger on a diHerent set of batteries and the original
set of batteries on another charger.
PART A - CHARGER TURNS OFF TOO SOON
Check to oe sure the oower suoely cord is securely connected to a live outlet. ii the power suoply outlet is live
proceed with the next step.
To determine if the charger did shut off too soon. disconnect and reconnect the cnarger D.C. outcut connector.
This Will restart the charger. Observe cnarger output on
the ammeter.
1. The ammeter needle jumos smartly to between 20
and 25 amos and then tapers below 14 amps within
15 minutes. This indicates that the battenes were truiy
charged. The apoarent short charging time is in
response to the batteries' ability to accept charge and
the electronic timer is pertorming properly.
2. The ammeter needle jumps smartly to between 20 and
25 amps. but does not taper below 14 amps within 15
minutes. It the battenes have been properly maintained and chargee regularly, this generaily indicates
that the batteries were not fully cnargea. If possibie.
use a hydrometer to check the specific gravity of several battery cells. If !he specific gravity readings are
more than 30 poims (.030) lower than normal full
charge readings. the electronic timer has malfunctioned and the complete Electronic TImer Kit must be
rep lac ea. Refer to Section 1. Part D-"Electronic
TImer Kit Replacement." for correct procedure.
If the batteries have not been used or charged regularly. they may be sulfated and will not produce their
full capacity. Repeated cycles (at least 5) of a light
discharge followed by a full charge will generally
result in the recovery of most of the battery's capacity.
Do not interpret this reduced battery capacity as being
caused by the charger turning off too soon. The
charger is working properly if. after several charge
cycles. the battery caoacity increases to near normal.
Sulfation occurs most often when the batteries have
been stored without weekly charging. New batteries
may also be sulfated due to extended shipment or
storage time prior to sale.
As batteries age. individual cells may weaken causing
a reduction in battery capacity. This condition normally resuits in a finish charge rate higher than 10
amps and less time is required to fully charge the
batteries. Do not interpret this shorter charging time
and reduced battery capacity as being caused by the
charger turning off too soon. The battery is aging
naturally and the charger is working properly. When
the batteries will no longer pertorm as required they
should be replaced.
PART B - CHARGER DOES NOT TURN OFF
New batteries with ali good celis should rise to at least
2.5 volts per cell. This will allow the finish charge rate to
taper below 8 amperes. As batteries age individual cells
may weaken and these cells may not reach 2.5 volts.
This will result in finish charge rates greater tha~ 8
amperes. and less time will be required for the batteries
to reach fuil charge. At a finish charge rate of 8 amperes
or less the charge time should not exceed 18 hours. At a
finish charge rate greater than 8 amperes the charge
time should ,not exceed 14 hours.
_._"_.'-
'
.. :
...
If the cnarger remains on longer than the scecliied maximum time. cneck to see it the charger turns on immediately when the D.C. output cord is connected without
the normal two to five secono delay. If the charger turns
on instantly without the two to five second delay the .
Electronic Timer Kit has probably failed. This type of malfunction generally results in the charger not turning off
and the compiete Electronic Timer Kit must be reolaced.
Refer to Section 1. Part D - "E!ectronic TImer Kit
Replacement." for correct procedures.
If the charger remains on longer than the maximum time
specified and the two to five second delay is present.
verify that the green wire from the Electronic Timer Kit
and the secondary transformer coil lead are securely
connected to the diode lead as shown in Figure 4. The
charger will NOT turn off if the green wire is loose or
disconnected. If the green wire is securely connected.
the E:ectronic Timer has malfunctioned and the complete Eiectronic Timer Kit must be replaced.
If a precision digital type D.C. voltmeter is available. a
test to verify that the Electronic Timer has malfunctioned
can be made. Connect the charger to the batteries and
115 Yac
N'Ur
allow to charge normaily. After the charge rate has

taperea to its lowest POlOt. measure the battery terminal
voltage using a D.C. voltmeter capable of reading in
incrementS at .001 VOltS. Continue charging and check
the battery vOltage reading every hour. If the battery voltage increases jess than .012 volts. or if the battery voitage decreases cetween successive hourly readings. the
charger should turn off. If the charger does not turn off.
the Eiectronic Timer has maifunctioned and the complete ElectrOnic Timer Kit must be replaced.
PART C -
CHARGER RUNS TOO LONG BUT DOES

TURN OFF
In the event at A.C. power interruption when the charger

is on. the charger Will automatically restart when A.C.
power is restored. This power outage can make the
apparent cnarge time seem longer than the actual
charge time. To check tor A.C. power interruPtions plug
an electric clock into the same outlet to whiCh the A.C.
cord is connected. Charge normally and note any time
difference between the test clock time and the actual
time.
SCCNCI~COI~
~
~~
CJ
.AN
. 2
SIYIG
r.\N
......
FIGURE 6
Transformer Coil Voltage Test
(without capacitor)
AT
~
FIGURE 7
Transtormer Coil Voltage Test
(with capacitor)
B..ECmONC"
KIT
_ TODCPUXI
IlATlEl'IES
FIGURE 8
Charger Wiring Diagram.
..
:~
SECT10N 6 -
AC LlNE FUSE OR CIRCUIT

BREAKER BLOWS
if this oC:::.Jrs wnen the charger Dower sUDDly cora is
connec,ea to an outlet. without the DC outout connec,or
connec:ea to the banery connecter. the c:"1arger power'
suooly cora may be Shorted, Disconnec: the power
suoPly cora from Its outlet ana the DC outout connector
from the battery connector. then C!1eck to oe sure the
E:ec:ronlc Timer Kit is NOT bypassed. With a suitable
continUity tester check the CirCUit across the power
suooly cora orongs as Shown In Figure 2. THE ClRCUIT
SHOULD NOT 8E COMPLETE. If the CirCUit IS complete.
check the relay contacts to "le sure they are open ana
have not weloed c!osea. If the relay contacts are ooen.
the power supply cord IS shorted and must oe replacea.
If the power suo ply cord checks good the transformer
cOils may be snorted. Refer to Section 7 - "Transtormer
Short or Burn-Out" for test proceaures.
SECTION 7 - TRANSFORMER SHORT OR BURN OUT

Failure of the transformer can be the resuit of naturai aClnc
premature shorting of adjacent coil turns or Dverneatlng ciam~
age. The most common cause of transformer overheating and
premature burn-out is the result of misuse. connecting the
cnarger to a battery system OT lower vOltage than specified on
the Charger. (See Section 3) Darkening of all the transformer
seconaarv COil winoinos is an indication of DOSSIOle overneating oamace. A low or comolete lack oi outout would be
observed on the ammeter. however the transformer may hum
or the AC line fuse or cirCUit breaker may blow when the
charger is turned on. To test the transformer. aisconnect the
power suo ply cord from its outlet and the DC outout connector
from the battery connector. Then disconnect the tra.nsformer
secondary coil leads #1 and #4 from the diode !erminals and
disconnect the transformer capacitor coil leaas from the
capacitor terminals. Use care when disconnecting the capacItor lead so the wires do not break.
DANGER-HIGH VOLTAGE: With the charger operating, the charger capacitor voltage is
approximately 650 volts AC. Use extreme
caution wnen Working near the capacitor

terminals.
in oraer to 300ly AC ::lower directly to the transformer
primary COil :r.e ;;:iec:ronlc Timer Kit must De oypassea.
Refer to Section 1. ?3rt A for bypass orocedures, With
the E:ec:ronlc Timer r<it bypasseo ana taKing care tor
personal saierv. connect the power sUDpiy cord to an
Outlet. If the AC line fuse or CIrCUIt breaKer blows, the
transformer IS snortea Internally ana must be replaced. If
thIS does not occur. C!1ecx the transformer seconaary
and caoacltor Call vOltages as snown In Figure 6. uSing a
SUitable AC voltmeter. If the measured voltages are suostantlally lower than those snown. the transformer IS
snortea Internally ana must be replacea.
If the transformer secondary Call voltage and capacitor
coil voltage c!1eck gOOd. disconnect the power suo ply
cord from ItS outlet. Check the caoac:tor to be sure its
rating is 6 Mfd. 660 VOltS AC. and then carefully reconnect
the capaCitor cOllleaas to the capacitor terminals. Then.
taking care for personal safety. reconnect the power
supply cord to an outlet and measure the transformer
secondary voltage again. The correct voltage reading IS
snown in Figure 7, if the transformer secondary voltage
reading is the same as measured with the capaCitor disconnected. trom Figure c. the caoacltor may be open. the
caoac:tor COil may be ooen or the caoac:tor coil terminalS
may not be maKing prooer electricai contact Refer to
Section 1. Part C. item 2 for caoacltor test proceaures. If
the voltage readings are correct. both the transtormer ana
capacitor are good. refer to Section 1, Part C. item 1 for
further tests of the DC circuit
If it should become necessary to reclace a terminal on
one of the transformer leads. the new terminal must be
Crimped AND soldered. NOTE: Some transformer leads
may be aluminum wire and a solder must be usea on
these wires that is intenaed for use on aluminum. such
as Alcoa ~807 solder With Alcoa #69 flux. If the'se materials are not available locally. contact the Lester fac:ory,
NO. 7-124
Eaton
~) Hydraulics
. Division
2000 Series Char-Lynn-ID Motors
006
Valve
Pin HOrn,
Balancing
Ring
Shaft
Face
Seal
Bearing
and
Shaft
Ass'y
Back-up
Washer
Bearing
Housing
Geroler
Valve
Plate
Tie
Bolt
Valve
Seal
Splined
Drive
C)
Wear
Plate
Key
Inner
Face
Seal
Shaft
Seal
~1
Plug
Spring
Exclusion
Seal
Valve
Drive
Case
Drain
Plug
Seal
Tools required for disassembly and reassembly.

Torque wrench 500 Ib-in[57Nm] capacity
12-16[300-450] * breaker bar
9/16 socket
Small screwdriver 6-8x1/4[150-200x6,5] blade
3/16 allen wrench
.
Press
*Unless indicated otherwise, measurements
are given in inches[mm].
**Shaft seal installation tool
**Bullet
for 1 diameter shafts
The following tools are not necessary for disassembly and
reassembly, but are extremely helpful.
Alignment studs (2)
,-
8[200J
6J
JL ~
5/16[8 1
-"1 1[251"\---
rAPprox.1/2[13]
Ii ii iii iii il
3/8[9,5] Dia. Steel Rod
3/8-24 UNF
Grind Flat Spots on Each Side

** Available--by special order
Copynght 1985 Eaton Corporation
.-'~
Disassembly
3
a
Cleanliness is extremely important when r2pairing

hydraulic motor. Work in a clean area. Before dis
connecting the lines, clean the port area of the mo
tor thoroughly. Use a wire brush to remove foreign
material and debris from around the exterior joints
of the motor. Check the shaft and keyslot. remove
all nicks, burrs or sharp edges that might damage the
bearing housing seals when installing the shaft and
bearing assembly. Before starting the disassembly
procedures, drain the oil from inside the motor.
Remove 4 bolts from motor.
Figure 3
3 Lift valve housing straight up. If done carefully the pins, springs, balance ring assembly, and
valve will remain on the valve plate.
Figure 1
1 Place the motor in a vise with the output shaft
down. Clamp across the mounting flange of the motor not the housing. Excessive clamping pressure
will cause distortion. When clamping, use some protective device on the vise, such as special soft jaws,
pieces of hard rubber or board.
,---~a~
Case
Seal - - "
Plug
.1 __ Drain
Although not all drawings show the motor in a

vise, we recommend that you keep the motor in
the vise during disassembly and reassembly.
Follow the clamping procedures explained
throughout the manual.
Figure 4
4 Carefully remove 3[76] diameter seal from

valve housing.
5 Remove case drain plug-with seal, from valve
housing.
6 Remove 2 pins and 2 springs from balance
ring assembly, see Fig. 5.
)
Tie Bolts
Figure 2
"-~
Disassembly
L1
~,
y~'"
,v
~;n~
15 Remove me 3 [76] diameter seal from wear

plate, see Fig. 7.
Wear
/Plate
Bearing
Housing
Inner
Face Seal
Balance Ring
Figure 5
7
Remove balance ring assembly.
8 Remove inner and outer face seals from

balance ring.
9
Shaft Face Seal
Remove the valve.
Figure 8
16 Remove the wear plate.
17 Remove the shaft face seal from the wear plate.
18 Remove the 3 [76] diameter seal from bearing
housing.
Bearing
Housing
\
)
Shaft &
Bearing
Assembly
Figure 6
10
Remove the valve plate.
11 Remove the 3(76) diameter seal from valve

plate.
12
Figure 9
19 You may need a press to remove shaft and
bearing assembly from bearing housing. (Key must
be removed before removing shaft.)
Remove the valve drive.

Bearing
Housin g ---.....
Backup Washer
Figure 10
Figure 7
)
13 Remove the Gercler. Be sure to retain the rol

lers in the outler ring if they are loose.
14
Remove the drive.
20 Use a small screwdriver to remove shaft seal,

back-up washer and exclusion seal from bearing
housing, see Fig. 10. Do not damage bore of
housing.
Nota: Individual parts of shaft and bearing assembly
are not sold separately. Replace as a unit.
Check all mating surfaces. Replace any parts that

have scratches or burrs that couid cause leakage.
Clean all metal parts in clean soivent. Blow dry wl(n
air. Do not wipe dry with cloth or paper towel be
cause lint or other matter can get in the hydraulic
system and cause damage. Do not use a coarse grit
or try to file or grind these parts. Check around
the keyway and chamfered area of the shaft for
burrs, nicks or sharp edges that can damage the
seals when reassembling the bearing housing.
Note: Lubricate all seals (prior to installation) with
petroleum jelly such as Vaseline. Use new seals when
reassembling this motor. Refer to parts list (6129)
for proper seal kit number.
21 Use a press to install exclusion seal in outer bore

of bearing housing. Lip of seal must face outward. See
Fig. 11. I f a press is not available use a plastic or rubber hammer, being careful not to damage or cock
seal in the bore.
Shaft Face
Re'assembly
26 AI ignment studs can be very helpful in reassembl y of the motor. See special tool listing page 2. If
you use studs. install 2 studs diagonally opposed in
the bearing housing.
27 I nstall the shaft face seal in the wear plate as

shown in Fig. 11. Do not distort seal.
28
I nstall the wear plate, see Fig. 11.
29 Apply a light film of petroleum jelly to the

3[76J diameter seal and install seal in the wear
plate.
30
I nstall the drive into the output shaft.
31 Align the notch on the outside of the Geroler

with the notch on the wear plate. I nstall the
Geroler against the wear plate. Be sure to retain
the rollers in the outer ring if they are loose.
Shaft
Shaft Seal
!:~~==~~t4r---- Face
;.
Seal
Wear Plate
Back-up
Washer
\"~~~~~I[~__-seal
Shaft &
Searing Ass'y
Exclusion
Seal
32
I nstall the valve drive in the Geroler.
Note: I nstallation at this time involves 3 steps in the

timing of the motor. Timing determines the direction
of rotation of the output shaft. Timing parts include:
1. Geroler
2. Valve 0 rive
3. Valve Plate
4. Valve
Rotate
Valve
Clockwise
112 tooth max.
to Engage
\
Spline
CQ
Figure 11
22
Place back-up washer into seal bore. Place

shaft seal onto installation tool
and press
seal into seal bore of the housing.
23
Clamp housing in vise, see Fig. 1.
24 Place protective bullet (see note below) over

shaft. Apply petroleum jelly to inside diameter of
dust and shaft seal. You may need a press to install
shaft and bearing assembly. Do not distort shaft
seal. Damage to this seal will cause leakage.
Note: Bullet
for 1" shafts, available-by special order. Use tape over other shafts to
prevent cutting the seals.
25 Apply petroleum jelly to the 3(76] diameter
seal. Install seal into the bearing housing.
tJ.~
Anyone of
6 Ports open
to Outside
of Valve
Figure 12 Timing Alignment
Timing Step H= 1-Locate the largest open pocket in
the Geroler and mark it on the outside edge of the
Geroler.
3 (76] diameter seal. Install seal in groove of valve
plate.
.;~'~."~
Reassemblv
_\
)
34 Align the notch on the outside of the valve

plate with the notch on the Geroier as shown In
Fig. 12.
Timing Step FI= 2- Locate the slot opening in the
valve plate which is in line with the largest open
pocket of the Geroler.
Timing Step FI= 3- Locate anyone of the side openings of the valve and align this opening with the
open slot of the valve plate that is in line with the
largest open pocket of the Geroler. I nstall the valve
by rotating it clockwise until the spline teeth
engage (1/2 spline tooth max. ). This will provide
the proper rotation when pressurized as shown in
Fig. 13.
Imp-ortant: Install face seals in the positions shown

in Fig. 15. or the motor will not operate properly.
Do not force or bend the face seals. Any damage to
these seals will affect the operation of the motor.
Pin Notch
Balance Ring
Figure 15
38 Align pin notches in balance ring with pins in

bore of valve housing. I nstall balance ring assembly
in valve housing.
Clockwise
Rotation
Balance
Ring -
-)
Counter
Clockwise - - - - Rotation
Housing
Figure 13
Figure 16
Valve
Housing
Pin & Spring
N~
Seal
Alignment
Studs ~
------'-J
Figure 14
Figure 17
35 Install 2 springs and 2 pins in the holes located

in the bore of the valve housing, c:;s shown in Fig. 14.

3[76] diameter seal. Install seal in the valve
housing.
37 Apply petroleum jelly to inner and outer face
seals. I nstall seals on balance ring as shown in Fig.
15.
39 Insert your finger through port of valve

housing. Apply pressure to side of balance ring as
shown in Fig. 16. Hold ring in position until
valve housing is in place against valve plate. See
Fig. 17.
Note: After installing the valve housing on the valve
plate check for proper placement. Push down on the
valve housing. You shou Id get a sl ight spring action.
Reassembly
40 Install the tie bolts. If you use alignment studs,
install 2 bolts opposite the studs. Finger tighten the
bolts. Remove the alignment studs and replace with
the 2 remaining bolts. Torque all 4 bolts alternately
to 450 Ibin [50Nm].
41 Install seal on case drain plug then install in

valve housing. Torque to 50 Ibin[6Nm].
Figure 18
Wheel Motor
On wheel motors, a different bearing housing is used,
see Fig. 19. Other than this the parts are the same as
the standard motor and the same disassembly and
reassembly procedures apply.
)
Exclusion Seal
Seal
Figure 19
Shaft Face
Seal
Bearingless Motor
This motor is the same as the standard motor without the shaft/bearing assembly, and bearing housing.
The mounting flange replaces the bearina housing,
see Fig. 20. Follow same disassembly and reassembly
procedures as rear section of standard motor.
Figure 20
, :'.J ....
,~
...:..,..J

Condor V2033XL 92350

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MODEL V2033XL, V2033

8300 IMPERIAL DRIvE

WACO, TEXAS 76702-1447

P.O. Box 21447

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

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

DO NOT ALTER OR MODIFY THIS CONDOR WITHOUT PRIOR WRITTEN

SERVICE & MAINTENANCE

A div. of TIME Manufacturing Company

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

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

I. PREPARATION, INSPECTION, AND MAINTENANCE .............................................................. 1

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

II. MACIllN"E OPERATION .................................................................. 2

Rated Work Load ...................................................................................................................... 2

ill. MOVING FROM JOB-SITE TO JOB-SITE ................................................ 5

Loading and Unloading ............................................................................................................. 5

IV. STORAGE ............................................................................. 6

APPENDIX: DECALS ILLUSTRATION ................................................................................................ 8

IMPORTANT: A COPY OF THE ANSIISIA A92.6 - 1990 MANUAL OF RESPONSIBILITIES IS

PREPARATION. INSPECTION. AND

The condition of this CONDOR is very

Check steering link to knuckle

Check for abnormal wear between

KNOW TillS CONDOR AND ITS

Check that all decals and warning

Some major areas to check daily are:

A. OVERALL MACHINE CONDITION

Check cylinder mounting pins, pivot pins,

Check for damaged or cracked welds

TIRES AND WHEELS:

Check that all functions operate

for cracks, tears, cuts, or missing or

Check emergency lowering

D. PLATFORM AND UPPER

Re-check the structural condition of the

tight and clean and free of corrosion.

Check for missing bolts & nuts - Replace

indicator lights and meter are not damaged.

II. CONDO" OPERATION

the hydraulic tank fluid level with

The platfonn will support a combined weight

be visible in sight glass. Add Shell Tellus

Rated work load, on extension deck only, is not to

Check for hydraulic leaks at all fittings

D Make sure the battery charger and the

Check that extension deck is locked in

D Keep battery tops clean and dry.

Check Electrolyte level daily in each cell.

1. To engage ann stand, raise platfonn,

2. To store arm stand, raise platform so that

Select desired drive speed with the "high/low/

Tum "controls" switch to "lower" position, to

To drive forward or reverse, squeeze lever switch

In an emergency, push red button. To operate,

Brakes are automatically released whenever the

Tum switch to "upper" position, to operate

To steer left or right, squeeze lever switch on

Lift lockpin, at right side of deck, and push

Ensure that the ramp is sufficiently strong to

The ramp should be set, not steeper than this

G. 'REMOVABLE' UPPER CONTROL