Condor Operator'S Maintenance AND Parts Manual

SIN 5259
CONDOR
OPERATOR'S
MAINTENANCE
AND
PARTS MANUAL
. ~., ...-"
PREVENTATIVE MAINTENANCE INSPECTION
.,~...~. .,oT,'his- field insp?ction list provides for a sy~tem~tic inspection of the Condor. The item~
"f" I ,>..~ed to be Inspected or checked dally will basically ensure a gOQ<;t safe Unit
:,."",.., performance prior to start-up work operation. By accomplishing these inspecttons on a
daily basis, any potential malfunction will be identified and detected before it expands into
~. major problem. The 50-hour inspection will detect any defective, damaged or
Improperly secured part.
'The 50-hour time interval is for normal operation. Should the unit be subjected to
extensive use, or if the application involves operation in abnormal environmental
,conditions. then the inspections should be made more often.
It is suggested that a maintenanc~ log be kept and abnormal conditions or items of any
kind should be recorded.
Daily Inspection
A. VISUAL
Overall Condition Inspect platform, boom, turret and carriage to

make certain that no physical damage is
evident. Look for missing components. loose
parts. etc.
Tire Condition Inspect tires for wear, cuts and proper pressur~
(pneumatic filled only).
Battery Cable Connections Inspect for looseness and corrosion of

terminals.
Hydraulic Fluid Leaks Inspect to ensure that there is no evidence of

fittings or hoses leaking.
Main Electrical Connections Inspect harness connections at rear of ground

box and at platform console to ensure that they,
are tight.
B. FLUID CHECK LEVEL

Engine Oil Level If low, add as recommended by engine
manufacturer in required quantity.
Engine Coolant Level Add as required (water-cooled engine only).
Fuel Tank Level Check level.
Hydraulic Tank Level If I'ow, add Shell Te"~s T32 as required.
Battery Electrolyte Level Add as required.
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3. BATTERIES
A. Electrolyte level - all caps present.
B. Cables and connections - ground connection.
C. Battery hold-down.
4. ENGINE
A. Fuel level.
B. Oil level.
C. Mounting.
D. Check for fuel, oil leaks.
5. HYDRAULIC SYSTEM
A. Hydraulic leaks.
B. Loose or damaged hoses, tubing.
C. Fluid level, hydraulic tank breather cap. Refill only with Shell Tellus T32
hydraulic fluid.
D. Hydraulic valves and control levers.
E. Cleanliness of hydraulic fluid - non-milky, bright in color.
6. MULTI-AXIS 5° SLOPE SENSOR
A. General condition.
B. Loose or damaged wires.
C. Push to test. Moveable on mounting.
D. Warning light/alarm in platform is operable.
KNOW THE UNIT AND ITS CAPABILITIES. Report any unusual operation, erratic sway
or motion of boom or platform while being operated, excessive, unusual noise,
abnormally slow or fast operation.
'-1 C-A-U-T-IO-N"I
Defective components, structural damage, missing parts or equipment malfunctions

jeopardize the SAFETY of the operator and other personnel and can cause extensive
damage to the Condor. A POORLY MAINTAINED machine could become the greatest
OPERATIONAL HAZARD you may encounter.
\
LUBRICATION
5. ROTATION GEAR BOX
• Lubricant. ...................... . S.A. E. 90 weight EP oil.
.Time IntervaL .................. . Check every 50 hours. Change every 500 hours
of operation or yearly, whichever comes first.
.Procedure ....................... . Remove drain plug. Refill until level reaches

about 1 inch from top of fill hole.
6. DRIVE TORQUE HUBS
• Lubricant. ..................... . S.A. E. 90 weight EP oil.
• Time Interval.. ................ . Check periodically and fill, as required. Change

every 500 hours or yearly, whichever comes
first.
.Procedure...................... . To check level, rotate wheel so that level plug is

horizontal. Remove plug. If steady flow of oil
pours forth, unit is sufficiently full.
7. HYDRAULIC SYSTEM - KEEP SYSTEM CLEAN
.Fluid LeveL ................... . Check level daily. Maintain fluid level at full
mark on dipstick with the unit in fully retracted
position.
• Hydraulic Oil Filters .......... . Change return line filter located in hydraulic
tank after the first 30 days or 50 hours of
operation. Thereafter change the filter every 3
months or 300 hours of operation.
.Tank Breather.................. . Clean every 50 hours of operation. Remove

from tank and clean with solvent. Air blow dry.
.Hydraulic Tank ................. . Drain oil tank every 500 hours or yearly,
whichever comes first and replace filter element.
Add oil to tank to required level.
(NOTE l
Use only SHELL TELLUS T32 or equal. DO NOT MIX hydraulic oil.
It may be necessary to lubricate or service the hydraulic system more frequently when
operating in abnormal environments such as dusty conditions.
PARTS SECTION
INDEX (Contld.)
Figure Title
27 Topping Cylinder
28 Platform Rotation Cylinder
30 Platform Assembly
31 Platform Control Console Assembly
32 Platform Skirt
33 Pl atform Fork
35 180 0 Platform Rotation Assembly
35A Platform Non-Rotation Assembly
39 Four-Wheel Drive (Option #35543)
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(3-SECTION BOOM)
_ _~~B~OVOrM
_ _ _ _ _ _ FIGURE 21A ASSEMBLY
59
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54
13 .
14
55
92 56
97 57
100 .24
25--\.l!-
86
69
FIGURE 1 FINAL ASSEMBLY (2-Section Boom)
TOP-MOUNTED PLATFORM OPTION
.1
3/86
REF DESCRIPTION PART NUMBER QTY

1 Tie-Down Ring 32536 1
2 Pin, Topping Cylinder to Boom 68241 1
3 Cover, Turret - Left Front 35053 1
4 Cover, Turret - Right Front 35054 1
5 Cover, Turret - Left Rear 35055 1
6 Fiberglass Turret Cover Assembly 35060 1
7 Cover, Turret - Right Rear 35056 1
8 Hinge, Top Hatch 35581 1
9 Hatch, Door - Right 35058 1
10 Hatch, Door - Left 35059 1
11 Hinge, Piano 33017 2
12 Rivet, Pop - 3/16" Dia. BOW34192 58
13 Screw, Hex Hd. Cap 3/8" x 3/4" Self-Tapping BOW31846 17
14" Latch, Turret Cover LBL00200 2
15 Bracket, Latch LBL00256 3
16 Cover, Rear Center 35057 1
17 Latch, Hood LBL00210 1
18 Hatch, Top 35061 1
19 Spring, Gas 35376 1
20 Gas Spring "Bracket Assembly 35377 2
21 Plate, Backing 32843 6
22 Screw, Hex Hd. Cap 1/4 11 -20UNC x 111 Lg. BOW30004 22
23 Flatwasher, 1/4" BOW31431 12
24 Lockwasher, 1/411 BOW36725 22
25 Clip, Speednut 1/4 11 -20UNC BOW432 10
26 Washer, Fender 1/411 BOW32572 10
27 Washer, Neoprene 3/8 11 35681 17
3/86
FIGURE 2 SAFETY DECAL &PLACARD LOCATION (2-Section Boom)
1 Decal - WARNING 32200 1

2 Decal - GENERAL OPERATING INSTRUCTIONS 35366 1
3 Decal - PLATFORM CAPACITY 35045 1
4 Decal - CO 21834-1 2
5 Decal - NO 21834-2 2
6 Decal - OR 21834-3 2
7 Decal - NO STEP 32156 2
8 Decal - CAUTION - AERIAL OPERATION 35365 1
9 Decal - DANGER 21882-3 2
10 Deca 11- DANGER 21882-2 2
11 Placard - Model and Serial Number 15843 1
12· Decal - DANGER 21882-1 . 2
13 Decal - 46 QUBIC-8 35040 2
14 Decal - TRANSPORTING DIAGRAM 35041 2
15 Decal - TIRE PRESSURE 65 PSI 21971-3 4
16 Decal - LUBE FITTING FOR PINS 35773 1
17 Decal - CALAVAR CORPORATION 35682 1
18 Decal - PLATFORM CAPACITY 600 LBS. 35805 1
19 Decal - DO NOT LIFT BOOM 21971-2 2
20 Decal - FORWARD 35043 2
21 Decal - ARROW 35042 2
22 Placard - GAS 21849 1
23 Placard - HYDRAULIC FLUID 21850 1
24 Decal - MADE IN USA - 6-Inch 35656 2
25 Decal ,- LUBE LOCATIONS 35774 1
3/86
FIGURE 2 SAFETY DECAL & PLACARD LOCATION (2-Section Boom)
,....
-
-
3/86
INTERVAL SYMBOL CHEC K SPEED REDUCER
o SO HOURS or SEMI-MONTHLY CENTRAL LUBE BRACKET
o 100 HOURS or MONTHLY
FOR PINS
o SOO HOURS or ANNUALLY

5 PLACES
ENGINE
TYPE OF LUBRICANT
OIL FILTER
CG - CHASSIS GREASE:
SHELL DARNA AX 70330, or EQUAL
SL - SPRAY LUBE: TORQUE HUB
CROWN 7045 HEAVY DUTY OPEN GEAR
AND WIRE ROPE LUBE, or EQUAL CRANKCASE FILL
EO - ENGINE OIL:
SAE 30 WEIGHT
GO - GEAR OIL:
SAE 90 WEIGHT EP CRANKCASE DRAIN
PLA TFORM LEVELING CYLIN DER

1 PlACE (rotate turret
BOO\t1 TO SKIRT PIN
while lubing)
ROTATION CYLINDER WHEEL BEARINGS
2 PLACES WHEEL BEA'RING GREASE
PLATFORM FORK PIVOT PIN
AND RELATED LINKS
5 PLACES
f!:-Sect i on Boom -] LUBRICATION CHART FOR QUBIC- 8 MODEL 46 Sheet 1 of 2
INTERVAL SYMBOL 2 - EACH SIDE
o 50 HOURS or SEMI-MONTHLY
o 100 HOURS or MONTHLY AIR CLEANER

o 500 HOURS or ANNUALLY OIL BATH
TYPE OF LUBRICANT
TIE RODS
CG - CHASSIS GREASE: 1 - EACH SIDE
SHelL OARNA AX 70330, Of EQUAL
SL - SPRAY LUBE:
CROWN 7045 HEAVY OUT Y OPEN GEAR
AND WIRE ROPE LUBE, or EQUAL
~ EO - ENGINE OIL:
SAE 30 WEIGHT
GO - GEAR OIL: HYDRAULIC
SAE 90 WEIGHT EP STEERING
TANK OIL CYLINDER
(A TF Dextron II)
~ ENGINE OIL DIPSTICK
HYDRAULIC
LINE FILTER
TOPPING CYLIN DER

ROTATION GEAR 2 PLACES
TEETH & PINION
Sheet 2 of 2
2-Sect i on Boom 1 .LUBRICATION CHART FOR QUBIC- 8 MODEL 46
FIGURE 10 TURRET ASSEMBLY
39
32 38 44
30
31 10
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21
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1 9
22
17
12 1
I I)
25------'
26
27 4
28
3/86
Turret Assembly 35050

1 Turret Weldment 35796 1
2 Power Module Assembly Ref. Fi gure lOA 1
3 Screw, Hex Hd. Cap 1/2"-13UNC x 411 19. BOW30116 3
4 Rotary Coupling Re f. Figure 9 1
5 Fuel Tank Assembly Ref. Figure 111 1
6 Cylinder, Topping Ref. Figure 27 1
7 Pin, Topping Cylinder to Turret 35013 1
8 Valve, Proportional Control - 4-Bank 32560 1
9 Valve Assembly 58189 1
10 Switch, limit 40207 1
11 Valve, Solenoid 58079 1
12 Filter, Return line 32522 1
13 Console, Ground Control Ref. Figure 1_6 1
14 Harness, Engine 35068 1
15 Speed Reducer Assembly Ref. Figure 17 1
16 Mount, Turret Cover - lH 35571 1
17 Mount, Turret Cover - RH 35572 1
18 Harness, Valve Wiring 35609 1
19 Pin, Master leveling Cylinder to Turret 35014 1
20 Pad, Boom Rest 30324 2
21 Screw, Hex Hd. Cap 3/4 11 -10UNC x 411 19. BOW30160-450 4
22 Flat Washer, 3/4 11 BOW31418 4
23 Nut, lock 3/4 11 -10UNC BOW46986 4
24 Screw, Flat Hd. 3/8 11 -16UNC x 3/411 19. BOW34415-750 10
25 Screw, Hex Hd. Cap 5/16 11 -18UNC x 2-1/211 19. BOW46035 4
26 Flat Washer, 5/16 11 BOW36751 4
27 lockwasher, 5/16 11 BOW36726 4
28 Nut, Hex 5/16 11 -18UNC BOW31202 4
29 Screw, Hex Hd. Cap 1/4 11 -20UNC x 1/2" 19. BOW30000 2
30 lockwasher, 1/411 BOW31325 10
31 F1 at Washer, 1/411 BOW31411 10
32 Screw, Hex Hd. Cap 1/4"-20UNC x 3/4 11 19. BOW30002 8
33 Screw, Hex Hd. Cap 1/4 11 -20UNC x 211 19. BOW30008 2
34 Screw, Hex Hd. Cap 3/8 11 -16UNC x 3/4 11 19. BOW30052 14
36 Flat Washer, 3/8" BOW31413 22
37 Screw, Hex Hd. Cap 3/8 11 -16UNC x 1/2" 19. BOW30050 4
38 Screw, Round Head #10-32UNF x 1/211 19. BOW31144 2
39 Lockwasher, #10 BOW31323 2
40 Plate, "Boom Pin 32148- 2
41 Pin, Main Boom Pivot 35012 2
42 Washer, Motor Mount 35696 4
43 Nut, Flanged BOW46986 4
44 Counterweight 35795 1
45 Pin, Pivot Half - Main Boom 35012 2
46 lockwasher, 1/2" BOW31329 7
48 Screw, Hex Hd. Cap 1/2"-13UNC x 2 ! /211 19. BOW30110 4
3/86
FIGURE 33A PLATFORM FORK, TOP-MOUNTED OPTION
1 Fork Weldment 35650 1
3/86
INTERVAL SYMBOL
o 50 HOURS or SEMI-MONTHLY CHECK SPEED REDUCER SHEAVE PIN

o 100 HOURS Of MONTHLY
2 PLACES
o 500 HOURS Of ANNUAllY

CENTRAL LUBE BRACKET
FOR PINS
5 PLACES
TYPE OF LUBRICANT ENGINE
OIL FILTER
SHEll DARNA AX 70330, or EQUAL
Sl - SPRAY LUBE:
TORQUE HUB
EO - ENGINE Oil: CRAN KCASE FILL
SAE 30 WEIGHT
GO - GEAR Oil:
SAE 90 WEIGHT EP
CRANKCASE DRAIN
ROTATION CYLI NDER

2 PLACES
RING GEAR
2 PLACES
(rotate turret
1 PLACE
B()()\1 TO while lubing)
PLATFORM FORK SKI RT PI N
PIVOT PIN WHEEL BEARINGS
AND RELATED LJ NKS WHEEL BEARING GREASE
5 PLACES
3-Sect i on ~-~--I LUBRICATION CHART FOR QUBIC- 8 MODEL 46 Sheet 1 0 f 2
INTERVAL SYMBOL
2 - EACH sIDe
o 500 HOURS or ANNUAllY AIR CLEANER

OIL BATH
TYPE OF lUBRICANT
SHEll DARNA AX 70330, or EQUAL
Sl - SPRAY lUBE:
TIE RODS
CROWN 7045 HEAVY DUTY OPEN GEAR 1 - EACH SIDE
EO - ENGINE Oil:
SAE 30 WEIGHT
GO - GEAR Oil:
SAE 90 WEIGHT EP
HYDRAULIC
TANK OIL
(A TF Dextron II) STEERING
CYLINDER
ENGINE OIL DIPSTICK
HYDRAULIC
LINE FILTER
ROTATION GEAR
TEETH & PINION
TOPPING CYLIN DER
2 PLACES
3-Sect i on Boom LUBRICATION, CHART FOR QUBIC- 8 MODEL 46 Sheet 2 of 2

--
"COco 0-
.-
.-
3/86
1 Tie-Down Ring 32536 1

5 Cover, Turret - Left Rear 35055 1
7 Cover, Turret - Right Rear 35056 1
11 Hinge, Piano 33017 2
12 Rivet, POP - 3/16" Dia. BOW34192 58
13 Screw, Hex Hd. Cap 3/8" x 3/4" Self-Tapping BOW31846 17
14· Latch, Turret Cover lBlO0200 2
15 Bracket, latch lBlO0256 3
16 Cover, Rear Center 35057 1
17 latch, Hood lBlO0210 1
18 Hatch, Top 35061 1
20 Gas Spri ng "Bracket Assembly 35377 2
22 Screw, Hex Hd. Cap 1/4 11 -2QUNC x 111 19. BOW30004· 22
24 lockwasher, 1/4t1 BOW36725 22
25 Clip, Speednut 1/4"-20UNC BOW432 10
26 Washer, Fender 1/4" BOW32572 10
27 Washer, Neoprene 3/8 11 35681 17
3/86
FIGURE 2 SAFETY DECAL & PLACARD LocATION (3-Section Boom)
TOP-MOUNTED PLATFORM OPWION
00
..-
3/86
FIGURE 2 SAFTEY DECAL & PLACARD LOCATION (3-Section Boom)
1 Decal - WARNING 32200 1

4 Decal - CONDOR (small) 50277 2
5 Decal - MADE IN USA 35656 2
6 Placard - HYD. FLUID 21850 1
10 Deca 1 - DANGER . 21882-2 2
13 Decal - 46 QUBIC-8 35040 2
16 Decal - LUBE FITTING 21079 2
17 Decal- CALAVAR CORPORATION 35682 1
19 Decal - DO NOT LIFT BOOM 21971-2 2
23 Decal - CENTRAL LUBING FOR PINS 35773 1
24 Decal - LUBE LOCATIONS 35774 1
3/86
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16
34
35
36
3
21 I
22 1
32
(!""'--"~ 30
1 31
12 I ()
1 0
25/
26 4
27
28
11/85

2 Power Module Assembly Ref. Figure lOA 1
3 Mount~ Rubber 35313 4
4 Rotary Coupling Ref. Figure 9 1
5 Fuel Tank Assembly Ref. Figure 11' 1
6 Cylinder~ Topping Ref. Figure 27 1
7 Pin~ Topping Cylinder to T~rret 35013 1
8 Valve~ Proportional Control - 4-Bank 32560 1
10 Switch~ Limit 40207 1
11 Valve~ Solenoid 58079 1
12 Filter~ Return Line 32522 1
13 Console~ Ground Control Ref. Fi gure 1,6 1
14 Harness~ Engine 35068 1
16 Mount~ Turret Cover - LH 35571 1
17 Mount~ Turret Cover - RH 35572 1
18 Harness~ Valve Wiring 35609 1
19 Pin~ Master Leveling Cylinder to Turret 35014 1
20 Pad~ Boom Rest 30324 2
21 Screw~ Hex Hd. Cap 3/4"-lOUNC x 4" Lg. BOW30160-450 4
22 Flat Washer, 3/4 11 BOW31418 4
23 Nut ~ Lock 3/4"-10UNC BOW46986 4
24 Screw~ Flat Hd. 3/8"-16UNC x 3/4" Lg. BOW34415-750 10
25 Screw~ Hex Hd. Cap 5/16"-18UNCx 2-1/211 Lg. BOW46035 4
26 Flat Washer, 5/16 11 BOW36751 4
27 Lockwasher, 5/16 11 BOW36726 4
28 Nut~ Hex 5/16 11 -18UNC BOW31202 4
29 Screw, Hex Hd. Cap 1/411 -20UNC x 1/211 Lg. BOW30000 2
30 Lockwasher, 1/4" BOW31325 10
31 Flat Washer, 1/411 BOW31411 10
32 Screw~ Hex Hd. Cap 1/4"-20UNC x 3/4 11 Lg. BOW30002 8
33 Screw~ Hex Hd. Cap 1/4"-20UNC x 211 Lg. BOW30008 2
34 Screw~ Hex Hd. Cap 3/8 11 -16UNC x 3/4 11 Lg. BOW30052 14
35 Lockwasher~ 3/8 11 BOW31327 22
37 Screw~ Hex Hd. Cap 3/8 11 -16UNC x 1/2" Lg. BOW30050 4
38 Screw~ Round Head #10-32UNF x 1/211 Lg. BOW31144 2
40 Plate, -Boom Pin - 32148 2
43 Nut, Fl anged BOW46986 4
11/85
-------
CONDOR QUBIC-8 MODEL 46
TORQUE HUB (CALAVAR PART NO. 32084) - BILL OF MATERIALS
Item Part No. lli Description

1 WIB140 1 Hub-Spindle Subassembly
lA 1400703 1 Spindle
IB 1501301 1 Seal
1C 1500803 1 Bearing Cup (JLM506810)
10 1500804 1 Bearing Cone (JLM506849)
IE 1500805 1 Bearing Cup (JM205110)
IF 1500806 1 Bearing Cone (JM205149)
IG 1500603 1 Hub
IH 1900904 1 Spacer
1I 910006 1 Retaining Ring
IJ 950002 2 Pipe Plug
IN 970004 9 Stud
2 1400066 1 Internal Gear
3 1200028 1 Carrier Assembly
3A 1200503 1 Carrier
3B 1200310 6 Thrust Washer
3C 1200803 96 Needle Roller
3D 1201002 3 Spacer
3E 1200101 3 Planet Shaft
3F 1300028 3 Cluster Gear
3G 920002 3 Roll Pin
4 1500073 1 Ring Gear
5 1940001 2 110 11 Ri ng
6 1500406A 1 Cover Assembly
6A 1500406 1 Cover
6B 1900402 1 Cover Cap
6C 930004 4 Bolt
60 1900401 1 Disconnect Cap
6E 1900101 1 Disconnect Rod
6F 940001 1 110" Ring
6G 940002 1 "Oil Ring
6H 950001 1 Pipe Plug
6J 901201 1 ID Pl ate
7 1l00104A 1 Input Shaft Assembly
7A 1100104 1 Input Shaft
TB 910007 1 Retaining Ring
7C 1901501 1 Spri ng -
70 1201002 2 Spacer
8 1100017 1 Input Gear
(Continued on next page ..... )
(Cant 'd. )
Item Part No. Qty Description

9 1901001 1 Thrust Spacer
11 1200301 2 Thrust Washer
12 930101 12 Bolt
13 1930201 4 Shoulder Bolt
14 1100203 1 Coupling
16 960201 16 Flat Washer
12
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FIGURE 12 PUMP/DRIVE ASSEMBLY (WISCONSIN GAS ENGINE)
~ Engine & Pump Assembly 35330

1 - ~Engine, 37 HP (Gas) 40017 1
2 - ~Bracket, Alternator Mounting 40166 1
3 - ~Strap, Belt Tension Adjuster 40162 1
4 - ~Cover, Alternator Pulley 40170 1
5 -r-V-Belt, 3/8" X 1811 32573 1
6 - Solenoid, 12 V 32111 2
7 Throttle Wire 21607 1
8 - r-Bell Housing 40171 1
9 - I"""Coupling' 68221 1
10- ~Pump, Hydraulic 32524 1
11 2
12- c....'
1
13-t-Alternator 32218 1
14-I-Clevis - 1/411 x 211 BOW 20 23 2
15-t-Valve, Check 21368 1
16-I- Ci rcuit Breaker 80044 2
17-I-Re 1ay 80045 2
18-t-Rel ay, Anti -Restart 67280 1
19-t-Pin, Clevis BOW2120 2
20 -,-- t- Pin, Cotter 1/16 11 x 111 Lg. BOW38210 2
21- 4
22- ~Lock Nut 1/4"-20UNC BOW34272 4
23- ~Screw, Hex Hd. Cap 1/411 -20UNC x 1/2" Lg. BOW 30000 2
24- '-Lockwasher, 1/411 BOW31325 2
l 25- ~Flat Washer, 1/411 BOW31401 2
26- ,.... 4
27- -Nipple, 1/211 x 311 Lg. Pipe BOW13449 1
28- -Coupling, 1/211 Pipe BOW13312 1
29- -Bushing, Reducer 1/211 to 3/8" Pipe 02653 1
30--Elbow, 90° - #8 JIC to #6 Pipe 04200 1
31--Cap, #8 JIC 02503 1
32--Screw, Hex Hd. Cap 5/16 11 -18UNC x 3/4" Lg. BOW30027 1
33- -Lockwasher, 5/16 11 BOW31374 6
34- t--Flat Washer, 5/16 11 BOW31432 6
35- r-Screw, Hex Hd. Cap 5/16"-18UNC x 111 Lg. BOW30029 5
36- t--Screw, Hex Hd. Cap 1/2t1-13UNC x 2-1/211 Lg. BOW30110 1
37~ ~Lock Nut 1/2t'-13UNC BOW34276 1
38- t--Spider 40233 1
39- t-Key Stock 3/8 11 x 3/8" X 2-1/411 Lg. BOW33978-001 1
40- I--Set Screw, Allen Hd. 5/16"-18UNC x 3/8 11 Lg. BOW40531 4
41- t--Screw, Hex Hd. Cap 5/811 -HUNC x 1-3/4" Lg. BOW30145-175
42- ~Lockwasher, 5/8 11 BOW31331 4
43- t-Screw, 'Hex Hd. Cap 1/2 11 -13UNC x 1-1/211 Lg. BOW30106 2
44- I-- Lockwasher, 1/211 BOW31329 2
45- t-Flat Washer, 1/211 BOW31415 2
46- ~Connector, Strai ght #20 O-Ri ng to #20 Pipe 00370 1
47- I--Connector, Straight #20 O-Ring to #20 JIC 02582 1
48- t-Bushing, Reducer #20 Pipe to #12 Pipe 00386 1
49- ~Connector, Straight #12 Pipe to #12 Pipe 04176 1
50...,- ~Elbow, 90° #6 JIC to #4 Pipe 00128 1
51- I--El bow , 90° #8 O-Ring to #6 JIC 02671 1
52- I--Elbow, 90° #4 O-Ring to #4 JIc 02236 1
53- I--Elbow, 90° Modified #12 JIC to #12 Pipe 35664 1
54- -Spring 67461 1
5"5- -Nut, Jam 1/4"-28UNF _ BOW32281 2
FIGURE .21 BOOM ASSEMBLY (2-SECTION BOOM)
~~l·
2~
24 . I
3
-
u-:
: - 17
35 ----f-===--16
I
'-15
30 29
51
52
39
14
?2 53
!_------- 34
1__----- 33
FIGURE 21A BOOM ASSEMsl Y
44 59
ij"
13
14
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69
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29 /~
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BOOM EXlENSlON C'tUNOER ASSY. _!<r~~4)1;~_ti0'gtt;!-i.;t!a

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_ SUClION EMERGENCY COUPlIIO ~"""""'I'-'I""""'PiOi~...!'! __ ~ _ ~ .gJ
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'---------------------------' 21568 .. . ..
'-------------------------------' .. CU. IN./REV.· -:::;-...;,;....;.;!.
WHEn. UOTORS
REF.:TORQ. HUB RAllO 30:1
PUVP AT MAX. STROKE (2.3 .C~ IN./REV.)

20 GPU MAX. AT 2150 ~PM
LOAD SENSING COMPENSATOR SETTING
WlTri DIr=FERENTIAL PRESSURE =
350 PSI
=
2500 PSI
........... WI
S(RIAL NOS. 5258 THRU 6219
_ _ .., . . _ _ _ _ _ _ _
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SANTA FE SPRINGS.
CALIFORNIA
I-:nn.e==.=~----------------I
UNLESS OTHERWISE SPECIF'ED:
DIMENSIONS ARE .10 INCHES A
~~~~r--~~~~lOlERANCESON: "':!'-: ~~
No~: Fi>~ C~I..I"'l>ee PA-~ No.s.)
(r) =z>e=sI~A~ T6"X~ H~1>. LTR. D.C.N. NO D4TE
RA.M. DRAWING NO REV.
(,S) l>€"S'4"N~ S/~ H:JJ>/2().l..INS LTR. D.R.N. NO D<JJ: 35784 A

RELEASE/~bNS SHEET 1 OF ,
,
.L.
FIGURE 21A BOOM ASSEMBLY (3-SECTION BOOM)
59
/oygoo
54 I.
13 .
14
55
92 56
87
_'::,..,-------:7 93 97 57
100 .24
25---1l!-
86
69
6
.. , ..~73
100
27
3
FIGURE ,21 BOOM ASSEMBLY (2-SECTION BOOM)
42
3 43
44
45
46
.47
,----137
I
','Q____ 38
53
to-Slip .
1--Cover, Engine 32676 1

2- -Pinion, Turret Rotation Ref. FiQure 17 1
3-
4*- -Motor, Wheel Ref. Fi Qure 4 2
5-r
6-rHub, Dnve 32084 2
7-rCover, Rear Ref. Fi gure 4 1
8- rHeat Exhaust Panel, Rear 32721 1
9- r-Bracket, Battery Support 32732 1
10-r-Electri c Motor and Pump Ref. Figure 20 1
11- !-Muffler Ref. Figure 18 1
12-rScrew, Hex Hd. Cap 5/16 11 -18UNC x 1/211 Lg. BOW30025 .' 2
13
14
15--Carriage Weldment 32719 1
16--Lockwasher, 5/16 11 BOW36726 6
17--Heat Exhaust Panel 32722 2
18--Hold-Down, Battery 32726 1
19--Hydraulic Tank Assembly Ref. Figure 15 1
20-r-Gear, Ring 21922 1
21- ~Fuel Tank .Assembly ;
-- Ref. Figure 14 1
22- ~Tire and Wheel Assembly - Drive Ref. Figure 6 2
23- rTire and Wheel Assembly - Steering Ref. Figure 6 2
24- ~Tie-Rod End - LH Ref. FiQure 7 1
Tie-Rod End - RH Ref. Fi gure 7 1
25- -Tie-Rod Ref. Figure 7 1
26- -J-Bol t, 5/16 11 -18UNC X 12-1/211 Lg. BOW217 2
27- -Washer, Fl at 5/16 11 BOW31432 6
28- -Nut, Hex Hd. 5/16"-18UNC BOW13202 6
29- -Cable, Battery 67296-025 1
30--Steering Knuckle Assembly - RH Ref. Figure 7 1
Steering Knuckle Assembly - LH Ref. Figure 7 1
31--Oil Bath Air Cleaner (Wisconsin Engine) Ref. Fi gure 19- 1
32- ~Lockstrip 68226 9
33-r-Screw, Hex Hd. Cap 1/211-13UNC x 2-3/411 Lq. BOW36111 18
34- ~
35-rScrew, Hex Hd. Cap 5/8"-11UNC x 411 Lg. Gr 8 ----BOW36157 9

36- t-~Jasher, Flat 5/8" BOW36717 9
37- ~Nut, Hex (Bowma-Grip) 5/8"-HUNC BOW46985 9
38-!--Lockwasher, 1/2" BOW33564 18
39-
4l1-t-Bolt, Wlng 32791 10
41- ~Screw, Flat Hd. Soc. Cap 1/2"-13UNC x 2-3/4" BOW36857 4
LG
42- ~Cable, Battery 67296-022 1
43.,.- ~Screw , Hex Hd. Cap 5/16"-18UNC x 1" Lg. BOW30029 12
44-
45-!--Strap, Ground 33038 1
46- I-Adapter 00357 1
47-!--Elbow, 90° 02454 1
48- I-E1 bow, 90° 02662 1
49- ~Screw, Hex Hd. Cap 1/4"- 20UNC x 1/2" Lg. BOW3000 8
50-!--Lockwasher, 1/4" BOW36725 8
51- rLifting Eye - Front (opti on) 32805 2
52- t-Liftinq Eye - Rear (opti on) 32804 2
FIGURE 6 DRIVE AND STEERING HYDRAULICS
.-
N
· CE PIN 35690) Iii:'
FOO~ME TmMm~:s~~~~~~~~~~~~~~
EL....
DRIVE KI T (FIE1J) SERVI .. \!y
--.---.:-~..:..-..:.----- ..... STEER~G
#35631 VALVE MTG. BRKT.

QTY (2) _.....;......._ __
./"" 35
5 11 7
12
21
23
,I
A 1
40
41 43
~5
FOUR-WHEEL DRIVE (OPTION 35543)
ROTARY COUPLING
. PORT NUMBERS:
11
4---h'lIiO...J
21
35
1---Motor, Drive (with brake) - 4 cu. in. 36393 2

2- --Block, Drive Ref. Fi gure 4A 1
3---Bushing, O-Ring #8-#12 35336 4
4- --Elbow, goo Swivel #4-#4 02219 2
5-f-- Elbow, go ° Swi ve 1 #8-#8 35353 4
6- ~Elbow, goo O-Ring #4-#6 02875 5
7-f--Union, STR #8-#8 02685 4
8- ~Connector, STR O-Ring #4-#6 00456 5
9-f--Connector, STR O-Ring #8-#12 00303 -- 6
10-f--Elbow, 45° Swivel #B-#8 02649· 4
11 Tube Assembly #8-#8 35120 2
12-f- Tube Assembly #8-#8 35119 2
13-f--Hose Assembly, #8 STR-#8 STR x 1411 Lg. 2
14 Hose Assembly, #8 STR-#8 STR x 15 11 Lg. 2
15-f--Hose Assembly, #8 STR-#8 Elbow, 90° x 51 Lg. .L
2
16-"--Hose Assembly, #4 STR-#4 STR x 43 11 Lg. / -4
17-f-Hose Assembly, STR-#4 STR x 5 11111 Lg. / 1
18-f--Hose Assembly, #4 R-#4 Elbow, 90° x 5 19" Lg /' 1
19- f--Cylinder, Steering .~ L 32545 1
20- f--El bow , goo O-Ring #B-II~ / 04523 2
21- "-Hose Assenbly, #4 STR-~~ 4'11" Lg. / / 1
22- I--Hose Assembly, #4 STR-#4 S x 5 11111 Lg./ 1
23- f--Reducer, #8-#4 00564 2
24- ~Motor, Drive (without brake) " " / / 40583 2
25- I--Elbow, 90° O-Ring #4-#6 A 02875 2
26- "--ElboW, goo O-Ring #8-#12 02664 4
27-.-Hose Assenbly, #4 STR-#4 S~" Lg) 2
28-I--Hose Assembly, #8 STR-#8 STR 83 11 Lg. "" 4
29-I--Hose Assembly, #4 STR-#4 S1: x 22" Lg. " 1
30- I--Hose Assembly, #8 STR-#S ° Elbow x 2411 Lg'> 2
31- I - Hose Assembly, #4 STR.}f STR x 34" Lg. 1
32-I--Tube Assembly, 1/4" / ~ 35122 1
33- I - Tube Assembly, ~;t -~ 35121 .1
34- t---Hose Assembly, #4 TR-#4 STR x 1911 Lg. ~ 2
35- I--Hub, Torque ~ 35317 2
36-"- HoUSing,:~ Coupli ng ~VQOI004 1
37- ---Elbow, 90° JIC-I4 O-Ring 0 36 3
38- --Elbow, 90° #8 JIC-I12 O-Ring 022l 4
39- --Reducer JIC-I4 JIC 0049,,· 1
40- --Tee, Run 14 JIC-I4 JIC 00344 2
41- -Cap 16 JIC 04012 1
42- ---Reducer 18 JIC-16 JIC 00388 1
43- -Tee, Rum 18 JIC-18 JIC 00303- 2
44- --Bracket, Valve Mounting 35631 2
45- -Panel 35621 1
~~ 46- -Washer, Flat BOW85293 4
47- - Washer, Lock BOW36727 4
48- ~ Nut, Hex BOW36603 4
1/89
1 Reducer, #6 JIC-#4 JIC---------+----00425----1---1

2 Tee, Run #6 JIC-#6 JIC 00488 1
3 Hose Assembly, #4 STR:#4 STR xlII Lg. 40180-238 1
4 Cap, #4 04003 1
5 Valve, 2-Speed 21491_ 1
11/85

•.. /
1- ~Motor, Drive (with brake) - 4 cu. in. ::21-568-- 2

2- I--Block, Drive Ref. Figure 4A 1
3-r--Bushing, O-Ring #8-#12 35336 4
4- I--El bow , goo Swivel #4-#4 02219 2
5- I--Elbow, goo Swivel #8-#8 35353 4
6- f-Elbow, goo O-Ring #4-#6 02875 5
7- I--Union, STR #8-#8 02685 4
8- ~Connector, STR O-Ring #4-#6 00456 5
9- I--Connector, STR O-Ring #8-#12 00303 6
10- I-Elbow, 45° Swivel #8-#8 02649 4
11-I-Tube Assembly #8-#8 35120 2
12-I--Tube Assembly #8-#8 35119 2
13-I-Hose Assembly, #8 STR-#8 STR x 1411 19. 2
14 Hose Assembly, #8 STR-#8 STR x 15 11 19. 2
15- ~Hose Assembly, #8STR-#8 Elbow, goo x 51 19. 2
16-I-Hose Assembly, #4 STR-#4 STR x 43 11 19. 4
17-I- Hose Assembly, #4 STR-#4 STR x 5 11111 19. 1
18-I--Hose Assembly, #4 STR-#4 El bow, goo x 5 I 911 19 1
19- ~Cylinder, Steering 32545 1
20- I-Elbow, 90° O-Ring #8-#8 04523 2
21- I-Hose Assembly, #4 STR-#4 STR x 4 11111 19. 1
22- I-Hose Assembly, #4 STR-#4 SIR x 5 11P 19. 1
23- I--Reducer, #8-#4 00564 2
24- I-Motor, Drive (without brake) 40583 2
25- I-Elbow, 90° O-Ring #4-#6 02875 2
26- I--Elbow, goo O-Ring #8-#12 02664 4
27- I--Hose Assembly, #4 STR-#4 STR x 83" 19. 2
28- I-Hose Assembly, #8 STR-#8 STR x 83" 19. 4
29- ~Hose Assembly, #4 STR-#4 STR x 22" 19. 1
30- I--Hose Assembly, #8 STR-#8 goo Elbow x 24" 19. 2
31- ~Hose Assembly, #4 STR-#4 STR x 34 11 19. 1
32- I--Tube Assembly, 1/4" 35122 1
33- I - Tube Assembly, 1/411 35121 1
34- I--Hose Assembly, #4 STR-#4 STR x 19" 19. 2
35- I--Hub, Torque 35317 2
11/85
34 /~
8l'
IJ"I'I
J"I'I
r-
c
'"<
~
J"I'I
~
--
~
-I
."
",
b
'"~
J"I'I
-
~
"'0
......
:z
w
24 ~
-~
~~
FOUR-WHEEL DRIVE ROTARY COUPLING (OPTION 35543)
20----.js,
18
21
1--1
16
15
-tl----14
10
6 11
7
12 ---------I
11/85
FOUR-WHEEL DRIVE ROTARY COUPLING (OPTION 35543)
1 -f-Spacer KVQ 01004 1

2 - t-Housing KVQ 01002 1
3 -f-El bOw, 90° #4 JIC-#4 O-Ring 02236 3
4 - f-El bOw, goo #8 JIC-#12 O-Ring 02664 4
5 - r Reducer #8 JIC-#4 JIC 00492 1
6 - f-Tee, Ru"n #4 JIC-#4 JIC 00344* 2
7 - rCap #6 JIC 04012 1
8 - rReducer #8 JIC-#6 JIC 00388 1
9 - rO-Ring ** 1
10-f-Plate, Keeper KVQ 01005 1
11 Lockwasher KVQ 01008 4
12-rScrew, Socket Hd. Cap KVQ 01007 4
13-f-Tee, Run #8 JIC-#8 JIC 00303* 2
14 nlate Mounting KVQ 01006 1
15--Seal Set ** 8
16-- Spool KVQ 01003 1
17-'-Connector, STR #4 JIC-#4 O-Ring 02525 3
18--Connector, STR #12 JIC-#12 O-Ring 00266 2
19--Connector, STR #6 JIC-#4 Pipe 02795 ,1
20- ~Connector, STR #4 JIC-#4 Pipe
21- ~Bushing, O-Ring #4 Pipe-#12 O-Ring
01160
21569
-
2
*4WD Fittings.
**Seal Kit (contains eight of Item 7 and one

of Item 2) 92079
11/85
FOUR-WHEEL DRIVE KIT (FIELD SERVICE PIN 35690)'
1 Valve Check 40795 2

2 Elbow, 90° LL #8-#8 02514 1
3 Flow Divider 21457 1
4 Coupling, STR M Pipe #8-#8 02658 3
5 Tee, Run - Male #8-#8 02577 2
6 Reducer, #8-#4 00348 2
7 Valve, Flow Control GPM 1
8 Valve, Flow Control - 6 GPM 35095 2
9 Valve, Selector 40594 1
10 Elbow, 90° O-Ring #4-#4 02236 1
11 Bushing, O-Ring #12-#8 04039 3
12 Coupling, STR O-Ring #8-#12 00303 1
13 Elbow, 90° - #4 JIC #4 Pipe 00314 2
14 Valve, Shuttle 35096 1
15 Coupling, STR Male 8-8 04085 1
16 Valve, Pressure Reducing 40597 1
17 Coupling, STR - #4 JIC-#4 Pipe 01160 1
18 Elbow, 90° #4-#4 03120 1
19 Connector, STR 4-4 02525 2
20 Hose Assembly 1
21 Hose Assembly 1
22 Tee, Service #4-#4 00344 1
23 Hose Assembly 1
24 Elbow, 90° Swivel #8-#8 02338 1
25 Tee, Service 90° Swivel #8-#8 00326 3
26 Hose 1
27 Tee, #4-4-4 02692 1
28 Collector, Block 40577 1
29 Elbow, 90° Swivel #4-#4 02219 1
30 Elbow, 90 #8-#8 02475 1
31 Coupling, Swivel #6M-#6FM Swivel 04215 2
32 Elbow, 90° - Male #4-#6 02444 4
33 Coupling STR - #4 JIC-#6 Pipe 02793 3
34 Hose Assembly, Long 2
35 Coupling, STR O-Ring 12-8 02237 1
36
37 Coupling, STR #4 Pipe-#4 Pipe 04174 1
38 Coupl ing, .8-8 02658 1
39 Hose Assembly 2
40 Connector, STR 8-8 04085 1
1/89
FOUR-WHEEL DRIVE KIT (FIELD SERVICE PIN 35690)
1 Reducer, #6 JIC-#4 JIC - - - - - - - - - + - - - - 0 0 4 2 5 - - - - - 1 - - 1

2 Tee, Run #6 JIC-#6 JIC 00488-1
3 Hose Assembly, #4 STR=#4 STR x 111 Lg. 40180-238 ---1
4 Cap, #4 04003 1
5 Va lve, 2-Speed 21491 1
1/89
,REF DESCRIPTION - - ._-." "
PART NUMBER QTY
"
1- --Motor, Drive (with brake) - 4 cu. in. 36393 2
2- --Block, Drive Ref. Figure 4A 1
3 ~ushing, O-Ring #8-#12 35336 4
4- --Elbow, goo Swivel #4-#4 02219 2
5- --Elbow, 90° Swivel #8-#8 35353 4
6- --Elbow, 90° O-Ring #4-#6 02875 5
7- --Union, STR #8-#8 02685 4
8- --Connector, STR O-Ring #4-#6 00456 5
9- ~Connector, STR O-Ring #8-#12 00303 ,- 6
10-~Elbow, 45° Swivel #8-#8 02649· 4
,Ai-~Tube Assembly #8-#8 35120 2
~- ~Tube Assembly #8-#8 35119 2
~- ~Hose Assembly, #8 STR-#8 STR x 1411 19. 2
Hose Assembly, #8 STR-#8 STR x 15 11 19.
~-
2
~Hose Assembly, #8 STR-#8 Elbow, goo x 51 19. 2
/
~- f--Hose Assembly, 4 STR-#4 STR x 43 11 19. /
-4
)1- ~Hose Assembly, 1T STR-#4 STR x 5 11111 19. 1
~- ~Hose Assembly, #4 R-#4 E1 bow, goo x 5 I 911 19 / / 1
19- ~Cy1inder, Steering .iR 32545 1
20- ~E1bow, 90° O-Ring #8-#_ / 04523 2
,21"'- f-Hose Assembly, #4 STR-#~X 4' 11" Lg. / / 1
$ - f-Hose Assembly, #4 STR-#4 S x 5 111" 19./ 1
23=-- ~Reducer, #8-#4 00564 2
24- ~Motor, Drive (without brake) '" '" / / 4058~ ,.., 2
25- ~Elbow, 90° O-Ring #4-#6 . A 02875 2
26- ~Elbow, goo O-Ring #8-#12 02664 4
Hose Assembly, #4 STR-#4 S~" L9) '4..,,.., . ~ n -.-.n"''- \ 2
83" 19. "'~ t..... .. .'\7 "
~
cq~-= f-Hose Assembly, #8 STR-#8 STR '4'

',4
,'T"" HJ.... .,.,,';..'.;'-!
f-Hose Assembly, #4 STR-#4 S1 x 2211 Lg. 1
r;A'~: ~f"':1Ln '\
r-Hose ~ssembly ,#8 STR-#~ecwew-X--24111.9'> l.... .....1 ~- • /I. Ii) , 2
I - Hose Assembly, #4 STR-) STR x 34" 19. 1
Tube Assembly, 1/411 / . I~ '''' "'35122 1
I - Tube Assembly, 1/41~/, '\. '" 35121 .1
.. Hose Assembly, #4/STR-#4 STR x 19" 19. 2
--Hub, Torque / " 35317 2
36- -- Hous i ng, Rotapy Coup 1 i ng '\vVQOlO04 1
37- --Elbow, 90° #4 JIC-#4 O-Ring 0 36 3
38- --Elbow, 90;i#8 JIC-#12 O-Ring 02Z64 4
39- - Reducer-Itt Jl C-'-4\JiC'=3 00492 1
40- -- Tee, Rim f1f~4_l.!.D 00344 2
41- --Cap #6 JIC 04012 1
42- -Reducer #8 JIC-#6 JIC 00388 1
43- --Tee, Rum #8 JIC-#8 JIC 00303- 2
44- --Bracket, Valve Mounting 35631 2
45- -Panel 35621~- 1
~~ 46- -Washer, Flat BOW85293 4
47- -- Washer, lock BOW36727 4
48- -- Nut, Hex BOW36603 4
.....,
i
1/89
f./ ,7
OPERATION/MAINTENANCE
AND
ILLUSTRATED PARTS MANUAL
FOR
CALAVAR SELF-PROPELLED CONDOR
QUBIC-8 MODEL 46
HAVING PLATFORM CAPACITY OF 500 LBS. {227 KG}
Calavar Corporation provides this Manual for the guidance of all

owners, operators and servicing personnel in order to obtain the
longest possible trouble-free service. It contains general data;
specifications; vendor information and specifications; illustrated
parts breakdown; and a special section on safety. '
CORPORATION
Serial Number____________~__--------____---------------
Date De 1ivered~_____________________________
Customer________________________________________ ~-
NOTE: Additional copies of this Manual {Calavar Part No. 92221}

may be obtained through the Parts Department at Calavar
Co~poration, Santa Fe Springs, California.
SERIES I (Starting with Serial No. 5259)

SELF-PROPELLED CONDOR QUBIC-8 MODEL 46
INDEX
OPERATION AND MAINTENANCE SECTION

Introduction
Calavar Warranty
Unloading Instructions
Check-Out Instructions
Factory Recommended Transporting Diagram
Conversion Tables, Degrees to Percentages
General Information:
• Condor Qubic-8 Model 46 Brochure
• General Data/Specifications
• Function Time Table
• Description of Hydraulic System
• Description of Electrical System
• Presetting Proportional Controllers
Troubleshooting Guide
Preventive Maintenance
• Preventive Maintenance Inspection
• Tightening Torque Values
• Hydraulic Oil Specification Sheet
• Lubrication Charts (2 and 3-Section Booms)
• Lubrication (Data Sheets)
• Lower Ring Gear-Bolts and Lockstrips
• Recommended Spare Parts List
VENDOR SECTION
.,\
• Wisconsin Engine (or optional Deutz Diesel Engine)

• WSI Rol-Seal Motor for Drive
• WSI Rol-Seal Brake
• Fairfield W1B Drive Torque Hub
• HPI/Nichols Proportional Control Valve
• Sundstrand Hydraulic Power Systems: Series "L" Pump
• Hydraulic Rotary Coupling
• Return Line Spin-A-Filter
• Sundstrand Multi-Axis Tilt Alarm
• Sundstrand Control Handle
• Sundstrand Ground Control Box Wiring Schematic
• Sundstrand Aerial Control Box Wiring Schematic
• Synchro-Start D.C. Solenoids
• Counterbalance Valve Cartridge
• CPI Waterproof Limit Switches
• White Hydraulics Motor for Turret Rotation
• Braden Speed Reducer for Turret Rotation
INDEX (Cont'd.)
PARTS SECTION
Parts Breakdown (See Section for Index)
Hydraulic Schematic (Calavar Drawing #35784)
Electrical Schematic (Calavar Drawing #35540)
SAFETY SECTION
"Self-Propelled Condor Operation and Safety Manual - Telescoping
Boom Models" - Form SP92212-5M-1085
"Safety Inspection for Self-Propelled Condor" - #242/2.5M/5-82
INTRODUCTION
The two primary functions of this Manual are to provide the customer with a
complete and up-to~date Parts Section, covering Condor Qubic-8machines
presently in production, and to assist in the training of operators and mechan-
ics: If used properly, it will provide the customer with a source of information
that will aid in solving the bulk of maintenance problems quickly and inexpens-
ive lye
This Manual also contains a Vendor Section. Calavar has included in it the
specification/parts/maintenance sheets for various critical components. Also
included is a general Trouble-Shooting Guide for your Condor unit.
Throughout this Manual, reference may be made to serial numbers of Condor units.
When ordering parts, use of this serial number will assist our Parts Department
in giving you prompt and accurate service. Serial numbers should be used at all
times in phone conversations with Calavar Service personnel. Also, the use of
correct serial numbers and part numbers will expedite completion of warranty
claims sent to Calavar.
Calavar has included a special section that deals with the safe operation of the
Condor Qubic-8, as well as information about certain items that must be inspected
periodically to ensure a safe operating unit. This Manual has been produced as
a valuable tool for our customers. It is in the best interest of everyone
involved with the operation of the machine to read and thoroughly understand all
sections of this Manual.
Condor Models are designed and built to conform to Calavar's understanding and
interpretation of all applicable OSHA and ANSI Rules and Regulations.
• OSHA Paragraph 1910.67 - Vehicle-Mounted Elevating and
Rotating Work Platforms--Labor
• OSHA Paragraph 1926.556 - Aerial Lifts--Construction
• ANSI Standard A92.5-1980 - Boom-Supported Elevating Work
Platforms
It is imperative that all owners and operators of the Condor read, understand
and conform to these regulations. Ultimate compliance to OSHA Regulations is
the responsibility of the employer utilizing the equipment.
CORPORATION
9200 SORENSEN AVE. • SANTA FE SPRINGS. CALIFORNIA 90670-2645 • (213) ~1 • TELEX 69-8378 • TELECOPIER (213) ~2265
Self-Propelled Booml and Scillon

WARRANTY
Calavar Corporation C'Calavar") warrants each new aerial work platfonn made by Calavar and bear-
ing the trademark "Condor" to be free from defects in mareriaJ. and workmanship.
The obligation and liability under this Warranty is expressly limited to repairing or, at Calavar's op-
tion, replacing free of charge at its factory in Santa Fe Springs, California or at an authorized repair facility
as designated by Calavar, any pan proving defective under nonnal use and service within 180 days after
said aerial work platfonn is first placed in service or within one year after the original shipment of said ae-
rial work platfonn from Calavar's plant. whichever first occun.
Parts claimed to be defective and for which repair or replacement is desired shan be. if requested by
Calavar. returned transportation prepaid to Calavar's factory for inspection. Replacement pans provided
under the terms of this Warranty are for the remainder of the Warranty period applicable to the aerial work
platfonn in which they are installed as if such pans were original components of the aerial work platform.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES. EXPRESSED OR IMPLIED, IN-
CLUDING BUT NOT LIMITED TO WARRANTIES OF MERCHANTABIUTY AND FITNESS FOR ANY
PARTICULAR PURPOSE, AND THE OBLIGATION AND UABIUTY OF CALAVAR UNDER THIS WAR-
RANTY SHAll NOT INCLUDE ANY TRANSPORTATION OR OTHER CHARGES OR THE COST OF IN-
STALLATION OR ANY UABILITY FOR DIRECT. INDIRECT OR CONSEQUENTIAL DAMAGES OR
DELAY RESULTING FROM THE DEFECT.
Any operation beyond rated capacity or the improper use or application of equipment or the substitu-
tion upon it of parts not approved by Calavu or any alteration or repair by others in such manner as. in
Calavar's judgment. to affect the equipment materially and adversely shall void this Warranty. No repre-
sentative of Calavar is authorized to change this Warranty in any way, and no attempt, effort or promise to
repair equipment of Calavar either by Calavu or by any representative of Calavar at any time shall change
or extend this Warranty in any way. This Warranty covers only new and unused aerial work platfonns
manufactUred by Calavar. Products or parts manufactured by others are covered only by such warranties as
are extended to Calavar by its suppliers.
IMPORTANT
UNLOADING INSTRUCTIONS FOR
Before unloading the Condor, inspect for any physical damage. Note any such
damageon·the·freight·bill and report it to·the carrier.
CAUTION: The self-propelled Condor Qubic-8 Model 46 weighs approximately

13,000 pounds and. must be unloaded on a sturdy ramp. For unloading the unit,
.select a site that is suitable for making the installation check-out and in-
spection. A "Condor Installation and Inspection Report" form has been provided
and must be completed before putting the Condor into service.
Operating instructions are located on a placard, which is attached to the
inside of the access door to the ground controls. Before starting the engine,
check-out the items as instructed on the placard and then proceed to operate
the Condor following the Check-Out Instructions in this manual.
Note: Grasp the control handle knob as if it were a ball, palm upwards on
top of the knob and the fingers on the bottom. Squeezing with the
fi.ngers will lift the bottom side of the control knob. This will
unlock the control handle so that it can be moved in either direction.
When the control handle is released and brought back to the neutral
position, it will lock automatically.
CAUTION: The lift controls are of the proportional type. The speed of movement
is dependent on the position of the control lever. Controls should always be
moved gradually. The normal driving position for the Condor is with the turret
counterweight over the drive wheels--the decal for controller movement is based
on this configuration. When the counterweight is positioned over the non-drive
axle, the drive and steering controls will be reversed. Try each control momen-
tarily to orient yourself with the direction of operation.
CAUTION: Before driving the unit down the ramp, test the automatic braking
system by moving the Condor slightly back and forth to make certain the brakes
apply each time the drive controller goes back to the neutral position. Move
th.eunit on the truck or trailer and down the ramp approximately a foot at a
time, allowing for steering corrections to be made. Keep the unit in alignment
with the carrier and ramp during the unloading procedure. It may be necessary
to elevate the boom slightly to clear the ground as you proceed down the ramp.
All Condor models are equipped with a slope-sensing device which has been
incorporated into the system. This device senses a 50 out-of-level condition--
that is, a condition in which the Condor is operating on a terrain that slopes
upward or downward by 50 or more. The slope sensor will automatically cancel
all boom functions at both control stations when such a situation occurs. An
indicator light, located in the aerial control console, will also warn of this
condition. Once the unit has reached an out-of-level condition of 50 or more
and boom functions are inoperable, the operator may, at his option, correct
UNLOADING INSTRUCTIONS FOR
(Cont'd.)
the situation by reversing drive direction, or by selecting an alternate route.

EVen though this is a safety device, it must not be considered a fail-safe
system. The operator must use normal safety precautions when operating thi s
equipment. The slope-sensing device isa safety system and must not be dis-
connected. Should this system be found indperative~ the unit must be grounded
and must not be used uritilthis system has been repaired.
CHECK-OUT INSTRUCTIONS FOR
The following instructions constitute a step-by-step procedure for checking

out ,the, self-propelled Condor Qubic-8 Model 46, while simultaneously acquaint-
ing operating personnel with its operation. The procedure will not take over
an hour and will give both operator and maintenance personnel a better under-
standing of the operation of the Condor. It will also provide an opportunity
to acquire experience in the operation of the unit.
Prior to placing the Condor into service, two things are necessary: first,
a full examination of the unit should be made, and, second, the ItCondor
Installation and Inspection Report lt should bl:.! completed and returned to the
factory. Each unit has undergone a thorough Quality Control inspection and,
furthermore, leaves Calavar in first-class condition. Unfortunately, trans-
portation damages may occur and you should be aware of such damages. If such
,damage has occurred, make a note of the damage on the consi gnee copy of the
freight bill. Calavar Corporation is not responsible for damages to units in
transit.
1. Visually inspect all parts of the Condor that are exposed. Check for
loose nuts, bolts, damaged hydraulic lines, broken wires, or structural
d.amages.
2. Check tires for cuts, slashes, etc.
3. Check hydraulic oil level; add Dexron II A. T.F. oil, if required.
4. Fill the gas tank. On units with Wisconsin gasoline engine, use
regul ar, leaded or unleaded gas.
5. Check the battery with a hydrometer. The battery must have a full
charge.
6. All hydraulic valves are located on a panel inside the turret cover
and are exposed by opening the inspection cover. After visual inspec-
tion of the turret compartment, close the inspection door before placing
the unit in service.
7. Turn on the master key switch at the ground station located inside the
turret door. Depress the Itstartll button and allow the engine to warm
up the idle. When the unit has warmed up and the ground/aerial selector
switch is in the Itgroundlt position, the unit can be operated by activating
switches marked in universal symbols for boom up, boom down, turret
rotation (left or right) and boom extend/retract. The Itstoplt button will
kill the engine with a momentary touch only. It is not necessary to turn
the master key switch off between running operations. This switch only
provides the operator with a means of electrically locking the Condor.
SELF-PROPELLED CONDOR QUBIC-B MODEL 46
(Cont 'd.)
Note: The Condor cannot be driven from the ground control console. Move
the selector switch to the aerial position, close the access door,
and then proceed to the platform.
NOTE UNIVERSAL SYMBOLS FOR AERIAL AND GROUND CONTROL CONSOLES.
B. With the master switch on, switch to the aerial position. The Condor
can be started or stopped from the aerial position. Position the unit
in an area that is free from any overhead obstruction. Lift the
bottom of the controller knob for boom up, push slowly to the up posi-
tion, and raise boom about 6 feet. When released, the controller will
return to the neutral position automatically. Learn to operate the
controller slowly to obtain the smoothest possible operation.
9. The self-propelled Condor has been designed to drive with the counter-
weight'over the drive wheels. This configuration will provid~ the best
tradlOn and a familiar driving position ..
10. A modular valve is located on the base between the drive wheels. It con-
tains several features: a flow divider cartridge, two diverter cartridges,
a two-speed solenoid cartridge, and a counterbalance valve. This modular
valve divides the oil for slow speed travel (with adjustable differential
action to round corners) and diverts the oil flow for high speed travel.
The counterbalance valve softens the brake release and application effi-
ciently without an accumulator.
11. The wheel drive has the following features:
• There is a high-low speed selection toggle switch (not universal
symbol) on the aerial control box.
• In high speed mode, no aerial functions can be operated (even if the
operator activates the controllers that command the aerial functions).
• In high speed mode, with the boom in stowed position, the vehicle has
a 0-3 MPH speed capability (fully proportional).
• In low speed mode, the vehicle has a 0-1.5 MPH speed capability (fully
proportional).
• All aerial functions can only be operated in low speed mode.
• At no time can the operator shift from high to low while the unit is
in movement (the high-low toggle switch is only functional when the
controller for the drive function is in the neutral position).
(Cont 'd.)
12. Operate the boom at the horizontal position until you have familiarized
yourself with its operation and the feel of the controllers. The more
smoothly you operate the controller, the more smoothly the unit will
respond.
13. Gradually operate the unit up to maximum elevation and extension.
14. All self-propelled Condor models are equipped with a slope-sensing device
which has been incorporated into the system. This device senses a 5°
out-of-level condition--that is, a condition in which the Condor is operat-
ing on a terrain that slopes upward or downward by 5° or more. The slope
sensor will automatically cancel all boom functions at both control
stations when such a situation occurs. An indicator light, located in
the aerial control console, will also warn of this condition. Once the
unit has reached an out-of-level condition of 5° or more and boom functions
are inoperable, the operator may, at his option, correct the situation by
reversing the drive direction, or by selecting an alternate route. Even
though this is a safety device, it must not be considered a fail-safe
system. The operator must use normal safety precautions when operating
this equipment. The slope-sensing device is a safety system and must not
be disconnected. Should this syst~m be found inoperative, the unit mu~
be grounded and must not be used until this system has been repaired.
CALAVAR CORPORATION
SELF-PROPELLED TELESCOPIC AERIAL YORK PLATFORM
CONDOR INSTALLATION AND INSPECTION REPORT
Dealer's fIaIIe _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
~l ______________________
Address
-------------------
Serial Ntnber _ _ _ _ _ _ _ _ _ _ __ Oate ________________
This CONDOR was inspected and tested before leaving CALAVAR. Due tg environmental conditions, loading, transporting
and unloading the unit, it will be necessary for you to check the following items to assure the user of a first clas
product. This report. when completed. must be returned to Calavar Corp •• 9200 Sorensen Ave., Santa Fe Springs. CA
90670.
ltell Initial If
110. Description of Inspection or Test O.K. ReIIilrks
1 GElERAL APPEARAIICE
A Visual Damage to unit

B Visual fluid leaks I
C Paint damage i
I
i
Z ENGINE SERVICING I
i
!
I
A Enaine oil level
B Battery condition i
1 Electrolvte level !
2 Terminal security :
!
3 GROUND CONTROL STATION
A Enaine start
B Choke operati on
C Starter operation
D Governor ooeration
E Alternator operation
F Station selection
G Boom liftina
H Boom extension
I Turret rotation
J Enaine stop
K Speed control
l Emeraency
4 TIRE CONDITION LF LR RF RR
A Ti re pressure
(Note Decal on Base) .
B lua nuts
(OVER)
tell Initial If
o. Description of Inspection or Test O.K. Remarks
AERIAL CONTROL STATI(JI
A Enqine start
B Boom liftina control Up Down
C Boom extension Out In
D Turret rotation CW CCW
E Platform rotation Left Right
F Platform tilt Left RiQht
G Drive hiQh Forward Reverse
H Drive low Forward Reverse
I SteerinQ Left RiQht
J Brakes Forward Reverse
K 2-speed shift Low HiQh
L EnQine stOD
M 5° slope liQht
HYDRAULIC C(JIJ(I(EIffS
A Platform swing actuator

B Pin retainer
C Boom lift cx1inder
D Pi n reta i ner
E Master leveling cylinder
F Pin retainer
G Slave leveling cylinder
H Pin retainer
I Boom extension cylinder
J Pin retainer
K Steed ng cy1 i nder
L Pin retainer
M Drive motors Left I Right
N Brake assembly Left RiQht
0 Drive block
P Positive traction
0 Turret rotation Qear box
R Turret rotation motor
, S Hydraulic pump
,
T Hvdraulic tank
U Hydraulic filter
V Valve Panel (Proportional)
W Valve (Solenoid)
1 ELECTRICAl C(JlJQflEIITS
A Moving warning horn

B Two-speed limit switch
C Deadman foot switch
D Hour meter
8 GENERAl SERVICING
A Hydraulic oil level

B Air cleaner oil level
C Turret lube Doints
0 Chassis lube Doints
E Boom Lube Doints I
Inspection performed by ____________

Name Title Date
FACTORY RECOMMENDED
TRANSPORTING DIAGRAM
PALLETS
CONVERSION TABLE
DEGREES TO PERCENTAGE
Since the conversion of gradeability is often referred to

in percentages and then on the other hand often referred
100%
to in degrees, this chart is being provided for your
convenience to quickly convert percents to 95%
degrees.
90%
85%
80%
75%
70%
65%
60%
55%
50%
45%
40%
35%
30%
25%
20%
15%
10%
5%
--- 100 ft. ---

GENERAL DATA/SPECIFICATIONS
1. Gasoline Engine
(a) Wisconsin Model VG4D (37 HP Air-Cooled Gas Engine)
(b) Operating Speed (2,150 RPM)
(c) Idle Speed (1,250 RPM)
(d) Battery (12-Volt, l40-Amp Hr)
(e) Alternator (37 Amp)
2. Diesel Engine (Option)
(a) Deutz Diesel Model F2L9l2
(b) Operating Speed (2,200 RPM)
(c) Idle Speed (2,200 RPM)
(d) Battery (12-Volt, l40-Amp Hr.)
(e) Alternator (33 Amp)
3. Pump
(a) Sundstrand Series L38
(b) Compensator Pressure Setting (2,500 PSI)
(c) Load Sensing Differential (350 PSI)
4. Proportional Control Valve
(a) HPI/Nichols
(b) Main System Relief (3,200 PSI)
(c) Operating Voltage (0-12 Volts)
5. Solenoid Control Valve
(a) Manifold Design with Cartridges
(b) Operating Voltage (12-Volt)
(c) Operating Flow{2 GPM)
6. Holding Valves (Set and Sealed at Factory)
(a) Platform Leveling (pilot-operated check valve)
(b) Boom Li ft Ho 1di ng Valve (2,900 PSI)
(c) Boom Extension Holding Valve (2,'900 PSI)
(d) Platform Rotation (pilot-operated check valve)
GENERAL DATA/SPECIFICATIONS
(Cant Id.)
7. Ring Gear Bolts

(aY Base to· Ring Gear (105 ft-lbs.)
(b) Turret to Ring Gear (205 ft-lbs.)
8. Weight (Approximate Only)
13,000 lbs.
9. Tires
12 x 16.5; load Range 110 11 ; Pneumatic;
Inflation Pressure = 65 PSI
SELF-PROPELLED AERIAL WORK PLATFORM
• Zero Tail-Swing • 46-Foot Working Height

• 500 Pound Unrestricted Platform Capacity
PLATFORM: Welded tubular steel construction with expand-
Key Features and ed metal floor and continuous top railing. Protected opening for
Technological Improvements easy access. Self-leveling with power adjustment. Control
console for all functions.
BOOM & ELEVATING SYSTEM: Both systems are acti-
Calavar engineers have once again produced a sig- vated by double acting hydraulic cylinder with built-in load-
nificant advancement in the aerial· work platform holding valves. Boom elevation from -20· to +70· above hori-
state-of-the-art. In addition to the benefits listed zontal Two section, steel telescoping dry-type boom. Inner
section slides on low friction, adjustable wear pads. All hoses
above, the Condor Qubie-a@> Model 46 provides and wiring are contained in plastic track inside the boom,
many other important new features. eliminating all mechanical moving parts.
• Unequalled rough-terrain capability TURRET: Heavy plate stee~ welded construction, mounted
on sealed bearing internal-tooth ring gear. Driven hydraulically
• Front-wheel drive and steer by a planetary gear reducer with built-in brake. Continuous
• Tru-Tral(l3 power steering 360· rotation in either direction. Swing out doors allow for easy
• Patented boom design (U.S. Patent 4,506,480) maintenance. Turret houses engine, hydraulic pump and valves,
emergency system, rotation gear reducer, ground control pane~
• Central lubrication system for boom pivot pins hydraulic and fuel tanks.
• Integrated power module(englne, hydraulic pump
and tank assembly) for ease of service PLATFORM CONTROL CONSOLE: Sealed, spring-
loaded proportional controllers (with deadman feature) for
• Planetary gear reducer with built-in brake for drive, turret rotation, boom extensiOn/retraction and elevation.
smoother turret rotation Toggle switches for steering, platform tilt and rotation, emer-
• 18 gradeability (32%)
0 gency power functions, and hi-low speed. Slope-sensor light
and engine starVstop button All functions marked with
permanent-type universal symbols.
CAPACITY: 500 lb. (227 kg) unrestricted platform capacity in GROUND CONTROL CONSOLE: Permits ground oper-
any boom position with or without 180' platform rotation. ation of all boom functions, turret rotation, engine starVstop,
CHASSIS: Rigidly welded Heavy steel plate. aeriaVground selector switch, power switch and emergency
power system. Variable speed control for boom functions. All
functions marked with permanent-type universal symbols.
STEERING: Front-wheel drive and steer with Tru-Trak@>
power·steering.
ELECTRICAL SYSTEM: 12 volt DC, heavy duty, 140 A.H.
rated storage battery with externally driven 37 Amp alternator.
HYDRAULIC SYSTEM: Closed-center, load-sensing sys-
tem using pressure-compensated, piston pump directly driven
byengine. Pumpdelivers23 gpm(87 Lpm) at 2400 rpm. System
pressure 2500 psi (172 bars).
WHEEL DRIVE: Two-speed drive for high gradeability or
high speed Torque hubs on steer wheels driven by reversible
hydraulic motors. Disc brakes are automatically spring applied
and hydraulically released.
ENGINE: Wisconsin ModeIVG4D gasoline engine, aircooled,
37 HP at 2400 rpm. Oil bath air filter.
SAFETY FEATU RES: 5· multi-axis slope sensor with warn-
ing light. Drive/descent warning horn. Emergency power system
for retraction, rotation and lowering. Meets or exceeds all ANSI
A92.5-1980 and OSHA requirements.
Specifications Boom Angle vs Reach and Height
English Metric 2-Section Boom
Platform Capacity (Unrestricted)..... 500 Ibs. 227 kg Tip-Mounted Platform (Standard)
Platform (tubular steel) .............. 60"x30"x43v." 1.52x.76x1.1 m
Platform Height .....•......•.....•.. 40 ft 12.2 m
Working Height ..•..............•... 46 ft 14.0 m
Length (stowed) 2-Sectlon Boom..... 26 ft 7.92 m
Length (stowed) 3-Section Boom (opt)21 ft 6 in. 6.55 m
Height (stowed) ..................... 7 ft 10 In.
Width .•.•.......•................•.. 7 ft 10 in.
2.39 m
2.39 m •
40'0"
(12.19 m)
Outside Turning Radius .......•..... 15 ft 4.57 m
Inside Turning Radius ..•........•.•. 7 ft 2:13 m
3$6'"
(11.43 m)
Wheel Base ......................... 8 ft 2.44 m
Gross Weight (approximate) ......... 13,000 Ibs. 5896 kg t
32'0"
Gradeability•.....•••...•.....•...... 18° (32%) 18° (32%) (9.75 m)
Fuel Tank Capacity •.•..•.•.•....... 27 U.S. gals. 102 L

Hydraulic Tank Capacity .........••. 27 U.S. gals. 102 L
25'0"
Travel Speed .••.•.................. 0 to 3 mph 0 to 4.8 km/hr (7.62 m)
Tires; pneumatic ..•................. 12x16.5; Load Range "0"
Turret Tail-Swing .••••....•.......... Zero Zero
Ground Clearance ..............•... 12" 30.5 cm
35'0"
(10.67 m)
dE 17'0"
(5.18".
Standard Equipment 34'0"

t
S'O"
.
~(lo.36 m)EtIJ (2.44 m)
Front-Wheel Drive and Steer Gauges: Fue~ Hydraulic, Ammeter
Emergency Power System 5° Multi-Axis Slope Sensor --~~~---=:~!!!!!!!!..~---r-
Lifting Eyes
Drive/Descent Warning Horn
Hour Meter
Tip-mounted Platform Configuration
I~~
~
-1'0"
10.30m)
-----26:(7.92 m)- -~3'O" I--'-r,~
(10.08 m)"""-' -4'0"
(1.22 m)
Optional Equipment Solid or Foam-Filled Tires

Platform Rotation, 180° Air line to Platform 2-Section Boom
Three-Section Boom Platform Work Light Top-Mounted Platform (Optional)
Top-Mounted Platform Configuration: Rotating Beacon/Strobe light
48 ft (14.6m) Working Height, 750 lb.
I
Head and Tail Lights
(340kg) Platform Capacity
Four-Wheel Drive
110 V Generator
Electrical Outlet at Platform, 110V
I
Deutz Diesel Engine
lister Diesel Engine
Dual Fuel (propane and gas)
Foot-Type Deadman Switch
Hand Pump for Emergency I ,
42'0"(121 m)
39'6"
43.5 Ib. LP Tank

Electric Battery-Powered Unit
Lowering Only
Platform with Gate Entrance
Special Paint (one color)
t (12.04 m)
t \
34'0"
Hostile Environment Kit (10.36 m)
ZERO TAIL SWING f

27'0"
(S.23m)
.:::===~======-=~
-
31'6"
O' (9.60 m)
J -.-
IS'6"
(5.84m)
10'0"m)
(3.05
Specifications subject to change without prior notice.
SOLD, RENTED & SERVICED BY:
CORPORATION
9200 Sorensen, Santa Fe Springs. CA 90670-2645

(213) 946-6561 • Telex 69-8378 • Fax 213-946-2265
All Condor units meet or exceed deSign and test standards required by the Form NO.444R-5M·1287 Copyright 1985, CalavarCorporation
American National Standards Institute and OSHA Printed in U.S.A.
DESCRIPTION OF HYDRAULIC SYSTEM
Following is a detailed description of the hydraulic system for the Qubic-8 Model 46. This
description is to be used in conjunction with Hydraulic Schematic Drawing #35399.
The hydraulic system of the Condor is of the "closed-center" type; that is, when control
valves are in the neutral or center position, the internal passages of the valves are closed
off to the flow from the pump. The system operates at a maximum pressure of 2,500 PSI,
set and maintained by the pump compensator.
The main Hydraulic Pump #37198 is a Rexroth Model AA 1OV. It is a variable-volume,

pressure-flow compensating (load-sensing) axial piston pump having a capacity of 20
gallons per minute at a speed of 2,150 RPM. The pump load-sensing coml'ensator
control automatically adjusts the pump delivery to maintain flow requirements of the
system at a pressure of approximately 350 PSI above the load.
The pump is driven directly from the engine shaft and draws its fluid from the hydraulic
reservoir. The hydraulic fluid is multi-viscosity Shell Tellus T32. Filtration of the fluid is
accomplished by a 100-mesh Sump Strainer #21473, located in the tank, and also by,a
10 micron Filter #32522 located in the system return-line.
r A Check Valve #21368 is located in the main system pressure line. This valve is used
to prevent flow from entering the main pump when the emergency system is used.
The pump discharge flow is directed to the H.P.I. Proportional Control Valve Assembly
#32560. The pump is equipped with a sensing port that is connected to the proportional
control valve assembly. This connection of the sensing port measures the pressure drop
across the control valve spool opening (orifice) and automatically adjusts the pump
displacement to match the demand. The load-sensing differential pressure is
approximately 350 PSI and is set and maintained by the pump compensator.
When the engine is started and running at idle and no function is in operation, no pump
flow exists. However, the pump does develop standby pressure that will equal the load~
sensing differential pressure of approximately 350 PSI. A control function must be
operated to place the pump or stroke in order to deliver the required flow/pressure.
!.
(Cont,rd. )
Proportional Control
The Proportional Control Valve Assembly #32560 is used for operating the drive,
lift, rotation and boom telescope functions. The valve is manufactured by
HPI/Nichols and is a load-sensing, four-way directional and proportional con-
t.rol 'system operated by a variable DC electrical signal (0-12 volts DC).
The valve assembly is composed of a manifold, which is drilled and ported to
accommodate four solenoid valves, four cartridge compensators, Various orifices,
shuttle valves and a solenoid-operated auxiliary function module. This makes
it possible to perform one or more independent or simultaneous operations
(driv..e; boom up or down, boom extension or retraction, and turret rotation).
When one or more controllers are actuated, an electrical signal causes the
directional Valve spool(s) to move proportionately to the controller lever
movement. For example, small controller movement results in a small spool
movement in. the directional valve.
The combination unloading and relief valve of the subplate has an internal
pilot pressure line with its dampening throttle (compensator). The internal
pilot pressure lines sense the load pressure of the first-operated directional
control valve, and maintain the pump pressure at approximately 85 PSI higher
than the required load pressure. This maintains a constant pressure drop of
B5 PSI across the entering metering orifice of the fully balanced spool. The
flQw, through the valve depends only on the position of the spool, regardless
of load changes.
Drive Function
When the drive control is activated, it energizes the drive control valve, and.
thus, allows the flow of oil to go to the Drive Motors #21568 through the
rotarycouplin #32554 .. , A ,Modular Valve Assembly #32800 is incorporated into
the qrive system. The modular valve consists of a flow control valve, a flow
divider, solenoid valve, diverter valve, a shuttle valve, a needle valve, and
a double counterbalance valve with relief section. These components are of the
cartridge type, wi th a mani fo 1d block that is i ntri cate ly ported.
When the drive controller is activated and the flow is going to the drive motors,
the hydraulic fluid is directed to the brake system , as welL The brakes are
spril1g~ loa.ded so that they lock when there is nO pressure in the hydraulic
'System. _Therefore, they must be released by the hydraulic flow. As the flow
,enters the modular vahte, the pressure opens the poppet of the counterbalance
valve .and actuates the shuttle valve, permitting the oil to flow to the brakes.
The, brakes are thus released, and the fluid passes through the flow control
valve in an unrestricted path.
When the brakes are applied as the drive control is returned to the neutral
position, the flow gently ceases its travel to the drive motors, providing a
(Contld.)
DriVe Function (Contld.)

-
smooth braking action. This operation is accomplished by incorporating into
the system the double counterbalance valVe which is pilot-operated and which
permits the motors to operate briefly after the controller is returned to
neutral. In addition, the oil is restricted by the flow control valve.
The unit is equipped with a two-speed drive and is only operational under
certain conditions. The low-speed drive can alwaYs be selected by operation
of Solenoid Valve #58079, located on the turret .. The high-speed drive, however,
canorily be executed when the boom is below horizontal and fully retracted.
For safety, the two-speed drive feature is automati ca lly controlled through
the electrical and hydraulic drcuitry. When the boom is raised above hori-
zontal, a lim.it switch is activated, which in turn energizes the solenoid
valv~ #5807:9. This valve is a three-way, two-position, spool-type direct-
acting sblenoid~ The ,spool shifts as the solenoid is energized, directing the
flow .of()il to the diverter valve in 'the drive valve assembly #32800 and
c:aus i I1g it to shi ft also.
The diverter valve is a two-position double-selector valve that is used to
direct the flow of oil to two separate ci-rcuits. As the spool of the valve is
moved, .one ,set of outlet ports starts to close and the other set of outlet ports
starts to open. This .enables 'smooth shifting from one speed to the other:
connetting the drive motors either inparall~l or in series.
Positractionis an additional feature of the drive system. For this system, a
needle valve is installed ion ,the drive motor line. Closing of .this needle
valve forces the f1oW.of oil thro!Jgh a flow divider. On this valve, the inlet
flow p,asses 'throl.(gh two matched or,ifice.s to the outlets at a 50/50 ratio. If
,the flow to one outlet increases, the greater pressure drops across that spool,
causing the spools to shift, r2stricting that outlet and equalizing the flows.
Thus, the purpose of the divider is to ensure that both drive motors are
operating in an equal manner.
Boom Lift Function
The second valve section (moving from left to right) of the proportional Valve
Bank #32560 is used to control the boom lift function. When the appropriate
control is activated, the 'hydraulic flow is directed to the topping cylinder,
which either raises or lowers the boom. Installed in this drcuit is a lock
valve 'which the fluid m.ust'p'ass throu'gh before entering the cylinder. This
v~lve is a counterbalance valve with relief valve section, and is of a cartridge
co.nfiguration~ It is used t.o lock the fluid in the piston side of the cylinder.
As the control is actuated, pressure opens the poppet, allowing free flow to the
cylinder. As the pressure ceases, the valve locks. When the direction of fluid
'is reversed, the fluid is emptied from the cylinder .and the fluid returns through
the relief valve settion, which is opened by pilot pressure. An orifice is
instalJedin ,the topping circuit to smooth this operation.
(Cant '-d.)
Turret Rotation
The third section of the proportional control valve bank is used to control
the turr(?t rotation. When control is activaJed, flow is directed to the
appropriate side of the Rotation Motor #32762, causing the turret to rotate
right or left.
A Crossport Relief Valve #32763 is installed in the motor circuit. The
purpose of this valve is to protect the rotational gear box against excessive
_pre_ssure caused by the sudde.n stopping of the rotation function. Shuttle
Valve #35096 is used to release the brake on the speed reducer for turret
rotation.
Boom Extension-Retraction
The fourth valve (the last section of the proportional valve bank) is used for
the boom extension-retraction function. When the appropriate control is ener-
gized, the hydraulic fluid is directed to the boom cylinder for either extending
or retracdng the boom inner section(s). Before the fluid enters the cylinder,
it must first pass thrqugh a cylinder lock valve. This lock valve is of the
internal _cartridge type5. and isa double counterbalance valve equipped with a
relief .valve section.._ . T.he fluid is free to flow in one direction through the
b~ll check. As the pressure ceases, the valves lock. When its direction is
reversed, the fluid is flushed from the cylinders. It then comes back through
the relief valve section, which is opened .by pilot pressure.
A separate relief valve is installed on the piston side or the extension side
of the cyl i nder and js set at 1400 PSI. This valve 1imits the amount of out-
~ard forc;e than can be applied with the cylinder.
Steering, Platform Tilt~ Platform Rotation

The steering, platform tilt, and platform rotation, if equipped, are controlled
by spring-centered, four-way directional solenoid valves. These three Valves
1t58189 are banked together as one unit, in a parallel circuitry having a common
inlet and a return to the tank outlet.
The· pressure line of the solenoid valve bank is connected to the auxiliary
func;tion module of the proportional valve bank. When one of these functions is
operated, it activates _the solenoid of the auxiliary function valve, which
~h_ifts the spool and allows the flow of oil to extend to the solenoid valve
ban.k.. In this particular phase of the system, there is no compensator used to
establish the load-sensing factor back to the pump, so the flow going to the
auxiliary functions will reach maximum pressure when the solenoid is activated.
To ljmit the flow, a flow control valve set at 2 GPM is installed in the valve
modul e.
The -flow of oil first enters the steering solenoid valve. By actuating the
steering toggle control switch, the appropriate solenoid coil is energized.
Thi.s shifts :the valve _spool so the flow of oil is directed through the rotary
(Cont'd.)
Steering" Platform Tilt, Platform Rotation (Cont'd.)
coupling #32554 to either the rod or the piston side of the Steering
Hydra.ulJcCylinder #35087. This particular solenoid valve is equipped with
a cylinder lock valve attached directly to the solenoid. The lock valve
consists of a two-,stage poppet, which minimizes decompression shock and
provides for prolonged, PQsitive holding of the cylinder piston. With the
solenoid xalv,e i,n ~he neutral position, flow from both ends of the cylinder
i~ blocked by the double cylinder lock v.alve .. When energization of the
solenoid has directed the flow to one side of the cylinder, the pressure
0R~ns the poppet and simultaneously moves the piston over to the opposite
poppet, thus allowing fr~e flow to the cylinder. The return fluid is allowed
to return to the tank.
Pl atform Ii 1t
The center valve of the solenoid valve bank #58189 is used to control the
platform tilt. The Cylinder #30596 actually performs a two-fold function.
I.t is primarily used as the slave cylinder in the leveling system. Its second
functi.on is that of tilting the platform on a vertical plane.
'To simplify the explana-tion of the tilt system, a brief description of the
leveliJ19, system is inserted at this point. .
The leveling system employs two hydraulic cylinders, a Master Cylinder #35075
and a, Slave Cylinder #~05_96. This isa closed loop system and the flow of oil
is not ,dependent upon the pump flow and/or pressure. The flow of oil is caused
instead by movement of the boom. As the boom is lowered, the master cylinder
retracts. This forces the fluid from the piston side of the master cylinder
and directs it to the piston side of the slave cylinder~ This in turn causes
the slave cylinder to extend. The cavity left in the rod side of the master
cylinder is replenished by fluid that is forced out of the rod side of the
slave cylinder. When boomi,s raised, the reverse occurs.
The fluid is locked in the system by use of a double over center counter-
ba14nce valve equipped with a relief valve section. The relief valve is set
higher than the load-induced pressure; it is used to protect the system against
situations that ,m.ay cause higher-than-normal pressures. (An example of such a
situation would be an bver10~ded platform.)
The system is designed to keep the platform level when the unit is in a static
condition. Because of this, the fluid must be trapped in both sides of the
slave cylinder until released. This is accomplished by a double-pilot Ball
G.h,eck Va,lve #30322 installed at the cylinder. This valve permits a free flow
in onecttrection. This is achieved by the fluid unseating the spring-loaded
ball check. The flow is blocked in the other direction; to release it,
pre~sure must be _a,pplied to the pilot piston in order to unseat the ball check.
The Master Cylinder #35075 is unaffected, since it is basically being held in
statii; positi,on by the boom or the lift cylinder.
. (Co·nt Id.)
Platform Tilt (Contld.)

The last valve in the Solenoid Valve Bank #58189 is used for the platform
rotation system (Note: This is an option. Unless specified, units may not
be equipped with this system.) The rotation mechanism, located on the end
of the inner boom, consists of Hydraulic Cylinder #35469 with a bell-crank
arrangement. As the solenoid valve is energized for rotation to the left,
flow passes through a pilot-operated Check Valve #21480. This unseats the
popp~t, allowing the floW to go to the appropriate side of the rotation
cy}inder •. Needle Valve #21479 is installed to enable rotation speed to be
adj~sted.
The system return to the tank is equipped with a 10 micron Filter #32522.
Emergency Power System
Should the main system fail or malfunction, an emergency battery-powered
syste.m is provided as a ba.<:kup to the system. This system can lower the
b.oom, retract the boom and ro.tate the turret, one function at a time. The
Power Source #35659 consists of a 12-volt DC battery-powered electric motor
with an integral hydraulic pump. The p.ump is equipped with a built-in relief
Va 1ve and cl1eck valve. An .addJ ti ona 1 CheGk Valve #21368 is i nsta 11 ed in the
system to prevent the flow from entering the main pump while the emergency
s"'y.stem is being used. _
DESCRIPTION Of ELECTRICAL SYSTEM
The self-propelled Condor Qubic-8 Model 46 utilizes a 12-volt DC electrical

system with a negative ground. The control circuit has some unique features
that require a detailed explanation. These features are described below
(refer to Electrical Schematic Drawing #35540).
Ignition
Turning the master key switch at the ground control console brings +12 volts
to the control circuits.
Engi ne Start
The engine can be started from the ground console or the aerial console,
regardless of the position of the selector switch (ground control/aerial con-
trol) on the ground console.
When the start contact is made, relay R1 is energized. The normally open
contacts of R1 are closed, bringing power to the starter motor. Also, latching
relay coil LR1A is energized and closes the normally open contacts of LR1A.
This brings power to the following:
• the running hour-meter
• the strobe light/rotating beacon
• the 50 slope alarm
• the wanning-light circuit for 50 slope alarm (the light comes on only when
the device senses 50 out-of-level condition)
• the ignition coil
• gasoline valve of LP gas valve, depending on the position of selector
switch forgasolfne/lP gas.
At ~he same time, the normally closed contacts LR1B of latching relay are
closed. This enables the HI-speed circuit to operate.
When the voltage output of the alternator reaches a predetermined level, coil
R11 is energized, and normally closed contacts R11 are opened. This removes
power from coil Rl. As long as the voltage is high, R1 cannot be energized
and the starter motor cannot be activated (~\anti-restart" protection).
Choke
The control switches for choke operation are the momentary type. The choke
can be operated either from the ground console or the aerial console, regardless
of the position of the ground/aerial selector switch. When either one of them
is closed, coil R12 is energized and normally open contacts R12 are closed,
energizing the choke solenoid.
DESCRIPTION OF ELECTRICAL SYSTEM
(Cont 'd.)
Engine Stop
The engine can be stopped either from the ground console or the aerial
console, regardless of the position of :the ground/aerial selector switch.
When the stop switch is closed, the coil of the latchin.g relay LR1B is
energized and the normally open contacts LR1A are opened. This removes
power from the circuits they had energized at the starting of the engine.
The normally closed contacts LR1B are also opened. This has the effect of
disabling the high-speed relay coil, as well as removing power from both
the aerial and ground control circuits.
Aerial/Ground Selector Switch

There are 3 sets of contacts on the aerial/ground selector switch. When the
sWitch is moved to aerial position, 12 volts are brought to mode #6 on one
set of contacts. This allows activation of the HPl auxilliary-head circuit
(when the following functions are operated: steer, platform tilt, and plat-
form rotation), the drive hand controller, and the engine throttle circuit.
When the selector switch is in the ground position, power is brought to the
low-speed circuit, which places the machine in low-speed mode. Power is .
brought to the ground control functions through a variable resistor which
controls the speed of the functions (when in the ground mode).
The seco nd set of contacts on the aeri a1 /ground selector swi tch enables boom
lift, turret rotation, and boom extension by bringing power to wire #4 when
in the aerial mode. Both contacts LR2A (high-low speed circuit) and R6 (slope
detection circuit) must be closed to complete the circuit.
When in the ground mode, wire #40 enables the operation of engine-throttle
circuit when the ground functions are in operation.
The third set of contacts on the aerial/ground selector switches the control
of the throttle solenoid between the aerial functions and the ground functions.
5° Slope Alarm
A ti rcuit is incorporated to prevent the operation of boom functions when the
unit is on a slope that exceeds 5°. This circuit employs a multi-axis slope
sensor; containing a pendulum and time-delay relay.
With the key switch on, the slope sensor is activated and prepared to cancel
boom operations should the unit exceed 5° out-of-level. When 5° out-of-level
condition is sensed by the slope sensor, contact is made by the pendulum which
(Cont'd.)
energizes the time-delay relay. If the pendulum remains in contact longer

than approximately 4 seconds, the coil R6 is energized. The normally closed
contacts R6 are opened. This prevents the aerial functions (boom lift, boom
extension and turret rotation) from operating. The indicator light on the
aerial control console also warns of this condition. However, the drive
circuit remains operational.
Emergency Power
The machine is equipped with an emergency power system which allows the
operator to bring the platform down in case there is a malfunction of the
engine or the main hydraulic pump. There is a separate electric motor and
hydraulic pump for this emergency sttuation. The following three functions
can be operated: boom lower, turret rotation (left or right), boom telescope
(extend or retract). In the aerial console, separate toggle switches are used
for control. In the ground station, the normal function switches are used.
In both consoles, an emergency power switch must be held down to start the
emergency electric motor and ,activate the controls. Controls can be operated
from either the ground station or the aerial station, regardless of the posi-
tion of the ground/aerial selector switch on the ground console.
When the emergency control switch in the aerial console is held down, power
runs through wi re . #3 to theappropnate contacts of the emergency control
toggle switches. Each functton is controlled by three ganged form C-switches.
One set of contacts provides power to the desired function by being wired to
the appropriate proportional output wire. The seco,nd set of contacts freezes
(grounds) the opposite, corresponding function. For example, if turret rotation
IIleftll is called for, turret rotation IIright" is grounded. This means that
contradictory commands cannot be given simultaneously from the two consoles.
The third set of contacts energizes the coil R3 through wire #68 and closes
normally open contacts R3, which energizes the emergency-power electric motor.
In the ground console, the emergency control switch is a 2-ganged form C-switch.
One set of contacts energizes coil R3 through wire #68 and closes normally open
contacts R3, which in turn energi_zes the emergency-power electric motor. The
other set of contacts powers wire #260, which is connected to the common terminal
on the individual function controls. -This brings power to this point, regard-
less of the position of the ground/aerial selector switch.
The normally closed contacts LRIB are also opened. This has the effect of dis-
abling the high-speed relay coil, as well as removing power from both the aerial
and ground control circuits.
(Cont 'd.)
Drive
If the aerial mode has been selected, the drive hand controller is energized
and the handle position controls the forward speed within two ranges: high
and low. It·.the machine is inaeria1 mode, one can change the high-low
condition only when the drive hand controller is in the neutral position.
If the machine is in ground mode, the machine is forced into low speed mode
(as explained below).
To enter high speed mode, the drive speed switch is moved to the high speed
position. Jf t.he machine is in aeria,l mode and the drive hand control is
in neutral, then 12 volts is supplied through the drive speed switch to the
coil of LR2B. Between the drive speed switch and the coil is one limit switch,
which must be closed. This is on the turret. If the boom is above horizontal,
the high speed mode is not possible. The normally open contacts LR2B close and
coil R2 is energized. This in turn closes the normally open contacts R2 which
energize the high speed valve.
In addition, four normally closed contact LR2A are opened, preventing the aerial
operation of the boom lJf.t, turret rotation, extension and tilt.
To enter low speed mode, the drive speed switch is moved to the low speed posi-
.tion. A9.aJn, Jhe drive hand control. must be in neutral for this circuit to be
powe.red when in the aerial mode. The coil of latching relay LR2A is energized
And normally open contacts LR2A are closed, thus making possible the same aerial
operations which were preve.nted in the high speed mode. Furthermore, the
normally open contacts.LR2B are opened and the coil R2 is de-energized, thus
opening normally open contacts R2 and de-energizing the high speed valve.
High-Low Speed Circuit for Drive

The -high-fow speed circuit serves l,WO purposes. The first is to provide safe
operation when the boom is raised above horizontal. In this situation, the
~ravel speed is automatically shifted to low speed. The second is to permit
the oper:.a.tor to select the desired speed when in travel configuration (stowed
posit.ion) .
Platform Tilt and Boom Lift

the platform tilt is "enabled" by wire #47, which gets its power from the auxil-
iary switch wit.hin the bOQ!l1 11ft hand controller. The platform tilt receives
poweT only when the boom 1ift (toppi ng) controller handle is in the neutral
position.
PREVENTIVE MAINTENANCE
GENERAL
The finest equipment manufactured is only as good as it is maintained. Costly
repairs and loss of revenue can often b~ avoided by planning ahead, setting a
regular schedule and exercising preventive maintenance techniques. You can do
preventive maintenance NOW or costly repairs LATER.
This Section is devoted to the preventive maintenance program of the Condor
and is broken down into two phases: (1) INSPECTION and (2) LUBRICATION. A
lubrication chart (Sheets 1 and 2) and a complete preventive maintenance
interval checklist is provided.
The preventive maintenance inspection is generally, but not exclusively, the
responsibility of the operator. Since it directly affects his safety, it is
in his best interest that the inspection maintenance be carried out. The
preventive maintenance lubrication is the responsibility of the serviceman or
mechanic, since shop time will be required to perform the maintenance tasks in
some instances.
Many of the suggestions for preventive maintenance described and noted herein
may sound time-consuming and expensive. This is not the case. The program
has been carefully structured and, if followed closely, will result in an
extended life expectancy of the unit, as well as a reduction in downtime and
costly repairs.
The inspections and checks listed are not intended to replace any local or
regional regulations which may pertain to this type of equipment, nor should
the list and schedule be considered all-inclusive. Interval times may vary
due to climate and/or conditions~ depending on the location and use of the
~achine.
Always ensure that applicable safety precautions are strictly observed when
performing the maintenance inspections and checks. Make certain that damaged
components, or those in need of adjustment, repair or replacement, are corrected
before operation.
FUNCTION TIME TABLE (± 10%)
FUNCTION MODEL
Boom Extension 31 Seconds

Boom Retraction 21 Seconds
Topping - Up 40 Seconds
Topping - Down 30 Seconds
Turret Rotation - CW 120 Seconds
Turret Rotation - CCW 120 Seconds
200-Ft. Drive Forward - High 44 Seconds
200-Ft. Drive Reverse - High 44 Seconds
200-Ft. Drive Forward - Low 88 Seconds
200-Ft. Drive Reverse - Low 88 Seconds
Steering:
Stop to Stop 8 Seconds
Center to F\..Ill Left 5 Seconds
Center to Full Right 5 Seconds
4WD Low Speed

200-Ft. Drive Forward - Low 136 Seconds
200-Ft. Drive Reverse - Low 136 Seconds
Following is a detailed description of the hydraulic system for the Qubic-8

Model 46. This description is to be used in conjunction with Hydraulic
Schematic Drawing #35784.
The hydraul i c system of the Condor is of the "closed-center" type; that is,
when control valves are in the neutral or center position, the internal
passages of ,the valves are closed off to the flow from the pump. The system
operates at a maximum pressure of 2,500 PSI, set and maintained by the pump
, Gompensator.
The main Hydraulic Pump #32524 is a Sundstrand Model L38. It is a variable-
Volume, pressure-flow compensating (load-sensing) axial piston pump having a
capacity of 21 gallons per mi nute at a speed of 2,150 RPM. The pump load-
sensing compensator control automatically adjusts the pump delivery to maintain
flow requirements of the system at a pressure of approximately 350 PSI above
the load.
The pump is driven directly from the engine shaft and draws its fluid from the
hydraulic reservoir. The hydraulic fluid is Au.tomatic Transmission Fluid
Qe~ron II. Filtration of the fluid is accomplished by a 100-mesh Sump Strainer
#21473, 10ca.ted in the tank, and also by a 10 micron Filter #32522 located in
the system return-line.
A Check Valve #21368 is located in the main system pressure line. This valve
is used to prevent flow from entering the main pump when the emergency system
is used.
The pump discharge flow is directed to the H.P.I. Proportional Control Valve
Assembly #32560. The pump is equipped with a sensing port that is connected
to the proportional control valve assembly. This connection of the sensing port
measures the pressure drop across the control valve spool opening (orifice) and
autornatica lly adjusts the pump di spl acement to match the demand. The load-
sensing differential pressure is approximately 350 PSI and is set and maintained
by the pump compensator.
When the engine is started and running at idle and no function is in operation,
no pump flow exists. However, the pump does develop standby pressure that will
equal the load-sensing differential pressure of approximately 350 PSI. A con-
trol function must be operated to place the pump on stroke in order to deliver
the required flow/pressure.
PREVENTIVE'MAINTENANtE INSPECTION
This field inspection list provides for a systematic inspection of the Condor.
The items listed to be inspected or checked daily will basically ensure a good,
safe unit performance prior to start-up work operation. By accomplishing these
inspections on a daily basis, any potential malfunction will be identified and
detected before it expands into a major problem. The 50-hour inspection will
. detect any defective, damaged or improperly secured part.
The 50-hour time interval ·is for normal operation. Should the unit be subjected
to extensive use, or if the application involves operation in abnormal environ-
mental conditions, then the inspections should be made more often.
It is suggested that a maintenance log be kept and abnormal conditions or items
of any k.i.nd should be recorded.
Daily Inspection
A. Visual
Overall Condition Inspect platform, boom, turret and
carriage to make certain that no physical
damage is evident. Look for missfng com-
ponents, loose parts, etc.
Tire Condi tion Inspect tires for wear, cuts and proper
pressure (pneumatic filled only).
Battery Cable Connections Inspect for looseness and corrosion of
terminals.
Hydraulic Fluid Leaks Inspect to ensure that there is no
evidence of fittings or hoses leaking.
Main Electrical Connections Inspect harness connections at rear of
ground box and at platform console to
ensure that they are tight.
B. Fluid Level Check

Engine Oil Level If low, add as recommended by engine
m~nufacturer in required quantity.
Engine Coolant Level Add as required (water-cooled engine only)
. Fuel Tank Level Check level.
Hydraulic Tank Level If low, add ATF Dexron II as required.
Battery Electrolyte Level Add as required.
PREVENTIVE MAINTENANCE INSPECTION
Dai 1y Inspection
(Corit'd~)
C. Operational Test
Note: Start engine and follow all instructions and procedures. Be
observant of all instruments and controls for proper operation
as well as each function of the unit. Pay particular attention
to any. unusual noises or jerky performance.
Instrument Check
Hourmeter Is it recording properly?
Ammeter Is battery being charged?
Oil Pressure Gauge Is pressure indicating (Diesel engine)
Ground Control Console

Operation Check
Toggl e Switches With engine off, check that all
momentary switches return to neutral
when actuated and released.
Boom Functions Start engine and operate functions
through one complete cycle.
Emergency Controls Stop engine and operate emergency
controls.
Platform Control Console

.Qp_er:~t i on
Check
Toggle Switches With engine off, check that all momen-
tary switches return to neutral when
actuated and released.
Contro 11 ers Check that lever cannot be moved without
pulling knob. Check that lever returns
to center position when actuated and
released.
Boom Functions Start engine and operate all aerial
functions for one complete cycle.
Drive Functions Operate drive and steering functions.
Check braki ng.
Emergency Controls Stop engine and operate emergency controls.
Slope Sensor For procedure, refer to Vendor Section in
this manual for Sundstrand Multi-Axis Alarm.
Every Fifty (50) Hours of Operation
A. Carriage
Visual Damage Inspect for weld cracks, dents, or bends.
Steering Cylinder Check cylinder and pins holding cylinder
in pl~ce for proper installation.
Steering Tie Rods Check pin installations and connections
for loose, binding, worn or missing parts.
Steering Yokes Check installation, pins, caps, and
steering stop.
Wheels Check for loose or missing lug nuts, loose
or worn spindle, damaged or cracked rims.
Torgue Hubs &Motors Check hub and motor connector and disc
brake for leakage .
. Hydraulic Fittings Check for leaks and tightness.
Hydraulic Hoses Check for leaks, cuts, abrasions.
Tire Pressure Check for proper pressure (pneumatic filled).
Tire Damage Check for wear and cuts.
Rotation Gear Check bolts securing ring gear to chassis
for tightness and that all lock tabs are
in place.
B. Turret
Visible Damage Inspect for weld cracks, dents or bends.
Rotation Gear Check bolts securing gear to turret for
tightness.
Rotation Gear Box Check oil level. Check mounting bolts.
Inspect motor and coupling and pinion
i nsta llation.
Rotary Coupling Inspect for leakage; check mounting bolts
and bracket.
Hydraulic Valves Check mounting bolts and inspect for
damage or leakage.
Hydraulic Hoses Check for leaks, cuts, abrasions.
PREVENTIVE MAINTENANCE INSPECTION .
(Cont'd.)
B. Turret (Cont'd.)
Hydraulic Fittings Check for 1eaks and ti ghtness.
Electrical Wiring Inspect for fraying or cracked insulation.
Electrical Connections Check for corrosion, looseness and ensure
good contact.
Lift Cylinder Inspect for damage and leakage. Check
pin installation and retainers.
Master Leveling Cylinder Inspect for damage and leakage. Check
pin installation and retainers.
Counterweight Check mounting bolts for tightness.
Shrouding, Covers Check for loose, damaged or missing parts
and fasteners.
C. Main Power Source

Engine See engine manufacturer's manual for
maintenance checklist (Wisconsin or Deutz).
Air Cleaner Check oil level, mounting and connection.
Muffler Check shrouding, connection and mounting.
Exhaust Tube Check for rust, leaks and installation.
Engine Mounts Check bolts for tightness.
Throttle Solenoid and Linkage Check mounting, operation and connecting
parts.
Fuel System Check tank, mounting, fuel line and
connections.
Battery Check electrolyte level, mounting and hold-
down.
Battery Cables Check connections for tightness, corrosion
and frayed insulation.
Hydraul i c Pump Inspect pump for damage; check mounting
bolts and connection to engine.
(Cont1d.)
C. Main Power Source (Cont1d.)

Emergency Motor/Pump Inspect pump and motor for damage. Check
mounting bolts and electrical connection.
Hydraulic Hoses Check for leaks, cuts and abrasions.
Electrical Wiring Inspect for fraying, cracked insulation.
Electrical Connections Check for corrosion, looseness and ensure
good contact.
D. Boom Assembly
Pivot Pin Check pin installation and retainer.
Extension Cylinder Check for damage and leakage. Check pin
installation and retainer.
Hose and Cable Rounting Check routing of hydraulic hose and electri-
cal cable from turret to boom. Inspect for
ch~fing, broken ties or overly tight
routing.
Mechanical Cables (3-Section) Inspect cables for fraying or damage and
tightness (torque). Inspect for proper
installation on sheave.
Wear Pads Inspect for clearance, excessive wear.
Check mounting bolts and adjustment.
Slave Leveling Cylinder Inspect for damage and leakage. Check pin
installation and retainer.
Tie-Down Ring Check for tightness.
Limit Swi tches Inspect for damage. Check electrical
connection.
E. Platform and Skirt

Platform Mount Check platform to skirt mounting bolts
for tightness.
(Cont'd.)
E. Platform and Skirt (Cont'd.)

Hydraulic Hose and Electrical
Cable Routing Check routing from boom to skirt. Inspect
for chafing, broken ties or overly tight
routing.
Platform Slide Bar Check that it slides freely.
Rotary Actuator
(On units equipped with· Inspect for damage, leaks and mounting
optional 1aO o .platform bolts for tightness. Check hydraulic
rotation.) hoses for cuts and abrasions.
F. Ground Control Console

Mounting Check that bolts are secure.
External Electrical Connection Ensure connection is firmly made.
Instruments Inspect for damage.
Internal Wiring Inspect for fraying, broken insulation.
Check that connections are tight.
Slope Sensor Inspect for damage and check mounting
bolts for tightness.
Enclosure Check for any moisture; inspect cover seal.
Ensure cover is firmly secure.
.Toggle Switches Check that momentary-type returns to center
position when actuated and released.
Speed Control Ensure that knob is firmly secured to
shaft. Check that speed control rotates
freely.
G. Platform Control Console

Visible Damage Inspect for dents, etc.
Mounting Check that bolts are secure and tight.
Every Fifty (50) Hours Qf Operation
(Cont'd.)
G. Platform Control Console (Cont'd.)

External Electrical Connection Ensure that connections are firm.
Controllers (a) Check mounting screws for tightness.
(b) Check that handle cannot be moved
without first lifting on knob.
(c) Inspect rubber bellows for damage.
(d) Ensure that handle returns to center
when actuated and released.
Toggle Switches Ensure that momentary switches return to
center position when actuated and released.
Engine Stop/Start Check that switch stays in "ON" or "OFF"
position when actuated.
Electrical 110-Volt Receptacle Inspect for receptacle damage.
H. Operational System
Operation with ground panel controls:
1. Start engine and listen and/or observe; note any
(a) Unusual noise from engine or pump;
(b) Excessive engine vibration;
(c) Operation of hour meter and ammeter.
2. Actuate boom "raise" control switch and observe
(a) Increase in engine RPM (gasoline engines);
(b) That boom raises smoothly;
(c) That hydraulic hoses and electrical cable at rear of boom are
moving properly;
(d) Proper platform leveling;
(e) That switch returns to center at full travel release control;
(f) That there is no damage to chrome of lift cylinder rod;
(g) That platform stays elevated and does not lower under its own weight;
(h) With speed control in "slow", actuate boom "lower" switch; rotate
speed control slowly to "fast" and observe change in speed.
3. With boom horizontal, actuate boom "extend" switch and observe
(a) Any unusual noise in telescoping;
(b) That boom telescopes smoothly;
(c) That, at full ext;ension, switch returns to center when control is released;
(d) Visually in,pect inner boom sectionS for weld cracks, dents or scouring.
(Cont/d.)
H. Operational System (Cont'd.)

4. Actuate boom rotate control and observe
(a) Any unusual noise during rotation;
(b) That when control is released, switch returns to center.
5. Actuate emergency power switch (engine "OFF") and any of the boom
function controls and observe
(a) Any unusual noise;
(b) Function operates normally.
Operation from aerial controls in platform:

1. Place speed selector switch to "Fast". Actuate drive controller and
make sure that
(a) Travel starts smoothly and stops smoothly when control is released;
(b) Travel speed is in "high" range.
2. With speed selector in "Fas·t", actuate boom "raise" until at horizontal
or above and then actuate drive controller. Travel speed should auto-
matically switch to "slow" range.
3. Actuate steering control right and left, and make sure
(a) Steering wheels turn smoothly;
(b) Steering continues until stops are reached.
PREVENTIVE MAINTENANCE INTERVAL CHECKLIST
--Operational Hours Or Yearly, Whichever Comes First--
ITEM REQUIRING ATTENTION 50

DAILY HOURS 100 oUU 1,000
HOURS HOURS HOURS YEARLY
-
A) Carriage Assemblx
1 - Visible Damage--Weld Cracks, Dents X
2 - Steering Cylinder and Pins X
3 - Steering Tie Rods and Connections X
4 - Steering Yokes X
5 - lubricate Steering Points X
6 - Repack Wheel Bearings X X
7 - Visually Inspect Torque Hubs, Motors X
8 - Check Torque Hub Oil level X
9 - Change Torque Hub Oil X X
10- Inspect Wheel Mtg., lugs, Rims X
11- Inspect Tires for Cuts and Damages X
12- Check Tire Pressure (Pneumatic) X
13- Check Hydraulic Fittings and Hoses X
14- Check Rotation Gear Bolts X
B) Turret Assembh
2 - Check Rotation Gear Bolts X
3 - Check Rotary Coupling Mounting Bolts X
4 - Check Rotation Gear Box Mounting X
5 - Check Rotation Gear Box Oil level X
6 - Change Rotation Gear Box Oil X X
7 - Check Rotation Drive Motor and Pinion X
8 - Check Hydraulic Valve Mounting X
9 - Check Hydraulic Hoses and Fittings X
10- Check Wiring and Electrical Connections X
11- Inspect lift Cylinder X
12- Inspect lift Cylinder Pins X
13- Inspect Master Level Cylinder X
14- Lubricate lift and Level Cylinder Pins X
15- Check Counterweight Mounting Bolts X
16- Inspect Shrouding, Covers X
(Cont'd )
ITEM REQUIRING ATTENTION 50
DAILY HOURS 100 500 1,000
HOURS HOURS HOURS YEARLY
C) Ma i n Power Source
1 - Engine (Refer to Engine Manufacturer's Manual)
2 - Inspect Air Cleaner Connection X
3 - Change Air Cleaner Oil X
4 - Check Exhaust Tubing Connections X
5 - Inspect Muffler, Shrouding, Mounting X
6 - Check Engine Mounting X
7 - Check Throttle Solenoid and Linkage X
8 - Check Fuel Tank Level X
9 - Check Fuel Tank Mounting Bolts X
10- Check Fuel Line Connections X
11- Check Battery Electrolyte Level X
'12- Check Battery Mounting and Hold Down X
13- Check Battery Cable and Connection X
14- Check Hydraulic Pump Mounting X
15- Check Emergency Pump/Motor Mounting X
16- Inspect Hydraulic Fittings and Hoses X
17- Check Wiring and Electrical Connec-
tions X
D) Boom Assembly
1 - Visible Damage--We1d Cracks, Dents X
2 - Inspect Installation Boom Pivot Pin X
3 - Inspect Installation Master Level Pin X
4 - Inspect Installation Ext. Cylinder Pin X
5 - Lubricate Pins X
6 - Inspect Extension-Retraction Cables (3
Section 8ooIIl) X
7 - Check tables for Torque (3 Section
Boom) X
8 - Check Boom Wear Pads Mounting Bolts X
,9 - Check Boom Wear Pads Clearance, Wear X
10- Inspect Installation Boom to Skirt Pin X
11- Inspect Installation Slave Cylinder
Pin X
12- Inspect Slave Cylinder X
(Cant 'd.)
50 100 500 T,OOO
ITEM REQUIRING ATTENTION DAILY HOURS HOURS HOURS HOURS YEARLY
D) Boom Assembly (continued)
13- Lubricate Slave Cylinder and Skirt
Pins X
14- Inspect Hydraulic Hose and Electrical
Cable Routing X
15- Check Boom Tie Down Ring X
16- Inspect Interlock Limit Switches X
E) Platform and Skirt

2 - Check Platform to Skirt Mounting
Bolts X
For Units With 180° Platform Rotation
1 - Inspect Rotary Actuator for Damage X
2 - Check Mounting Bolts X
3 - Check Hydraulic Fittings and Hoses X
F) Ground Control Box

1 - Check Mounting of Enclosure X
2 - Check External Electrical Connection X
3 - Check Hour Meter and Ammeter for
Damage X
4 - Check Internal Wiring and Connections X
5 - Check Seal on Enclosure Cover X
6 - Check Slope Sensor Mounting Bolts X
7 - Check Toggle Switch's Return to Center X
8 - Check Speed Control Knob is Secure X
9 - Check Speed Control Operates Freely X
.
G) Platform Control Console
1 - Check Console is Securely Mounted X
2 - Check External Electrical Connections X
3 - Inspect Console for Damage X
4 - Check ,.
Controller Mounting Screws
. X
5 - Inspect Controller Rubber Bellows X
6 - Check Control Does Not Move Without
Raising Knob X.
(Cant 'd.)
50
DAILY HOURS 100 500 1,000 YEARLY
ITEM REQUIRING ATTENTION HOURS HOURS HOURS
G) Platform Control Console (continued)
7 - Check Control Lever Returns to Center X
8 - Check Toggle Switches Return to Center X
9 - Engine "Stop-Start" Retains Position X
10- Inspect 110 Volt Outlet for Damage X
H) HYdraulic System
1 - Check Hydraulic Tank Fluid Level X
2 - Clean Hydraulic Tank Breather X
3 - Change Hydraulic Filter X
4 - Change Hydraulic Fluid in Tank X X
5 - Check Hydraulic Fittings and Hoses X
.
GMftA
-- TlGIfTEJU"G TORQUE VALUES
SAE GRADE 2 SAE GRADE 5 SAE GRADE 8

nlhteninl Dry Torque Lull Tllhtenlnl Dry Torque Lull Tllhteninl Dry Torque Lub
Ft. Lb,. HIM Pt. Lb,. NIN Ft. Lb,. HIM Ft. Lb,. HIM Ft. Lb,. N/M Ft. Lbs. H/M
1/4 - 20 5.5 7.5 4.01 5.5 I 10.1 6.25 8.5 1Z 16.3 9 12.2
1/4 - 28 6.3 '.5 4.66 6r2 10 13 .• 7.2 9.8 14 19.11 10 13.6
5/16 - 18
5/16 - Z4
11
12
IS
16.3 ,• 10.'
12.2
17
19
Z3
25.1
13
14
17.6
19.0
Z5
25
33.9
33.9
111
20
24.4
21.1
3/11 • 16 20 27.1 15 20.3 30 40.7 Z3 31.9 45 61.0 3S 47.5
3/8 • 24 Z3 31.2 17 Z3 35 . 41.5 25 33.9 SO 67.' 15 41.5
1/16 - 14 30 40.7 Z4 32.5 50 67.8 35 41.5 70 95.0 55 14.6
7/16 ' 20 35 47.5 ZS 33.9 55 74.6 40 54. Z 80 1011.5 60 81.3

1/2 - 13 50 67.' 35 47.5 75 101. 7 55 74.6 110 149.1 80 1011.5
l/Z - ZO 55 74.6 40 54.2 90 122. 65 88.1 120 162.7 90 122.0
9/16 • lZ 70 95.0 55 74.6 110 149.1 80 101.5 ISO 20).' 110 I~'.I
'"6 - II 10 101.5 6o 81.) no 161.1 ,0 122.0 170 210.5 I lO 116. 1
SII • "
511 •• 1
.00
110
"5.6
.". I IS
15 .01.7
. II 5. 2
'50
170
2O}.'
2}8.S
110
130
"'.'
• 76.}
220
2~0
U'.}
US.,
170
180
2)0.5
2H.0
)/' - .0 175 211.) 1)0 '76.) 160 152.5 200 271.2 J80 515.2 2110 In.6
JI' - .6 IU 2U.' "5 1'6.6 JOO '06.7 no 2,8.) '20 56,.' }20 'H.9
711 - ,
." 12).7 125 "'.5 '30 51).0 )20 'n., 600 8').5 ~60 62).1
.
1/8 - U liS 250.1 .'0 "'.1 '70 6)1.2 )50 ,,'.5 660 8".1 500 618.0
I-I 250 )".0 "0 251.6 6'0 I" .1 "0 650.1 ,00 1220.2 680 ,22 .0
I • 12 270 200 .000 7~0 100}.}
...
)", 271.2 100 ",.0 5)0 ,'8.6 1155.'
I-III - 7 150 '7',5 270 )", I 80O 10n.6 60O 8".5 128O 17J5.' 960 1)0' .6
'-711 - 7 '00 SU" )0' '06.1 "".1 ". 1,'.1 ."0 1"2. , 1080 I"". )
1'1/" • 1 500 678.0 )80 515.2 112O 1511.5 no '1]8., IUO H61.6 1)60 18~).!I
'-11' - 12 5SO "5.6, '20 5".' InO .681.2 920 IZlt7.) 2000 2111.6 1500 20}).1
1-)/8 - 6·
1,)/8 • 12
".
,'0
8".8
toO). J
"0
56.
" ...
75,.2
) I~60
.610
,,".5
2271.7
1100
1260
I~'I.'
1708. )
2)80
2120
)226.8
)687.8
1]80
20'0
HI).)
2165.11
• -1/2 - , ,,0 "19.5 65° "'.) .''0 26)0.) 1"0 1"'.5 '160 ~2U.) 2,60 JI'!I.7
• -1/2 - 12 '8O ')28.7 no ,8'.1 2200 UU.' 16~0 222).5 ]560 ~826 .6 2660 }606."
FOOTNOTE 1 Foot/Poun •• to Nevton/Haters x 1.)551

CORPORATION
l
HYDRAULIC
OIL SPECIFICATIONS
for
CONDOR AERIAL WORK PLATFORMS
OIL COMPANY Chevron Gulf Shell Union Mobil Conoco
Brand Name ATF ATF ATF ATF Dexton

Dextron 11 Dexron 11 Donax T6 Dexron 220 1l
o Series
Viscosity, SUS @ 100 0 F 205 195 175 200 187 170
SUS @ 210 0 F 50.1 50.4 49 52.3 50 50
Viscosity Index 150 155 160 172 159 145
Flash Point OF 350 0 405 0 390 0 395 0 320 0 365 0
Pour Point OF _45 0 -50 0 -45 0 -50 0 -50 0 _45 0

CHECK SPEED REDUCER
INTERVAL SYMBOL CENTRAL LUBE BRACKET
o SO HOURS or SEMI-MONTHLY SPEED REDUCER - CHANGE OIL FOR PINS
5 PLACES

ENGINE
OIL FILTER
TYPE OF LUBRICANT TORQUE HUB

CG - CHASSIS GREASE: CRAN KCASE FILL
SL - SPRA Y LUBE:
AND WIRE ROPE LUBE, or EQUAL CRANKCASE DRAIN
EO - ENGINE OIL:
SAE 30 WEIGHT
GO - GEAR OIL:
SAE 90 WEIGHT EP

1 PLACE (rotate turret
BC>O\1 TO SKIRT PIN,
while lubing)
ROTATION CYLINDER WHEEL BEARINGS
2 PLACES WHEEL BEA'RING GREASE
PLATFORM FORK PIVOT PIN
AND RELATEOLINKS
5 PLACES
[y-s;ct i on 80~~--] LUBRICATION CHART FOR QUBIC- 8 MODEL 46 Sheet 1 of 2
INTERVAL SYMBOL 2 - EACH SIDE

AIR CLEANER
o 500 HOURS or ANNUALLY

OIL BATH
TiE RODS
TYPE OF LUBRICANT
1 - EACH SIDE
SL - SPRAY LUBE:
AND WIRE ROPE LUBE, or EQUAL HYDRAULIC
EO - ENGINE OIL: TANK OIL STEERING
SAE 30 WEIGHT
GO - GEAR OIL: (A TF Dextron II) CYLINDER
SAE 90 WEIGHT EP
ENGINE OIL DIPSTICK
HYDRAULIC
LINE FILTER
TOPPING CYLIN DER

ROTATION GEAR 2 . PLACES
TEETH & PINION
2-Sect i on Boom] .LUBRICATION CHART FOR QUBIC- 8 MODEL 46 Sheet 2 of 2

INTERVAL SYMBOL SHEAVE PIN
CHEC K SPEED REDUCER
o SO HOURS or SEMI-MONTHL Y 2 PlACES
FOR PINS
ENGINE
5 PLACES
OIL FILTER
TYPE OF LUBRICANT
TORQUE HUB
SHELL DARNA AX 70330, or EQUAL CRANKCASE FILL
SL - SPRAY LUBE:
EO - ENGINE OIL: CRANKCASE DRAIN
SAE 30 WEIGHT
GO - GEAR OIL:
SAE 90 WEIGHT EP
ROTATION CYLINDER
2 PLACES
PlA TFORM LEVELING CYLIN DER

1 PlACE (rotate turret
PLATFORM FORK BOOv1 TO while lubing)
PIVOT PIN
AND RELATED LINKS WHEEL BEARINGS
5 PLACES WHEEL BEARING GREASE
3-Sect i on Boom LUBRICATION CHART FOR QUBIC- 8 MODEL 46 Sheet 1 of 2

INTERVAL SYMBOL
Oso HOURS or SEMI-MONTHLY 2 - EACH SIDE

o 100 HOURS or MONTHLY AIR CLEANER
o SOO HOURS or ANNUAllY OIL BATH
TYPE OF LUBRICANT
TIE RODS
SHEll DARNA AX 70330, or EQUAL 1 - EACH SIDE
Sl - SPRAY LUBE:
AND WIRE ROPE LUBE, or EQUAL HYDRAULIC
EO - ENGINE Oil: TANK OIL
SAE 30 WEIGHT
GO - GEAR Oil: (A TF Dextron II) STEERING
SAE 90 WEIGHT EP CYLINDER
ENGINE OIL DIPSTICK
HYDRAULIC
LINE FILTER
ROT ATI ON GEAR

TEETH & PINION
TOPPING CYLIN DER
2 PLACES
3-Sect i on Boom-I LUBRICATION CHART FOR QUBIC..; 8 MODEL Lt6 Sheet 2 of 2

LUBRICATION
Refer to Self-Propelled Condor Lubrication Chart for Qubic-8 Model 46 for

location of items requiring lubrication and service. Recommended lubricating
intervals are based on normal use in normal environmental conditions. User is
cautioned to adjust the lubricating interval, accordingly, to meet each
individual condition and usage.
Specific lubricants, recommended by the component manufacturers, are generally
the best choice. Should these lubricants be unavailable in your area, consult
your local supplier for an equivalent. Under NO circumstances should lubricant
containing "Lithium" be used.
1. Pressure Gun Lube Points

• Lubricant Chassis Grease (Shell Darna AX70330
or equal).
• Time Interval Every 50 hours of operation.
• Procedure Service all fittings as indicated on
Chart. Clean lube fitting and apply
with pressure gun. Wipe away all
excess lubricant from exposed surfaces.
Over-lubrication can collect dirt and
foreign matter, both of which act as
abrasives.
When lubricating turret rotation bearings,
it is recommended that turret be rotated.
2. Air Cleaner (Oil Bath)
• Lubricant S.A.E. 30 Weight Engine Oil.
• Procedure Remove oil cup from bottom of air cleaner
and clean thoroughly. Fill to level line
indicated on the oil cup.
3. Steering Cylinder Pivot Points

• Lubricant S.A.E. 30-Weight Engine Oil.
• Procedure Apply with oil can to both sides of pivot.
LUBRICATION
(Cont'd.)
4. Rotation Gear Teeth and Pinion

• Lubricant Crown 7045 heavy dufy open gear oil .
or equal. .
• Time Interval 500 flours of operation or- yearly,
whichever comes first.
• Procedure Wipe clean gear teeth on rotation
ring and pinion. Spray on lubricant.
5. Rotation Gear Box

• Lubricant S.A.E. 90-Weight EP Oil
• Time Interval Check every 50 hours. Change every 500
hours of operation or yearly, whichever
comes first.
• Procedure Remove drain plug on side. Refill until
1evel~ reaches about 1 inch from top of
fill J101e.
~
6. Drive Torque Hubs

• Lubricant S.A.E. 90-Weight EP Oil
• Time Interval Check periodically and fill, as required.
Change every 500 hours or yearly, which-
ever comes first.
• Procedure To check level, rotate wheel so that level
plug is horizontal. Remove plug. If
steady flow of oil pours forth, unit is
sufficiently full.
To add oil, remove fill plug (on top of
gear hub) and level plug (horizontally).
Fill until oil flows from level plug.
LUBRICATION
(Cont'd.)
7. Wheel Bearings
• Lubricant Wheel-bearing Grease.
• Time Interval 500 Hours or yearly, whichever comes
first, or upon reassembly.
• Procedure Remove hub cap; clean out old lubricant
and repack.
8. Hydraulic System
a. Fl uid Level Check level daily. Maintain fluid level
at full mark or dipstick with the boom
fully retracted and in stowed position.
b. Hydraulic Oil Filter Replace filter element every 100 hours
of operation. Unscrew element and
replace with new element.
c. Tank'Breather Clean every 50 hours of operation. Remove
from tank and clean with solvent; air blow-
dry.
d. Hydraulic Tank Drain oil from tank every SOO hours or
yearly, whi chever comes fi rst, and. r~.place
filter element. Add oil to tank required
level.
Use only ATF Dexron II or equal. DO NOT
mix hydraulic oil.
9. Engine
Refer to engine manufacturer's recommended maintenance and service
procedure for lubricant and time interval.
Lubrication
Type-EP 90
Oil Temperature
• Continuous -160-F
• Intermittent - 200-F
Oil Change
• Initial - After 50 hours of operation
• Subsequent - 1000 hours or one year which ever comes first.
Oil Fill Level

• Unit mounted horizontal - half':'full
CORPORATION
LOWER RING GEAR-BOLTS &LOCKSTRIPS:

BILL OF MATERIAL
1. Kit #58004 for Condor ~IDdels 76, 68, 58, 56, 50, 6066, 5056, 4248,
and 3238.
Consists of:
• Lockstrip
Calavar Part #68237; Qty =9
• Special Hex Head Capscrews; 1/2-13 UNC x 1-3/4 long
Calavar Part #Bmi36107; Qty - 18
2. Kit #58005 for Condor Models 60N, 46N, 36N,4046N and 46Q8
Consi sts of:
• Lockstrip
• Special Hex Head Capscrews; 1/2-13 UNC x 2-3/4 long
Calavar Part #BOW36111; Qty = 18
3. Kit #58006 for Condor Models 48, 4046, and 3036N.

Consists of:
• Lockstrip
• Special Hex Head Capscrews; 1/2-13 UNC x 1-3/4 lonq
Calavar Part #BOW36107; Qty = 18
Note: Bolts are special (grade, strength and length) for the
Condor machines. Use only Calavar supplied bolts in the
above kits. DO NOT USE ANY OTHER BOLTS.
LOWER RING-GEAR BOLTS AND LOCKSTRIPS:
1. Install lockstrips as shown.

• Use Kit #58004 for Condor Models 76, 68, 58, 56,
6066, 5056, 4248.
• Use Kit #58005 for Condor Models 60N, 46N, 36N,
4046N. 46Q8
• Use Kit #58006 for Condor Models 48, 4046, 3036N.
2. Bolts are special (grade, strength & length) for the
Condor machines. DO NOT USE ANY OTHER BOLTS.
3. Do not use 10ckwashers.
4. Torque lower ring-gear bolts to 105 ft-#s ± 5 ft-#s,
using conventional criss-cross torque sequence.
5. Bend-up' ears (ends of lockstrips) on flat of bolt hex head
as shown. Bend two places for each lockstrip.
set.F-PROPELLED DIVISION
,It
9200 South Sorensen Avenue. Santa Fe Spnngs. California 90670 • (213) 946-6561 • Telex 69-8378 • Cable: Calacorp
RECOMMENDED SPARE PARTS LIST

QTY PART NUMBER DESCRI PT ION
1 35031 Solenoid Valve (Cartridge)

10 LEM00037 Filter Cartridge
1 80024 Relay - Plug-In
1 80023 Relay - Latching
1 80025 Circuit Breaker - 20 Amps
1 32111 Solenoid - Throttle and Choke
1 21568 Motor - Wheel Drive
1 40865 Control 1er
1 35689 Seal Kit - Steering Cylinder
1 92079 Seal Kit - Rotary Coupling
1 35689 Sea 1 Kit - Leve 1i ng Cy li nt1b t!Mr'Q".
1 35700 Seal Kit - Boom

1 35691 Seal Kit - Topping
1 GNH00113 Valve Assembly - Pilot
2 GNHOOI07 Solenoid Assembly
PrmteCI ,n uSA
PRESETTING PROPORTIONAL CONTROLLERS FOR CONDOR QUBIC-B MODEL 46
Controller settings must be made wi th a fully-charged battery on the Condor

machine.
1. Turn master key switch on.

2. Turn ground/aerial selector switch to lIaerial ll •
3. Pull start button to turn on power to aerial console. Do not start engine.
4. Take a volt-ohm meter (VOM); set scale to read 10 volts DC maximum.
5. Place common (-) lead of VOM.on ground (-) or black wire.
6. Place (±) lead of VOM on either green (forward) or white (reverse) wire
on the controller to be set.
7. Move the controller handle in the direction of the terminal selected
eru or IIRII) until engine throttle limit switch is just engaged.
Note: Switch is engaged when throttle is pulled in.
B. Adjust threshold screw on the controller until VOMreads threshold volts
on chart.
9. Move controller handle in the direction of terminal selected to full handle
position.
10. Set output adjustment for terminal selected IIFII output (forward) green
" .. wire; IIRII output (reverse) white wire to the proper setting.
11. Repeat steps 9 and 10 (above) for the other terminal; check that throttle
switc.h is turning on at specified volts in this direction, as well. If
reading is lower than specified, adjust it until it reads approximately
the specified settings.
12. Readings taken while engine is running will be slightly higher than
setti ngS made while the engine is off. . .
13. A lower battery condition wi 11 change setti ngs. (Check speci fic gravi ty
of the battery. An acceptable reading of a fully-charged battery will
read approximately 1. 200 on a hydrometer.)
FUNCTION OUTPUT FULL HANDLE POSITION THRESHOLD
Topping - Up 7.4 Volts 4 Volts

Topping - Down B.3 Volts 4 Volts
Boom Extension 9.0 Volts 4 Volts
Boom Retraction 9.0 Volts 4 Volts
Rotation CW (L) 6.6 Volts 4 Volts
Rotation CCW (R) 6.4 Volts 4 Volts
Drive - Forward 9.0 Volts 4 Volts
Drive - Reverse 9.0 Volts 4 Volts
BaN)
t
VENDOR SECTION
STARTING and
OPERATING INSTRUCTIONS
w I s c o N s I N
A'~(J(jted Engines
~ 7~": / OIL BATH AIR CLEANER

EXHAUST MUFFLER - _ _ _ __
/ CONTROL PANEL
OIL FILLER AND

BREATHER CAP
VARIABLE SPE ED
GOVER~R CONTROL
FUEL PUMP - - - - -
~r__r-"_-CYLINDER NUMBERS
I ~ _ _- OIL DIP STICK

FUEL STRAINER
- OPTIONAL -
BATTERY IGNITION
DISTRIBUTOR
-- FLYWHEEL SHROUD
OIL FI L TER
IGNITION COIL
OIL DRAIN PLUG
OPEN ENGINE - TAKE·OFF VIEW
Four Cylinder Engine

Models
VH4D • VG4D • V-465D
"~TELEDYNE WISCONSIN MOTOR

WORLD'S FOREMOST SOURCE FOR HEAVY DUTY AIR COOLED ENGINES
FIGURE 01 WISCONSIN GASOLINE ENGINE

~vnR
CO~POAArjON
9200 Sorensen. Santa Fe Springs- CA 90670-2645

VENDOR - 01- 00
(2131946-6561 • Telex 69-8378 • Fax 213-946-2265 SERIAL NO. FR(JC 5258 ISSUED JANUARY '90
E~NJ 46 GWIC OO
-
VENDOR SECTION
INTRODUCTION
WISCONSIN heavy duty air cooled engines are of the Teledyne Wisconsin Motor is backed by over 65 years
most advanced design and are built in a modern fac- of engineering experience in the design of internal·
tory, equipped with the latest machinery available. combustion engines for every conceivable type of ser·
Only the best materials, most suitable for the partic- vice. The performance of these engines is proof of the
ular part, are used. During production, every part is long satisfactory service you too can expect from your
subjected to rigid inspection, as are also the complete- engine.
ly assembled engines. After assembly, every engine is
operated on its own power and all adjustments are Like all fine machinery, the engine must be given
carefully made so that each engine will be in perfect regular care and be operated in accordance with the
operating condition when it leaves the factory. instructions.
SPECIFICATIONS
MODELVH4D MODELVG4D MODEL V-465D
Bore ....................... 3'A" Bore ..•.••..•.•............ 3%" Bore ....................... 3 3A"
Stroke ..................... 3'110" Stroke ...........•.•...••.. 4 .. Stroke ..................... 4 "
Piston Displacement - cu. in. 107.7 Piston Displacement - cu. in. 154 Piston Displacement - cu. in. 177
Horsepower - 1400 R.P.M .... 17.2 Horsepower - 1400 R.P.M. ... 25 Horsepower - 1600 R.P.M .... 41.6
. 1600 R.P.M .... 20.0 1600 R.P.M. ... 29 1800 R.P.M .... 47.5
1800 R.P.M .... 22.5 1800R.P.M. ... 32 2000 R.P.M .... 52.4
2000 R.P.M. ... 24.7 2000 R.P.M. ... ·34 2200 R.P.M .... 56.7
2200 R.P.M .... 26.5 2200 R.P.M. ... 36 2400 R.P.M .... 60.0
2400 R.P.M .... 28.0 2400 R.P.M. ... 37 2600 R.P.M .... 63.0
if 2600 R.P.M. ... 29.2 2800 R.P.M .... 64.5
2800 R.P.M .... 30.0 3000 R.P.M .... 65.9
Note: For continuous operation, allow 20% of horsepower shown, as a safety factor.
SAFETY PRECAUTIONS
• Never fill fuel tank while engine is running or hot; model VH4D, 2400 R.P.M. for model VG4D and 3000
avoid the possibility of spilled fuel causing a fire. R.P.M. for model V-465D.
• Always refuel slowly to avoid spillage. • Do not operate engine in a closed building unless the
exhaust is piped outside. This exhaust contains car·
• When starting engine, maintain a safe distance bon monoxide, a poisonous, odorless and invisible
from moving parts of equipment. gas, which if breathed causes serious illness and pos·
sible death.
• Do not start engine with clutch engaged.
• Never make adjustments on machinery while it is
• Do not spin hand crank when starting. Keep crank· connected to the engine without first removing the
ing components clean and free from conditions ignition cables from the spark plugs. Turning the
which might cause the crank jaw to bind and not reo machinery over by hand during adjusting or clean·
lease properly. Oil periodically to prevent rust. ing might start the engine and machinery with it,
causing serious injury to the operator.
• Never run engine with governor disconnected, or
operate at load speeds in excess of: 2800 R.P.M. for • Precaution is the best insurance against accidents.

_'r ....... R.VnR
CORPORAT,O'"
9200 Sorensen. Santa Fe Springs. CA 90670-2645

VENDOR - 01- 01
(213) 946-6561 • Telex 69·8378 • Fax 213·946·2265 SERIAL NO. FROII 5258 ISSUED JAllUARY '90
BaNI VENDOR SECTION
NEW ENGINE Instructions

• L U 8 RIC AT ION Operating without oil will ruin engine.
IMPORTANT
There is NO OIL in this unit. Refer to GRADE OF OIL chart (page 2) and
Fill crankcase to proper oil level, also clutch or fill with proper oil b.for. starting engine.
gear box if furnished, and oil bath air cleaner.
----------------------------------
• AI R CLEAN ER Oil both type - Add same grade oil as used in crankcase to the level line indicated on
cleaner bowl. Maintain oil level or dirt will be drawn in and damage engine.
Dry element type, optional equipment - DO NOT OIL - Follow instructions on cleaner body.
----------~-----------------------
-FUEL Use 'REGULAR' grade goso/ine. Engines built to operate on FUEL OIL, KEROSENE, L.P.G. or
NATURAL GAS are so identified in the model designation. Refer to 'FUEL' paragraphs ofinstructions.
Buy fresh fuel. Do not use out·ol·seoson gasoline.
----------------------------------
- NEGATIVE GROUND CIRCUIT ,ifengineisequippedwithSTARTINGMOTOR,DISTRIBUTOR
~
.. "... IGNITIONandFLYWHEELALTERNATOR,orGENERATOR.
~ ()~ GROUND ENGINE TO NEGATIVE TERMINAL ON BATTERY.
~ ~ CA UTION: Be absolutely sure of proper connection or damage to
the Alternator or Generator circuits will result.
---------------------------------- External dirt restricts cooling

- PREVENT OVERHEATING Keep Engine Clean
and internal dirt causes wear.
BREATHER CAP
_~ Temperat~re Clean at every
. V
......~ Safety SWitch oil change
~
! O_~>- ~
~ ~
Do not disconnect wire or CYLINDER and

: - allow terminal to touch HEAD COVERS
, head fins or shrouding. Remove and scrape
dirt from cylinder '-',""'-_.
and head fins.
Optional accessory mounted to cylinder head bolt
near spark plug - TO PROTECT ENGINE
AGAINST OVERHEATING. If engine stops, Service daily
check first to see if engine is overheated. Other con- Replace at least if necessary
ditions may have caused the engine to stop. Clean every other oil
air cleaner, air intake screen, fins, and check oil change~
level, spark plugs and wiring. Let engine cool at AIR INTAKE
least 10 minutes before restarting. Remove dirt and chaff from manifold Remove screen
ports and space between CYl. blocks. and brush clean.
--------_ ..... _-----------------------
- NEW ENGINE BREAK-IN
Proper breole-in will lead to trouble-free operation and in- speeds and loads for a short period of time. Run the en-
creased engine life. The factory test given to a new engine gine for a half hour without load at low idle speed (1000 to
is not sufficient to establish the polished bearing surfaces 1200 R.P.M.). The speed should then be increased gradual-
which are so necessary for good performance and long en, ly, to engine operating r.p.m. still without load, for an ad-
gine life. There is no quick way to force the establishment ditional two hours. If at all possible. operate the engine at
of good bearing surfaces, and these can only be obtained
by running a new engine carefully and under reduced
light loads for a period totaling about eight hours. before
maximum load is applied. / , ,
.... ,~ ... II ......V,~R
9200 Sorensen. Santa Fe Springs.. CA 90670-2645

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,213) 946-6561 • Telex 69-8378 • Fax 2' 3'946-2265 SERIAL NO. FROM 5258 ISSUED JANUARY 'go
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STARTING AND OPERATING INSTRUCTIONS

9 9
4
11
3
6
23
10
12
7 5
3
21 22
6 I AIR CLEANER
15 21 2 PRE-CLEANER
7 3 BREATHER CAP
.l!t'"---17 15
and OIL FillER
16 " CARBURETOR
5 CHOKE BUnON
6 CYLINDER NUMBERS
MODBS VH4D and VG4D 7 DIPSTICK
8 DISTRIBUTOR
9 9 EXHAUST MUfFLER
24 2 10 FUEL FILTER
18 4 11 FUEL PUMP
5 12 FUEL TANK
3
22 13 GENERATOR
14 IGNITION COIL
8 15 MAGNETO
16 OIL DRAIN PLUG
17 OIL FILTER
11 18 ROCKER ARM COVERS
7 6 19 STARTING MOTOR
14-_ _._ 20 STARTING SOLENOID
21 STOP SWITCH.
13 19 22 VARIA8LE SPEED
GOVERNOR CONTROL
17 - - - - 16 23 VENTHOtE
MODELV465D 24 ANTI-DIESEL VALVE
Fig. 1, REfERENCE VIEWS
GENERAL INFORMATION BEFORE STARTING NEW ENGINE GRADE OF Oil

These engines are of the four cycle type, in 1. Fill tank with Regular grade gasoline. SEASON OR GRADE
which each of the four operations of suc- TEMPERATURE OF OIL
tion, compression, expansion and exhaust OIL BURNING engine has letter '0' suf-
constitutes a complete stroke. This gives fixed to model designation - use 35 min-
imum octane fuel oil. Spring. Summer
one power stroke per cylinder for each two or Autumn SAE 30
revolutions of the crankshaft. LoP.G. BURNING engine has letter 'G' + 12cfF to +4OoF
added to model designation - use pro-
COOLING paneHD5. Winter 0
Cooling is accomplished by a flow of air cir- +40'7- to +15 F SAE 20-20W
NATURAL GAS burning engines re-
culated over the cylinders and heads of the + 15"F to ifF SAE lOW
quire a B.T.U. content of at least 1000. Below OOF SAE SW-20
engine from a combination fan-flywheel en-
cased in a sheet metal shroud. The air is di-
vided and directed by ducts and baffles to U.e oils classified as Service MS. SOcrSE
2 Fill crankcase base with the proper
insure uniform cooling of all parts. grade of engine oil as specified in
NEVER OPERATE AN ENGINE WITH "GRADE OF OIL" chart. Fill through VH4D VG4D V465D
the breather tube opening to the level in- Crankcase Capacity
ANY PART OF THE SHROUDING RE-
w~1 dicated by the FULL mark on
MOVED - this retard air cooling.
DIPSTICK. New Engine 3'h qts. ~'h qts. 6 qts.
IGNITION For run-in of new engines, use same oil Oil and filter change 4 qts. 5 qts. 7qts.
The spark for ignition of the fuel mixture is as recommended in GRADE OF OIL
furnished by a high tension magneto chart. Le .. - oil filter
driven by the timing gears at crankshaft or filter change 3'h qt•. "'h qts. 6 qts.
speed (models VH4D and VG4D). Check crankcase oil level every 8 hours,
change oil every 50 hours of operation.
Battery ignition (12 volt) distributor. is fur- To change oil, remove drain plug from
nished in place of magneto on engines oil pan. Oil should be drained while en-
Model VH4D. Fig 2 and fig. 3:
equipped with flywheel alternator. or as op- gine is hot; it will flow more freely. Fill clutch and gear reduction units to the
tional ignition (Std. on model V-465D). height of the oil level plug opening - Use
same grade oil as used in engine crank-
ROTATION case. Add sufficient oil between changes to
3. Clutch and gear reduction unit lubrica-
The rotation of the crankshaft is clockwise tion differs between the various engine keep oil up to the level plug opening.
when viewing from the flywheel or front models. All units operating in oil are fur-
end of the engine. and counterclockwise r0- nished with oil filler, level and drain Change oi t in clutch and reduction
tation of the power takeoff or rear end of plugs, suitable for any take-off shaft po- units at least every 500 hours of
the engine. sition. operation.
,
R.VnR
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(213) 946-6561 • Telex 69-8378 • Fax 213-946-2265 SERIAL NO. FROM 5258 ISSUED JANUARY 'go
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t
- .. VENDOR SECTION
STARTER
Fig. 7, VH4D, VG4D

Fig. 2, VH40 CONTROL PANEL
CLUTCH LUBRICATION
z CHOKE
::> BUTTON
'"
Fig. 5, VG4D, V46SD
CLUTCH REDUCTION LUBRICATION
high grade transmission oil. S.A.E. No. 90

to No. 110 viscosity. Change oil every 500
hours of service, while unit is warm.
OIL LEVEL
PLUGS STARTING
With reference to Fig. 1: Engines enclosed
in a sheet metal house are referred to as
Power Units, whereas those without a
Fig. 3, VH4D house are called Open Engines. Fig. 8, V46SD
CLUTCH REDUCTION LUBRICATION
Power Unit side doors should always CONTROL PANEL
Models VG4D and V46S, Fig. 4 and Fig. 5: be removed when operating. Models VH4D and VG4D only, Fig. 7
The clutch in both the power take-off and STARTING PROCEDURE Fig:s 6,7,8 5. Pull out ignition switch. if applicable
clutch reduction units is of the dry disc (tag reads "TO STOP PUSH IN"\.
type. therefore NO OIL should be put into 1. Check crankcase oil level and gasoline
the clutch housing. Grease fittings are pro· supply. Open shut·off valve in fuel MlI;gneto ignition engines (less ignition
vided for periodic lubrication of the bear· strainer. SWItch), have a lever type ground switch
ings. The HOUSING BEARING should be on side of magneto which is !llways in
greased every 50 hours of operation, and OIL BURNING engines must be started the ON or running position, except
the THROWOUT BEARING every day be- on gasoline and run for 2 or 3 minutes when depressed for stopping.
fore starting. use Mobil Gargoyle grease before switching to oil. Special instruc· Sa. Close choke by pulling choke button to
BRB No 3, Sinclair AF·l grease, or equal. tions are available for starting L.P.G. extreme out position.
and NATURAL GAS burning engines.
The PILOT BEARING is sealed and re- 5b. Tum engine over slowly one or two revo-
quires no extemallubrication. 2. Disengage clutch, if furnished. lutions. CAUTION: Be sure that crank
does not bind - apply oil to the crank
The SHIFfER SHAFT should be lubrica· 3. Prime new engine - if necessary, see jaw and crank nut extension for ease of
ted periodically if external oil fittings are Fig. 6. Hand primer lever at fuel pump engagement and release.
provided. (available option), should be worked·
back and forth until strainer bowl is full Push choke control button in about half·
- then an additional 5 or 10 strokes to way and then pull up rapidly on the
THE REDUCTION UNIT IS OPERATED starting crank. 00 not attempt to spin
IN OIL and the gear case oil level must be fill carburetor bowl. If primer does not
function - tum crankshaft one com· the engine with the starting crank. If en·
maintained to the oil DIPSTICK mark or plete revolution. gine does not start on the first pull up of
PLUG olM!ning. which ever is applicable. the crank, re-engage the crank and re-
In ROCKFORD units use No. 30 S.A.E. Gravity feed (power units), and electric peat the operation.
crankcase oil, for TWIN DISC units use start engines do not require priming.
With electric starting motor; depress
4. Set throttle about 112 open if variable starter switch button in place of hand
speed governor control is furnished. cranking. See Fig. 7.
With a two speed control, start in full 5c. After engine starts, push choke button
load position - idle after engine starts. in as required for smooth running.
Choke should be completely open (but·
ton in), when engine is warmed up.
Less choking is necessary in warm weather
or when engine is warm, than when colcl.
Should flooding occur, open choke fully
and continue cranking.
Model V46SD only, Fig. 8

6. After setting throttle as per paragTaph
4.
INSPECTION PLATE Turn IGNITION-STARTING SWITCH
to 'Start' position and at the same time
Fig. 4, VG4D, V46SD pull out choke button only sufficient to
CLUTCH LUBRICATION Fig. 6, FUEL PUMP PRIMER start the engine.
fIGURE 01 WISCONSIN GASOLINE ENGINE

COFaPORATION
9200 Sorensen. Santa Fe Springs. CA 90670·2645

VENDOR - 01- 04
12131946·6561 • Telex 69·8318 • Fax 213·946·2265 SERIAL NO. FRCIC 5258 ISSUED JANUARY '90
BalD VENDOR SEen ON
6a. Release choke button to open position af- PRE-CLEANER

ter engine starts, but rechoke if it tends
to stop. EVEN A HOT ENGINE RE- The collector type pre-cleaner, mounted to
QUIRES MOMENTARY CHOKING the top of the air cleaner as illustrated in
WHEN STARTING. When engine Fig. 9, removes the larger dirt and dust par-
starts release switch to 'RUN' position. ticles before the air reaches the main air
cleaner.
If flooding should occur, continue cranking
with the starting motor, but with the choke Clean bowl regularly of accumulated dust
open (choke button in). and dirt. 00 not put oil or water in pre-
deaner, this must be kept dry.
WARM-UP BREATHER CAP, Fig. 1, Ref.3
If all conditions are right, engine will start The crankcase is ventilated thru a breather
promptly in one or two attempts. After en- cap mounted ot the top of the oil filler tube.
gine starts, allow it to warm up a few min- At every oil change, it is recommended that
utes before applying load. Do not race or the cap be cleaned by washing in kerosene.
gun engine to hurry WARM-UP. The prop-
er oil film on various surfaces of the pis- DISTRIBUTOR, Fig. 1, Ref. 8
tons, cylinders, bearings, etc., cannot be es-
tablished until the oil has warmed up and If engine is equipped with battery ignition
become sufficiently fluid. Break-in new distrihutor:
engine per instructions on page 1. Every 250 hours of operation; add 3 to 5
drops of medium engine oil to the oiler on
TO STOP ENGINE side of distributor base.
Fig. 9 OIL BATH AIR CLEANER
Every 250 hours, apply 3 to 5 drops of light
Magneto ignition (open engines) have a engine oil (lOW), to the felt in the top of the
lever type gr<>und switch on the side of the cam sleeve, and 1 or 2 drops to the breaker
magneto. DEPRESS AND HOLD DOWN arm pivot.
UNTIL ENGINE STOPS. See Fig. 1, Ref.
2l. Every 250 hours, add a small amount of
high melting point grease to the breaker
Power units and battery ignition, Fig. 7, arm rubb\ng block.
are furnished with an ignition switch, "TO
STOP PUSH IN". Avoid excessive lubrication. Oil on the con-
tact points will cause them to burn.
Model V4650; turn IGNITION-5TART- GENERATOR - Belt Driver, Fig. 1, Ref 13
ING SWITCH to OFF position. See Fig. 8.
Every 50 hours of operation; add 3 to 5
If engine has been running hard and is hot, drops of medium engine oil into the oil cups
do not stop it abruptly from full load. Re- at both ends of the generator.
move the load and allow the engine to run
idle (1000 to 1200 R.P .M.), for 3 to 5 min- FUEL FILTER, Fig. 11
utes. Air circulation from the flywheel will
reduce the temperature of the engine much It is very important that the fuel be filteret..
faster and minimize valve warping. to prevent sediment, dirt and water from en-
tering the carburetor and causing trouble
or even complete stoppage of the engine.
The glass filter bowl should be inspected
MAINTENANCE frequently, and cleaned if dirt or water are
Fig. 10, DRY TYPE AIR CLEANER
present.
AIR CLEANERS
To remove sediment bowl, loosen nut below
The air cleaner is an essential accessory, fil- from the engine and the element, which is bowl, swing bail to one side and twist bowl
tering the air entering the carburetor and not removable, should be washed in a 101- as it is being removed. Clean screen and
preventing abrasive dirt from entering the vent to clean out accumulated dust and dirt. bowl thoroughly - replace gasket if it is
engine and wearing out valves and piston damaged or hardened.
rings in a very short time.
DRY TYPE AIR CLEANER, Fig. 10 OIL FILTER, Fig. 1, Ref. 17
The air cleaner must be serviced frequent-
Iy, depending on the dust conditions in Service doily; squeeze rubber dust unloader A BY-PASS type oil filter is furnished on
which the engine is operated. Check hose once or twice a day to check for possible ob- all Model VH4D and VG4D engines, except
connections for leaks or breaks and replace struction.1f engine is operating m very dus- where the use of other acceslOries prevent
all broken or damaged hose clamps. ty conditions, remove cartridge and shake mounting an oil filter.
Excessive smoke or 1088 of power are good out the accumulated dirt (do not tap or
indications that the air cleaner requires at- strike element - it may become damaged).
tention. Wipe out dirt from inside cover and bowl,
after removing baffle and dumping out
dust.
OIL BATH AIR CLEANER, Fig. 9
Once each week; the filtering cartridge
Service doily; or twice a day if engine is should be taken out and rinsed under a fau-
operating in very dusty conditions. Once cet with cold water, then wash by repeated
each week; in comparatively clean condi- dippings for several minutes in a IOlution
tions. of lukewarm water and a mild, NON-5UDS-
ING detergent. Rinse in cold water from
Remove oil cup from bottom of air cleaner the inside out, and allow to dry overnight
and clean thoroughly. Add the same grade before re-insta1ling. In cold weather, pr0-
of oil, as used in the engine crankcase, to tect element from freezing until dry.
the LEVEL LINE indicated on the oil cup.
Operating the engine under dusty condi- DO NOT USE GASOLINE, KEROSENE
tions without oil in the air cleaner or with OR SOLVENT - DO NOT OIL ELE-
dirty oil, may wear out cylindet'll, pistons, MENT.
rings and bearings in just a few days time. After ten washings or one year of service,
replace cartridge. New cartrida-es are avail-
Once a year; or oftener if conditions are able at your TELEDYNE WISCONSIN
severe, the air cleaner should be removed MOTOR Service Center. Fig. 11, FUEL FILTER

CORPOAATIOPli
9200 Sorensen. Santa Fe Spnngs. CA 90670-2645

VENDOR - 01- 05 ISSUED JANUARY '90
(2131946-6561 • Telex 69-8378 • Fax 213-946-2265 SERIAL NO _ fROIII 5258
BaNI .c. VENDOR SECTION
utor breaker arm RUBBING BLOCK is on

a high point of the CAM. Loosen the sta-
~onary contact LOCKSCREW slightly and
msert a feeler gauge between the points. By
means of a screw driver. tum ADJUSTING
~EW until correct gap is obtained.
Tighten locbcrew and recheck gap.
Points that are badly pitted or worn should
be replaced.
. ' VALVE TAPPET ADJUSTMENT

Models VH40, VG4D, Fig. 15
With the tappets in their lowest position
Fig. 12 (valves completely closed) and engine cold,
the clearance between valve stem and tap-
pet adjusting screw should be:
A FtJLL.FLOW oil filter is furnished on
model V465D engines as standard equip- Inlet - .008" Exhaust - .016"
ment. Since all of the circulated oil passes
thru the filter, it is very important that it be The inlet valves are to the inside of the
serviced regularly. Fig. 13 cylinder block. the exhaust valves are
The oil filtering cartridge should be re- toward the outside. Place feeler gauge bet-
80 that no immediate adjustment is neces· ween valve stem and tappet screw, and
placed after EVERY· OTHER OIL adjust clearance by means of two lh inch
CHANGE. If operating conditions are ex· sary. The IDLE ADJUSTMENT is for
smooth low speed operation and this adjust- tappet wrenches.
tremely dusty, replace cartridge after every
oil change. Use only Wisconsin Micro-Fine ment, if necessary, must be made with the
or Full-Flo oil filter cartridges from your carburetor throttle lever closed. Initial set- Model V46SD, Fig. 16
nearby Teledyne Wisconsin Motor Service ting is approximately 11h turns open.
The clearance between the valve and
Center. rocher arm, with the tappet in its lowest
MAGNETO BREAKER POINTS, Fig. 13 position (valve completely closed) and the
SPARK PLUGS, Fig. 12 engine cold.
At least once each season or when ignition
spark becomes weak, remove magneto end Inlet - .008" Exhaust - .014"
Incorrect gap, fouled or worn spark plug
electrodes, will have an adverse affect on cover, inspect points and check gap open· The rocker arms can be identified as fol·
engine operation. Remove spark plugs per- ing. If there is evidence of pitting or pyra- Iowa: When facing toward the sideof the en-
iodically - clean, regap or replace if neces- miding and it becomes n~ to resur- gine, the Exhaust Racker Arm is to the
sary. face or replace points, it will also be neces- right in the cylinder bead aild the inlet
sary to readjust the gap clearance. The rocker arm to the left.
Spark plug gap - .030 inch. BREAKER POINT GAP should be:
Measure clearance between the top of the
Use new spark plugs at the beginning of a .015 inch at full separation. valve and nose of rocker ann with a feeler
new season. Replacement plug must be of Tum engine crankshaft over until breaker
the correct heat range, equal to: points are at their maximum opening. L0os-
en the two locbcrews on breaker plate just
Model Thread Size Make enough 80 that plate can be moved. Place a
VH4D 18mm Champion D·16.1 0.015 inch feeler gauge between points. In·
VG4D (Wisconsin YD-6) sert end of small screw driver into adjust-
ing slot at bottom of breaker plate and open
V465D 14mm ChampionN.12Y or close the contacts by moving plate until
Wisconsin YD·30l a slight drag is felt when sliding the feeler
Torque spark plugs 25 to 30foot pounds for gauge from between the points. Tighten
Models VH4D, VG4D, and to 22 foot locbcrews and recheck point gap.
pounds for Model V465D. Before plaemg end cover on frame. clean
contact surfaces, coat with gasket cement
STARTING MOTOR; Fig. 1, Ref. 19 and mount new gasket. Assemble cover, r0-
tor and end cap.
No maintenance is required other than Fig. 15, VH40, VG4D
keeping the outside of the starting motor DISTRIBUTOR (Battery Ignition), Fig. 14 VALVE. TAPPET ADJUSTMENT
clean, and periodic inspection for insecure
mounting and loose or corroded cable con- The breaker point gap should be:
nections. .020 inch at full separation.
In extreme dust and dirt conditions it may To readjust point gap, turn engine over by
be necessary to occasionally remove the means of the hand crank until the diatrib-
starter from the engine and clean the Ben-
dix by brushing with Kerosene. Do not oil
Bendix.
BREAKER
POINT GAP
ADJUSTMENTS
CARBURETOR lOCKSCREW
The carburetor MAIN METERING JET is

of the fixed type and therefore no adjust- ADJUSTING
ment is necessary. SCREW
The correct amount of throttle {'late open-

ing for the proper low idle speed 18 obtained
by means of the THROTTLE STOP Fig. 16, V465D
SCREW. However, this is set at the factory fig. 14 VALVE TAPPET ADJUSTMENT

CORPORATION

VENDOR - 01- 06
12131946·6561 • Telex69'8378 • Fu213·946·2265 SERIAL NO. FROM 5258 ISSUED JAIIUARY 'go
BaNI VENDOR SECTION
gauge as 8hown. By meana of a Y. inch tap- screw driver. Connect the other two wires
pet wrench, tum the adjusting screw clock- of the timing light; one to the positive side
wise to decrease valve clearance and coun- of the battery, the other to ground. Chalk
ter-clockwise to increase the clearance. or paint the end of the 'X' marked vane of
the flywheel, white. Then, with the engine
The sequence in which the tappets are ad- operating at 2000 r.p.m. or over, allow the
justed is determined by the 1-3-4-2 firing flash from the timing light to illuminate
order. Start by adjusting No. 1 inlet valve the white vane. At the time of the flash the
clearance firat. then by just a short turn of leading edge of the vane should line UP
the crank, No.3 inlet can be adjusted. Re- with the running 8park advance timing
turn to No. 1 cylinder and adjust the ex- hole in the front face of the flywheel8hroud.
haust clearance. then adjust the No. 3
exhaust. Note: Timing can be checked without
The 8ame procedure appliea to the No.2 removing flywheel 8hroud screen (Fig. 17
and No. " bank of cylinders, 8tarting with show8 screen removed), by illuminating
No. " inlet valve. Mark each rocker arm leading edge of white vane with timing
with chalk a8 adjustment is completed, to light thru the %" diameter hole in rim face
prevent repetition. of flywheel screen.
Timing Adjustment for either battery or
magneto ignition: Refer to the INSTRUC-
TION and PARTS MANUAL of the specif.
TIMING ic engine model for adjustment procedure.
FIRING ORDER
The firing order of the cylinders is 1-3+2, QUTCH ADJUSTMENT
and the magneto or distributor rotor turns
at one-half tngine 8peed, as is the case with If the clutch begins to slip, it should be read- Fig. 19, VH4D
conventional 'In Line' engines. juated to prevent it from becoming over- CLUTCH REDUCTION ADJUSTMENT
The intervals between the firing of the cyl· heated and damaged. First, remove inspec-
inders is 180°. No. 1 cylinder is the one tion plate to expose the adjusting ring.
nearest to the flywheel in the left bank of Rel_ clutch by pushing shifter lever is loosened. Follow adjustment procedures
cylinders, when viewed from the flywheel forward (toward engine). as outlined in preceding paragraph.
end of the engine. No. 3 cylinder is the
other cylinder in this bank. No.2 cylinder VH40C1utch, Fig. 18
is the one nearest to the flywheel in the VG4D, V465D CLUTCH ADJUSTMENT
right bank of cylinders and No. " is the Tum engine over by meana of the starting
other cylinder in thi8 bank. The cylinders crank until clutch adjustment lock is visi· Rockford Clutch Fig. 20: After removing
are numbe~ on the head covers. ble thru the inspection opening. Loosen the inspection cover and disengaging
Note: When disconnecting imition wires, adjustment lockscrew one full tum. Keep clutch with the 8hifter lever, tum engine ov·
mark cap, and tag wires for correct r&-as- clutch from turning by securing the crank· er by means of the hand crank, until the
aembly. shaft at cranking end. Then, by meana of a clutch adjustment lock is visible thru the in
screw driver, tum adjusting ring one notch spection opening in the clutch housing. Pre
at a time in a clockwise direction, until a vent tak&-Off shaft from tuming by meana
TIMING CHECK, Fig. 17 very firm pressure is required when engag· of a drift punch wedged in place 88 shown.
ing the clutch shifter lever, and as the Then, loosen the lockacrew holding the ad·
The running spark advance for both mar- clutch snapa into engaged position. Secur&- justment lock in place. Insert a screwdriver
neto and battery ignition, is 23°, and tim- ly tighten adjustment lockscrew. in one of the notches and turn the adjust·
ing must be checked with the engine run- ing ring, in a counter-clockwise direction,
ning at 2000 R.P.M. or over. one notch at a time, until a very firm pres.
VH4D CLUTCH REDUCTION, Fig. 19 sure is required to engage the clutch with
Insert a 8mall screw driver into the No. 1 the shifter lever. Tighten adjusting lock·
terminal tower on the distributor cap, mak- The clutch in the clutch reduction unit is screw and mount inspection cover.
ing contact with the ignition wire terminal. the same as used in the power tak&-Off unit
Connect th~ red terminal clip, from an auto- and is adjuated thru two pipe tap openings;
motive Timing Light to the metal part of the one for the adjustment locbcrew and the TWIN DISC CLUTCH, Fig. 21:Pull adjusting
other for turning the adjustinJ ring. If one lockpin out and insert a piece of 1116" di·
of the tapa is inaccessible, adjustment can ameter wire into the hole on the side of the
be made thru just one opening by rotating lockpin to keep pin in outer position. Tum
clutch slightly after adjustment lockacrew the adjusting yoke in a clockwise direction
"Vi.............. SPARK
ADVANCE TIMING
REDto/
DISTRIBUTOR~~
HOLE IN SHROUD toBATIERY
to GROUND
Fig. 18, VH4D Fig. 20, VG4D, V465D
Fig. 17 CLUTCH ADJUSTMENT ROCKFORD CLUTCH ADJUSTMENT
9200 Sorensen. Santa Fe SOrings. CA 90670·2645

VENDOR - 01- 07
(2131946-6561 • Telex 69-8378 • Fax 213·946·2265 SERIAL NO. fl(It 5258 ISSUED JAllUART '90
BuHNJ VENDOR SECTION
PRECAUTIONS to be exercised in the use 6. Disconnect at least one battery lead if a

of this flywheel alternator: battery charger is used.
1. Do not reverse battery connecti9nB.
This is a negative ground system only.
2. Connect booster batteries - positive to GENERATOR - WIRING CIRCUIT, Fig. 24
positive and negative to negative. ~e model V4650 engine is equipped
a. Do not polarize the alternator. With a 12 volt-17 amp generator in a
4. Do not ground any wires from stator or negative ground electrical system. Do
modules which terminate at connectors. not reverse polarity-damage to both gen.
erator and regulator will occur. Engine
5. Do not operate engine with battery dis- will not operate with carburetor anti-
connected from system. diesel solenoid wire disconnected.
RECTIFIER
MOOULE
Fig. 21, VG4D, V465D
TWIN DISC CLUTCH ADJUSTMENT
as shown. or wedge a screw driver into the
adjusting yoke and against the side of the
inspection hole openings to keep the yoke IGNITION
from turning. then tum the take-off shaft SWITCH
counter-clockwise to adjust yoke enough 80
that the shifter lever requires a distinct
pressure to engage. Remove wire from lock-
pin and tum adjusting yoke slightly. to al- Make Connection, for :
low lockpin to snap into hole in floating ~~~~f·rm":t~arv. ;
plate. AUTOMATIC
CHOKE (optional) .... - -- Connect e~uipm.nt
A new clutch generally requires several ad- Solenoid. Her.
justments until the friction surfaces are SPARK PlUGS A :
worn in. Do Not let a new clutch slip. this ,..---.c.;.------.J
will ruin the friction surfacell. , START
, SWITCH
" (optional)
....--op;~.:
R YWHEEL ALTERNATOR
Fig. 22 and Fig. 23 S?~~o
(optional)
12 Volt· 10 Amp or 25 Amp Flywheel Alter·
nator, conllisting of a flywheel with Mag-
netic Rotor. Stator and Rectifier· Regulator
modules, is optional equipment on models
VH4D and VG4D·fumished when battery
ignition is required. There are no brushes.
commutator or belts to contend with and
no adjustments are necessary.
Fig. 23. WIRING DlAGRAM,Flywheel Alternator and Battery Ignition, Models VH4D. VG4D
Since the phYllicai appearance of both 10
amp and 25 amp alternator systeIDII are
very similar. they can be distinguished ....TTERy
from each other by the ammeter calibra-
tions; 0 to 15 amps for the 10 amp circuit
and 0 to 30 amps for the 25 amp circuit.
REGULATOR
MODULE
RECTIFIER
MODULE
ANTI·DlESEl
SOUiHOtO
'PRESTOUTE'
REGULATOR
Fig. 22, FLYWHEEL ALTERNATOR Fig. 24. WIRING DlAGRAM,Generator and Battery Ignition. Model V465D

e~!:~~
~200Sorensen. Santa Fe Springs. CA 90670-2645
VENDOR - 01- 08
2131946-6561 • Telex 69-8378 e Fax 213-946'2265 SERIAL NO. FROM 52SB ISSUED JANUARY '90
B9tD
TROUBLE SHOOTING
•••
continues to drip from carburetor with en· ENGINE MISSES
VENDOR SEen ON
gine standing idle.

Spark plug gap incorrect.
The three prime requisites essential to start· COMPRESSION
ing and maintaining satisfactory oper· Cylinders dry due to engine having been Worn,leaking or loose ignition cables.
ation of internal combustion engines are: out of use. Pour one fluid ounce of crank· Weak spark. See 'Ignition' test for spark.
1. A proper fuel mixture in the cylinder. case oil through spark plug holes. Breaker points pitted or worn.
2. Good compression in the cylinder. Loose or broken spark plug. A hissing Water in gasoline.
noise will be heard in cranking due to es·
3. Good spark. properly timed. to ignite caping gas mixture on compression stroke. Poor compression. See 'Compression'.
the mixture. Sticky valves.
Damaged CYlinder. head gasket or loose
If all three of these conditions do not exist cylinder head. This will likewise cause
the engine cannot be started. hissing noise on compression stroke. ENGINE STOPS
As a guide to locating some of the difficul· Valve stuck open. Piston rings stuck or worn. Fuel t8J\kempty.
ties in starting. causes are listed under the Valves adjusted with insufficient clearance.
three main headings of: Water, dirt or gum in gasoline.
Fuel Mixture, Compression, and Ignition. Gasoline vaporized in fuel lines, due to ex·
IGNITION
cessive heat around engine (Vapor Lock).
FUEL MIXTURE Test for spark by removing spark plugs See 'Stopping Engine'.
No fuel in tank or fuel valve closed. and observe spark at plug gap while tum·
ing engine over, No spark or weak spark Vapor lock in fuel lines due to using winter
PlUgged vent hole in fuel tank cap. may be attributed to the following: gas (too volatile) in hot weather.
Fuel line clogged. Ignition wires loose or disconnected at mag. Air vent hole in fuel tank cap plugged.
Fuel pump diaphragm worn or punctured. neto, spark plug, distributor or coil. Ignition troubles. See 'Ignition'.
Anti-diesel solenoid valve at carburetor in· Broken or frayed ignition wires.
operative (model V4650). Spark plug insulator broken. OVERHEATING
Check for disconnected, loose or broken Spark plugs wet or dirty.
wire. Crankcase oil supply low.
Carburetor not choked sufficiently, espec· Spark plug gap incorrect. Ignition timing wrong.
ially if engine is cold. Condensation on spark plUg electrodes. Low grade of gasoline.
Water, dirt, or gum in gasoline interfering Breaker point gap incorrect. Engine overloaded.
with free flow of fuel to carburetor. Breaker points pitted or fused. Restricted cooling air circulation.
Poor grade, stale or out-of·season gasoline. Breaker arm sticking. Part of air shroud removed from engine.
Carburetor flooded, caused by too much Condenser leaking or grounded.
choking especially if engine is hot. Dirt between cooling fins.
Carburetor float needle valve stuck open. Spark timing wrong. Intake or rotating screen clogged with dirt.
This condition would be indicated if fuel Weak battery. Faulty ignition coil. Restricted exhaust.
Page Weekly Seasonally

ENGINE MAINTENANCE SCHEDULE Ref. Daily or 50 hn. l00hn. 250 hn. or sao hn.
. ••
CHECK OIL LEVEL . Add to full mark - Do not overfill. 2
CHECK AIR CLEANER. Shake out accumulated dirt from
dry element cleaner - Maintain oil level in oil bath type cleaner.
CLEAN AIR INTAKE SCREEN. Clean cooling fins if necessary. 1
•
GREASE CLUTCH THROWOUT BEARING (VG..D. V465D). 3
•
CHANGE CRANKCASE OIL. 2
. •
CLEAN AIR FILTER ELEMENT. DRY Element and OIL Bath types.
. •
CLEAN CRANKCASE BREATHER CAP.
•
GREASE CLUTCH HOUSING BEARING (VG4D. V46SD). 3
. •
REPLACE OIL FILTER. In adverse conditions replace every oil change.
•
LUBRICATE DISTRIBUTOR SHAFT. .. •
CHECK COMPRESSION. Pressure should not vary more than 10 p.s.i. between
cylinders. Remove head· dean out corban deposits. Reseat valves if necessary.
- •
INSPECT SPARK PLUGS and BREAKER POINTS.
Replace if necessary and regap to specification.
5
•
INSPECT FUEL FILTER. Clean filter screen and gloss bowl. .. •
LUBRICATE DISTRIBUTOR CAM and breaker arm pivot. .. •
INSPECT COOLING SYSTEM. Remove shrouding and scrape off
dirt from between fins, around cylinden and from shrouding.
1
•
INSPECT STARTING MOTOR. Check for loose mounting and coble connections. 5
•
CHANGE OIL IN CLUTCH and REDUCTION GEAR HOUSINGS. 2
•
a..., ......I ....,....,,,.., .. n
9200 Sorensen. Santa Fe SOrings. CA 90670·2645
VENDOR - 01- 09
12131946-6561 • Telex 69·8378 • Fax 213·946·2265 SERIAL NO. FROM 5258 ISSUED JANUARY '90
ea 46QIDK·· VENDOR SECTION
Limited Engine Warranty

TELEDYNE WISCONSIN MOTOR. hereir. referred to as 'Teledyne Wisconsin',
warrants each new Wisconsin 4-cycle air-cooled engine sold by Teledyne Total
Power to be free from defects in material and workmanship, under normal use
and service, for a period of one (1) year (except in the case of an engine used on any
recreational type vehicle the period shall be ninety 190) days) after the date of
delivery to the original retail purchaser, and Teledyne Wisconsin will. at its option,
replace or repair, at one of Teledyne Wisconsin's factories, or ata point designated
by Teledyne Wisconsin, any part or parts which shall appear to the satisfaction of
Teledyne Wisconsin upon inspection at such point, to have been defective in
material or workmanship. This warranty does not obligate Teledyne Wisconsin to
bear any transportation charges in connection with the replacement or repair of
defective parts.
This Warranty shall not apply to any engine whicn shall have been installed or used
in a mCinner not recommended by Teledyne Wisconsin, nor to any engine which
shall have been repaired, altered, used in any type of competition, nor operated
other than within Teledyne Wisconsin Motor specified limits, neglected or used in
any way which, in Teledyne Wisconsin's opinion, adversely affects its perform-
ance: nor. to any engine in which parts not approved ·by Teledyne Wis-
consin have been used: nor to any accessories installed on the engine where the
accessory manufacturer has its own warranty; nor to normal maintenance
services or replacement of normal service items.
Teledyne Wisconsin reserves the right to modify, alter. and improve any engine or
parts without incurring any obligation to replace any engine or parts previously
sold with such modified, altered. or improved engine or parts.
THIS WARRANTY. AND TELEDYNE WISCONSIN'S OBLIGATION HEREUNDER, IS

IN LI EUOF ALL OTHER WARRANTIES. EXPRESS, IMPLIED, OR STATUTORY,IN.
ClUDING ANY WARRANTIES OF MERCHANTABILITY OR OF FITNESS FOR A
PARTICULAR PURPOSE, AND ALL OTHER OBLIGATIONS OR LIABILITIES,
INCLUDING SPECIAL OR CONSEQUEN TIAL DAMAGES OR CONTINGENT LIABIL-
ITIES ARISING OUTOF THE FAILUREOF ANY ENGINE OR PART TO OPERATE
PROPERL Y. No person is authorized to give any other warranty or to assume any
additional obligation on Teledyne Wisconsin's behalf unless made in writing and
signed by an officer of Teledyne Wi sconsin.
cut along dotted Iina
ratum to
TelEDYNE TOTAL POWER
3409 DEMOCRAT ROAD
MEMPHIS, TENNESSEE 38118
Individual INSTRUCTION and
SERVICE PARTS MANUAL avail-
able from all Wisconsin Distrib- Dear Customer:
utors, If you would like to receive a free copy of a list of Authorized Teledyne Wisconsin
Motor DISTRIBUTORS and SERVICE CENTERS in your area, please complete the following;
NAME ________________________________________________
STREET _______________________________________________
CITY _______________________ STATE _______ ZiP _________
ENGINE MODEL ___________ SERIAL NO. ________________________

R.vnn
CORPORATION

(213) 946-6561 • Telex 69-8378 • Fax 213-946-2265
VENDOR - 01-10
SERIAL NO. FROM 5258 ISSUED JANUARY 'go
89 VENDOR SECTION
Operation Manual
DEUTZ
F2L 912/W
Contents
Page
Foreword
Before Commissioning Your New Engine . 64
Safety Precautions . . . . . . . . . . . . 65
Description of Engine
Description of Engine . . 66
Numbering of Cytinders .. 67
Lube Oil Circuit . . . . . . . 68
Combustion Method . . . . ... 69
Layout of Fuel System (Deutz Injection Pump) 70
Layout of Fuel System (Bosch Injection Pump) 71
Engine Model and Engine Serial No. 72
Specification Data . . . . . 73
Operation of Engine
Fuel (Filling-up/ Air-bleeding) 74
Motor Oil . . . . . 76
Starting . . . . . . . . 79
Stopping . . . . . . . 82
Winter Operation . . . 83
Maintenance
Maintenance Schedule . . . . . . 89
Important: Commissioning New or
Overhauled Engines . . . . . . . 92
Checking Oil Level in Engine . . . . 93
Checking and Cleaning Air Cleaners . . . . . . . 94
Checking Water Separator on Two-stage Fuel Filter 97
Changing Motor Oil . . . . . . . . . . . . . . . . . 98
Inspecting/Cleaning the Cooling System . . . . . . . . 100
Checking Electrolyte in Battery . . . . . . . . . . . . . 102
Checking V-belt/V-belt Tension . . . . . . . . . . . . 103
Cleaning lube Oil Filter . . . . . . . . . . . . . . . . . 105
Checking Valve Clearance/Decompression Clearance 106
Cleaning Strainer of Fuel Feed Pump . . . . . . . . . . 108
Renewing Fuel Filter Cartridge . . . . . . . . . . . . . 109
Renewing Two-stage Fuel Filter Cartridge (1st stage) 110
Renewing Two-stage Fuel Filter Cartridge (2nd stage) 111
Workshop Maintenance
Checking Fastenings of Intake and Exhaust Manifolds . 112
Checking Cylinder Head Temperature Monitoring System 112
Testing Alternator/Starter Motor 113
Testing Injectors . . . . . 114
Trouble Shooting ... 115
Workshop Information . 118
EnginePreservation ... 121
FIGURE 02 DEUTZ DIESEL ENGINE
~'en,""n
CORPORATION
Santa Fe Springs. CA 90670-2645

VENDOR - 02 - 00
• Telex 69-8378 • Fax 213-946-2265 SERIAL NO_ FU 5258 ISSUED JANUARY '90
"'v>
"'0
O>~
.<1)
0>" Foreword
"''''
0><1) Foreword
~"
.v> Safety and dependability result
.... '"
~; ~~ from superior technology,
<1) "11
:~ correct operation, plus proper
-
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CD
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~.
§= Before Commissioning Your New Engine:
Surely you expect top service from your OEUTZ engine ... So please give this
care and maintenance
w"
",CO manual your top attention!
CD!"
.0
-•
:t> All necessary safety precautions and regulations have been observed in the design. choice
;;\'~ of material and manufacture of your engIne. and before the engine left our factory, it stood up
" 0>
N-.J satisfactorily to the severest lests and trials.
~O
W·
• N
",0> Maximum engine performance Is however not possible without a minimum of upkeep .
".", Remember that even simple household appliances need some care and attention once in a while.
0>'"
N So be sure to maintain your engine as scheduled herein and 10 use the fuels and lube oils
N
0> recommended. You will get a lot In return: a long lifespan of your OeUTZ engine. high power
'" ."
.....
output and reliability, plus low consumption rates and exhaust emissions .
When reading through this manual, you will
Should. on the other hand, any trouble arise on engine calling for overhaul or repair, do not tamper
@ with it but entrust the job to a workshop of the worldwide OeUTZ organization, where you will
lind the above symbol marking all important
safety instructions. Give particular heed to
~ find a staff of DEUTZ-trained mechanics. the latest special tools and facilities, and a full stock of Ihese instructions and proceed with special
a
care. Pass on these safety instructions to your
operating personnel.
,..,
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DEUTZ
General Safety Rules
Apart from the safety instructions given in this Cl
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Genuine Spare Parts manual. it is also necessary to observe the
official safely rules, which may vary from Care and Maintenance 0>
@
c=
country to country.
For ordering such spares, please always refer to the relevant Parts Catalogue. Otherwise ask Reliability of the engine largely depends on
~
~ .....
,."
your local DEUTZ distributor. close observance of the Maintenance
Schedule (page 89).
O~
By the way, you will agree with us that "Safety first" is a good slogan. So please be sure to refit The Right Work Clothing Never attempt to rectify faults or carry out
any guards and protective devices that should have been removed for carrying out work repairs for which you do not have the necessary
Work clothing should be closely fitting, so that
,." on the engine. it cannot be caught by rotating or projecting experience and special tools. Entrust the job
to your DEUTZ Service Slation, where DEUTZ-
;;a~
parts.
To prevent pollution of the environment, please let old fuel and oil run Into a special recep- trained personnel will give your engine expert
tacie. attention.
:z ,."
I Beware of Running Engine
Always stop the engine before refuelling.
~O Always stop the engine before carrying out

maintenance or repair work.
8~ <
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I Note: In view of the constant improvements to our engines, the specification data as well as other
information included in this manual are subject to change without notice
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Fig. 2
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1""1 Fig. 1
Description of Engine (Air intake side) Cylinder Numbers
o~ Description of Engine (service side) (shown: F2L 912 - with Deutz fuel-injection pump) 21
22
Air cowling
Injector
;a~:z
23 Rocker chamber covers
1 Exhaust manifold 11 Lube oil filter
24 Vertical plate, rear
2 Air intake manifold 12 Speed control lever
13 Lube oil cooler 25 Adapter housing
3 Injection lines
1""1 14 Oil filler cap 26 Flywheel
4 Vertical plate, front
I 5 Cooling air blower 15 Shutdown lever 27
28
Crankcase
Starter motor
6 Hydraulic pump connection 16 Oil dipstick
-0
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7
8
9
V-belt
Deutz fuel-injection pump
Fuel feed pump
17
18
19
Fuel filter
Crankcase breather
Waste air box
29 Alternator
<
a~ 10 V-belt pulley 20 Pushrod with cover tube
m
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66 67
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(7),, Description of Engine Description of Engine
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18 Combustion Method
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<11- FL912 FL912W
-'".."
<11 Direct Injection Two-stage Combustion
-
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(7)(1)
'f'o §::2 17, ..
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.-...........
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» 14.
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This Instruction Manual applies both to F2L 912 engines using direct injection and to F2L 912 W
engines using two-stage combustion.
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The difference in the two systems is dealt with in the sections "Specification Data«, "Starting"
and "Operation in Winter«.
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Fig. 4
8/ 7 QIisffil Direct-injection engines are used where high power output and compact construction are more
important than high eXhaust-gas quality. while two-stage combustion engines are designed for
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VI
Lube Oil Circuit
1 Oil sump 17 Pushrod
applications where low exhaust emissions are of prime importance.
0;a 1"'1
1"'1
2
3
4
Suction pipe
Oil pump
Delivery pipe
(hollow. supplying oil to rocker arms)
18 Rocker arm bearing
19 Push rod cover tube (surplus oil returning
- :z 5 Oil filler with cartridge (full-flaw) from rocker arm chamber to sump)
If) 6 Oil bore to 3rd main bearing 20 Oil pressure gauge
7 Oil pipe to oil cooler 21 Oil drain plug, for lube oil filter housing
:z 8 Oil cooler (version optional) 22 Main oil drain plug
1"'1
I 9 Oil bore to 2nd main bearing. valve drive
and piston cooling
23 Injection pump (connected to engine
lube oil circuit (on version with Bosch
10 Oil bore to 1st main bearing injection pump)
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0 11
12
13
Main bearing
Big-end bearing
Spray nOlzle for piston cooling <
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~ 14
15
Camshaft bearing
Oil duct to tappets
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,.. I rocker arm lubrication)
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Fig. 7
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Layout of Fuel System (here with Deutz injection pump) Layout of Fuel System (here with Bosch injection pump)
,...
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1
2
3
4
Fueltank
Fuel supply line
Fuel teed pump
Fueltiller
1
2
3
Fuel tank
Fuel supply line
Fuel teed pump
~ :z If) 4 Fuel filter
,.,.....
5 Injection pump 5 Injection pump
6 Injection lines 6 Injection lines
7 Injector 7 Injector
I 8
9
Backleakage line
Overflow line
8 Backleakage line
9 Overflow line
10 Fuel return line
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10 Overflow valve
11 Fuel return line
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<7>:J Description of Engine ________ Description of Engine
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.(/1 Specification Data
01 Engine Model and Engine Serial No.
~~
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,!lii The model designation A and the engine serial No, B are given on the rating plate (Fig 8).
<1>-n Model. F2l912 F2l912 W
-
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§:w The rating plate is attached to the crankcase below air cowling (Fig. 9)
The serial No. is also stamped into the crankcase, see Fig. 10. Number of cylinders . 2
w3
.... 00 Bore mm 100
CDY' Stroke. . mm 120
-•
.0 Piston displacement . cm' 1884
» Direction of rotation (facing flywheel) counter-clockwise
-n<D
",0 Working principle four-stroke diesel with
,,<7>
1\) ....
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direct
injection
I two-stage
combustion
W'
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1D<7> Weight (depending on version) approx. kg 255
t>t> Power output' kW(HP) see rating plate
<7>'" Speed' rev./min see rating plate
N
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<7> lubrication system forced lubrication ...
'"
-
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Oil capacity initial fill
refill
Valve clearance (engine cotd) .
Valve timing:
approx.ltr.
approx.ltr.
" mm
6
4,5
0.15
Fig 8 with Deutz injection pump
a
Inlet opens ,bTDC 26"
<~I
Inlet closes ,aBDC 67"
'"
m 1256111 Exhaust opens .bBDC 73"
Xl
~
Exhaust closes , aTDC 30"
:t> with Bosch injection pump
r-
lIIe Inlet opens ' , bTDC 32"
:z
o
i
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Inlet closes , ,
Exhaust opens
Exhaust closes ' "
, aBDC
, bBDC
' " aTDC
Piston crown clearance (measured with lead wire) mm
Injection release pressure (during operation), bar 175 t- 8
60"
70"
32"
1.0" 1,2
115 t- 8
E
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l'l Commencement of Delivery
Deutz injection pump
O~
up to 2300/min , bTDC 32" ± 1" 25° t 1"
above 2301/min , , bTDC 38" ~ 1" 25" t 1"
Bosch injection pump
;D~z
with advance unit , bTDC 22" ± I"
without advance unit
upto 1800/min , .bTDC 26" ± 1"
from 1801 - 2300/min , bTDC 30" ± 1"
m above 2301!min , bTDC 32" .. 1"
I
Firing order 1-2
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Fig.9 The power output and speed of the engine are stamped on the nameplate. ;:Q
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Engi_ne_ ()_p~@~!()n . __ . _. _.~~ ___ ~__ . ~ Engine Operation
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Starting up a new engine for the first time involves a number of preparatory jobs. some of which 1.2.2 Version with Bosch Injection Pump
-."
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tI> .."
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~§ must atso be carried out later on in the course of routine maintenance (see Maintenance Schedule
on page 89).
(Fig. 12)
• Loosen banjo bolt 1 by 2 3 turns.
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-
'PO
(l:t :!.
• Actuate priming lever 2 by pressing repea-
w::> 1, Fuel tedly until fuel emerges free of air bubbles
.... <0 at the loosened banjo bolt 1.
0011' 1.1 Grade
• Tighten banjo boft securely, while still
.~ Always use a reputable branded grade of gas Oil. the sUlphur content of which should be below pumping.
-•
..,,<0 0.5 %. and observe strict cleanliness when filling in. Higher sulphur contents affect the oil-change
",0
intervals (page 98). Allow ambient temperatures use winter-grade fuel only (see hints on page • loosen overflow valve 3 (Fig. 12) at the
"
IV ....
~O
'" 83). The fuel must be replenished promptly to prevent tile tank from running dry, otherwise fuel
filter and injection lines will need air-bleeding.
lower (larger) hexagon by 2 - 3 turns.
• Actuate priming lever 2 by pressing
w'
,IV
<DO> The following fuel specifications are approved: DIN 51601; NATO Codes F 54, F 75. F 76; BS 2869: repeatedly downwards against spring force
1>1> until fuel emerges free of air bubbles at the
",Ul A 1 and A 2': ASTM 0 975-78: 1-0 and 2-D; VV-F-800a: OF-A. DF-l and OF-2.
,;, loosened overflow valve 3.
I\)
0> 1.2 Air-bleeding • Tighten overflow valve securely. while still
-
Ul pumping.
." Never let the tank run dry!
en Any air which has found its way into the fuel Note:
c:: system can cause irregular running of the When operating the priming lever. the dis-
Fig. 12
~ engine and decrease its performance. even
leading to stopping of the engine and prevent-
tinctly perceivable "pressure poin!"J e. the
commencement of the lifting movement of the
a
ing its restarting. diaphragm. must occur in the first quarter of
<
0 Not only when the fuel tank has been run dry, its total travel. Failing this, tum engine over a
...,
v> N but also after changing the fuel filter or work- little by hand.
'" ing on the fuel line system. is it therefore (When operated by hand, the feed pump will
?
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r-
2: rn 0
,."
necessary to air-bieed the system as follows:
1.2.1 Version with Oeutz Injection Pump

only work if the camshaft of the injection pump
is in such position that the diaphragm of the
feed pump is not lifted.) C>
."
i.,. Z c::
....
N
(Fig. 11)
• Loosen bleed screw 1 by 2 . 3 turns.
?'i
00
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~
0
N
l!I'l C , ."
tedly upwards against spring force until fuel
emerges free of air bubbles at the loosened
Caution:
o~
bleed screw 1.
Fig. 11
• Tighten bleed screw securely. while still Stop engine before filling fuel tank!
pumping. Observe strict cleanliness! Do not spill any
,." fuel!
• Loosen banjo bolt 3 at smaller hexagon by
=a~z 2 . 3 turns.
tedly upwards against spring force until fuel
,."
I emerges free 01 air bubbles at the loosened
banjo bolt 3.
• Tighlen banjo bolt securely. while still
Vl
VI
0 pumping.
~~
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.(1) 2. MotorOil 2.4 Oil Viscosity
01
-I"
!.it 2.1 Filling In Oil (Fig. 13) 2.2 Checking 011 level (Fig. 14) The viscosity of the oil being greally inlluenced by the ambient temperature. the choice
SAE-grade should be governed by the ambient temperature. at engine site (see diagram). If
0'
the
ID" - see page 93 -
0'
-
" ID temperatures temporarily fall below the limit the SAE-grade selected. this will merely aHect the
~~
0>:1
starting performance but cause no engine damage.
W"
.... <0
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"to
010
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>:¢::::~:.... ··;:;;:~;··:~~:·:8'::·~~:::;;;:~::'%~;f.!::f.~:m.~~!1::::~~:mff.:~~':~?·f;:;:K:r::f~:::::m::~:::~~?:·::~@:::~~;.i
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<~ Fig. 13
2.3 Oil Quality

By preference. use oils of the API quality grade CD/SE or CD/SF. You will thus attain the longest
possible oil change intervals.
Oils of the API quality grade CC/SE and CC/SF can be used when halving the length 01 oil intervals
Fig. 14
Fig. IS
a !2
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0.
:: c -
~
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",
(see page 98).
Note:
* Only with engine oil preheating.
8
O~
During operation of the engine, not only part of the oi/lubricating the pistons is burnt but the Since a too viscous oil causes starting difficulties, the chOice of the viscosity grade during winter
thermal stress and the combustion residues mixing with the oil also entail a deterioration of the oil operation should be governed by the ambient temperature prevailing at the time of start·
and in particular of its chemical additives. Therefore, a complete change of the oil should be ing the engine. Oil changes as a function of ambient temperatures can be avoided by using multi-
", carried out al the recommended intervals. grade oils, which are again subject to the oil change intervals recommended on page 98. The
required oil capacities are given under "Specification Data" on page 73.
;liez As this deterioration is greatly influenced by the operating conditions as well as by the quality of
the fuel and oil used. the oil change intervals differ accordingly. Be sure, therefore. strictly to
observe the specifications given on page 98.
", Note:
I Do not mix different oil grades.
For manually started engines. other viscosity grades are prescribed than for electrically started
engines. The upper part of Fig. 15 therefore shows the viscosity grades for the manually started
~O
engine, while the lower part shows the grades for the electrically started engine.
a~ <
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80 76 77 .."
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3. Oil Bath Air Cleaner (if mounted) 5. Starting

Engine Operation
~~
=
(1)i» The air cleaner bowl 1, Fig. 16, must be filled 5.1 Starting with Etectric Starter
(i""" : ... with oil before starting up (use the same grade • Disengage clutch to disconnect engine from
°z of motor oil as for the engine).
-
)( (D
m(Jl
::' driven equipment, where possible.
~O
(D ::I. • Move speed control lever 1 or 2 (Fig. 17) to
W::I about quarter speed by hand or fool.
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(DII'
5.1.1 Version F2L 912 (Direct Injection)
.~
-•
without Heating Tube
"T\ID
..,0 • Insert starter key 1 (Fig. 18), turn clockwise
",01 todetenl.
N'"
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W,v • Check that charging pilot lamp 2 lights up.
<D~ • Push in starter key 1 deeper and turn farther
t;,,,, clockwise against spring pressure.
N Fig. 17
'"01
'" ."
• Starter motor turns engine; as soon as the
engine starts firing, release starter key 1.
..
~ with Heating Tube (Item 1, Fig. 19)
Fig. 16
~ • Insert starter key 3 (Fig. 18), "Stage 0".
~ • Turn clockwise, "Stage 1".
a
• Check that charging pilot lamp 2 lights up.
ffi< C) • To start, push in starter key deeper and turn

N 4. Important for your Engine's Power Output farther clockwise against spring pressure
through "Stage 2" to "Stage 3".
Power output, temperature level and exhaust gas qualtity of any diesel engine are governed by
»0 careful matching of combustion air and fuel injection volumes, and since the density of the com- • Starter motor turns engine; as soon as the
: 1ft c bustion air taken in varies with the atmospheric pressure and the ambient temperature, full rated
power is obtained only at standard reference conditions in respect of atmospheric pressure
engine starts firing, release starter key 3.
52
iz ~
", 5.1.3 Version F2L 912 W
(altitude of engine site) and ambient temperature. f"I
(Two-stage Combustion)
Standard reference conditions are as follows: 0.
• Insert starter key 3 (Fig. 18), "Stage 0". I;
(a) 101.3 kPa = 1013 mbar (sea level) and 20 "C (68 OF) • Turn clockwise, "Stage 1".
C
~C
for automotive engines to DIN 70020 Fig. 18
~ • Check that charging pilot lamp 2 lights up.
", (b) 100 kPa ~ 1000 mbar (100 m above sea level) and 27 "C (81 "F)
CI) for industrial and marine engines to DIN 6271. • To preheat, push in starter key deeper and
....
0
", turn farther clockwise against spring pres-
Where engines are operated at greater altitudes and/or higher ambient temperatures, they must sure to "Stage 2", and hold.
be de-rated (reduced fuel injection and hence engine loading) in accordance with special Tables
", available. • Preheat for about 30 to 60 seconds, while
Z observing that heater plug indicator 4 glows
;Ia G')
~
Z Note:
up.
• To start, turn key farther clockwise to "Stage
", 3".
I Therefore, never run your DEUTZ diesel in "thin air" under heavy-duty conditions unless your
engine has been de-rated accordingly, otherwise the engine's lifespan, reliability and exhaust • Starter motor turns engine; as soon as the
emissions may be affected, especially at altitudes above 1000 m and/or temperatures above engine starts firing, release starter key 3.
t:O 30 "e. Be sure to contact us or your equipment supplier in good time! Note:
Do not actuate the starter for more than 20
a~ seconds at a time. You will protect your banery
if you wait for 1 minute between each starting
<
/TI
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§;: anempt. o
z o
il Fig. 19 ;;0
=
l!O 78 79
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'111
<1>:> Engine Operation _____ ~. _.. _ Engine Operation
~:£
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.1/1 5.2 Starting Manually 6. Attendance in Service

I»
~:> 6.1 Motor 011 Pressure
111-
_I»
11I"T1 Possible down to about ... 5 "C. At idling speed.
-
" 111
<1>1/1 • Disengage clutch to disconnect engine from • the green oil pressure pilot light should have
CPo
0> :>.
driven equipment. where possible. gone out or
w:> • the pointer of oil pressure gauge 1 (Fig. 23)
--JIQ • Set speed control lever 1 or 2 (Fig. 20) by
o>JI' hand or foot about quarter speed in the - if mounted - should be in the green
.'))#'i.il'.'·"'~
sector. or
.~
-•
direction of the arrow.
"TIeD • Move decompression lever 1 (Fig. 21) from • the pOinter of the oil pressure gauge 2 (Fig.
1»0 stop to stop (see arrows) and then back J'. 23) - if mounted - should indicate about
,,<1>
",--J into the Initial position. This is important
J--:r-'7
~. / ' I: 1.0 bar.
~O
W· for safety reasons! 11. • / I,
J)I~"<H1f"V:)c'r~~
/ / '/ ." ~'•
• N
Note:
'f~
<1>01
Fig. 20 Ughting up of the warning lamp at low idling Fig. 23
&
0\) speed (engine warm) or a drop of the gauge
-
I\J
<1> indicator into the red sector is stHI permissible
UI if, when speed is increased, the lamp goes out
.." Caution I again or the indicator moves back into the
green sector.
@ 00 not actuate the decompression device
while the engine Is running. The minimum oil pressure Is 1.0 bar at 750 +
~ • Grasp crank handle 1 (Fig. 22) with both
SO/min.,/ow idling. Where a continuous moni-
toring of the oil pressure is desired also within
a
hands, all fingers and thumbs up, and the engine's working speed renge, this will
turn handle briskly until decompression
~<~
require optional extras.
shuts off automatically (after some 6 cam-
shaft revolutions) and the engine starts 6.2 Temperature (Fig. 24)
". firing.
~rn~ • As soon as the engine runs smoothly. cut Through the window of the temperature Indi-
back the speed. When a moderate load is cator', the pointer is to be seen in the yellow-
Ish-green sector when the engine Is at normal o
iZ~
applied and the speed is varied. the engine
will warm up to its working temperature in a working temperature. If the pointer Is in the 0>
short time. orange sector, this means that the engine 8
IG"O~=
is overheated and must be shut down Im- .
Fig. 21 mediately. In this case the cause of the over- Fig. 24
g: -" , heating must be traced on the lines indicated in
the Trouble Chart (see pages 116 and 117).
5.3 Starting at Low 6.3 Fan Drive
~~z
Ambient Temperatures If a mechanical V-belt breakage monitoring
system' (Fig. 25) is provided, the engine is shut
See "Operation In Winter", pages 83 - 85. down by the action of the tensioning pulley 1 in
the case of V-belt breakage.
",
I
~O
&
Caution!
a~ Before starting. make sure that no one is

standing in the close vicinity of the engine or
<
IT1
Z
~
driven machine. After carrying out repairs:
I Check that al/ safety guards have been refitted • Not mounted on all engine versions.
:5
i
~
and al/ tools have been removed from engine. Fig. 22 Fig. 25 :0
VI
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-
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n
.....
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~~
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<Dill
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01:;)
0>",
01"
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Engine Op~ra!i~n Engine Operation
• III
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7, Stopping
• Set speed control lever 1 or 3 (Fig, 26) to idl-
~~1t,
I
r;;
~J 'd~
~")fch;I :tJ".
, 8. Operation in Winter
8.1 Use winter-grade motor oil
""" " Ing position. ....:({ ,. <"' 1 ltl1·:·;-::.···~ ..:
\"X" "
-
)(
01 III :::"-~:-r.',.....11'1-~...;::;/, To ensure satisfactory cold starting, the choice
<PO
QI:;)
• Operate stopping lever 2 or 4 (Fig. 26) on • • j. M:', I , I '\ ,"'i of the viscosity grade (SAE-grades page 77)
W::>'
.... 00
QlI"
.~
the injection pump until the engine stops,
whereupon the pilot lamp 2 (Fig. 26a) should
light up again. i i. - '.;.! I]
,
, ,
.\'11'
,
should be governed by the ambient tempera-
ture prevailing at the time of starting.
As to the oil change intervals, it should be borne
-•
'
• Turn starter key 1 or 3 (Fig. 26a) fully anti- in mind that operation below - 10 "C requires
~~
">','~Ji,7/(.~f~
clockwise and pull out; this will cause the shorter oil change intervals (see page 98,
><01 pilot lamp to go oul. "Changing Motor Oil").
I\l ....
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W'
,I\) 8.2 Fuel
<Do.
",,,, Use winter-grade fuel in winter because with
l
Note:
01 til ordinary fuel, waxing may occur at low tem-
Like all internal combustion engines, the air-
'"
I\) cooled DEUTZ diesel engine should not be
peratures and clog the luel filler. At excessively
-
C1l
shut down suddenly from full-load running. It .v 1h.Il~,) 'I low temperatures, even winter-grade fuel may
til 1, "\ ','>,.,..." , tend to wax.
." is beNer to let the engine idle for 1 ' 2 minutes
to allow for temperature balance. ,~~-:;:.~ .,ijl Therefore, if only summer-grade fuel Is avail-
able, or if winter-grade fuel is used at exces-
@ sively low temperatures, we recommend the
Fig. 27
~ following percentages (see diagram) for mix-

tures of diesel fuel and kerosene or regular-
a
grade gasoline' . Admixture of the latter is how-
ffi<
C) ever permisSible for a short period only, but
N never for permanent operation,
»0 + 32 0
~rn o + 23 - 5 o
iZ ~
R
+ 14 -10
0.
8
iC -
o + 5 -15
" .,
CIt .. 4 -20
0
".,
r-
Lh
- 13 -25
-
".,
za')
~
Fig.26a -22 -30
Caution!
Z 'F
to
'c
10
--~-_
20 30 40 50 60
Prepare the blend in the tank itself: fill in the
".,
I ~Am'l8ftt t.,..,."t.,. "retl'." II, "........ gasoline' first, then add diesel fuel. The blend
[;<8''>/'1 is as easily inflammable as pure gasoline.
~O
c:
Maximum admixture of regular-grade gasoline' 30 %; when admixing more than 30 %, use
kerosene only.
<
a~ For using a commercial additive, please consult your DEUTZ Service Station. ITI
Z
~ o
o
i,., I ::a
-c , Never use premium fuel.
VI
.~
-
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0 i
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(I);,
~; Engine O~ration Engine Operation
-?
.~ 8.5 Starting
8.3 Additional Maintenance Jobs
~a
.." ..
_01
~
• The grade of 011 in the oil bath air cleaner - if fitted - should preferably suit the ambient
temperature just like the engine oil.
8.5.1 Starting with Electric Starter:
Version F2L 912 with Heating Tube or
-
(1)(/1 Version F2L 912 W (Two-stage combustion)
'PO
0> ;,. 8.4 Cold Starting Aids • Prior to starting. preheat for about 2 minu-
~.s tes. then start as per 5.1.2 or 5.1.3 respect-
o>JI' 8.4.1 Heating Tube (llem 1. Fig. 28)
• 0 ,. The heating tube should be used at ambient
ively .
-•
temperatures near or below freezing point. • Should the engine not fire smoothly or emit
~~
,,(I)
1\ not only lowers the starting limittemperat- grey-white smoke. do not attempt to accel-
erate with the speed control lever 1 or.2 (Fig.
ure. but proves also useful at temperatures
N""
~O
W· normally not requiring a starting aid. 29). but
.N • Afterheat for not more than 3 minutes in the
Located at the inlet of the air intake pipe 3. the
'g':
(1)<.11 heating tube 1 contains an electric glow coil 2 preheating stage.
r\) for preheating the combustion air. Note:
-
I\)
(I) Continue starting attempt for not more than 20
<.II
seconds if no firing occurs. Intervals between
""@ starting attempts should be 1 minute or so,

enabling the battery to recover. The next start-
ing attempt has to begin again in preheating
Fig. 29
position (1 minute).
f$I
VI<C
a
8.5.2 Starting Manually
~ . N Fig. 28
Manually Started Engines: at very low temp-
eratures it is advisible to cut in the decompres-
sion device and then merely t urn the engine
Note:
~rn Cold starting of a Diesel engine depends, among other things, on the capacity of the starter
before starting with speed lever in idling posit-
iZ ~
ion.
motor and that of the battery, as well as the turning resistance offered by the transmission and Starting procedure as per 5.2.1.
52
(")
driven machine. Since the starting equipment of the engine may differ according to its
application. no data on limit temperatures for cold starting are given in this Manual. Any DEUTZ 0.
~a ,., -
o :,..
c
~
distributor, however, will fumish you with the desired information on this subject.
The viscosity specification for lube oils should by all means be observed.
Cold starting requires satisfactory condition of the battery.
Lowering the limit temperatures by 4 - 5 "C is possible by raising the battery temperature to about
+ 20 "C. This is done by removing the battery with the engine stopped and storing it in a warm
room.
8.5.3 With Start Pilot
During starting operation. the start pilot sprays
fuel of very high ignition quality into the intake
pipe.
Assist starting operation by actuating the pump
until the engine fires smoothly. Closely ob-
8
-,., When installing the battery. ensure satisfactory terminal contact by keeping contact surfaces serve special instructions for visa F 27 pilots.
~ G') clean and bright. To avoid distortion of terminal cones, be sure to tighten screws only moderately.
At very low temperatures (below - 30 "C)
z In the case of extremely low temperatures, the engine is to be warmed up to ensure satisfactory
starting and lube oil supply. Parts for connecting preheating units, however. are provided only on
I
~O
engines intended for operation in very cold regions.
Lh
Cautfon!
a~ Do not inject an excessive amount of fuel. <

m
II z
Excessive quantities of fuel injected before
starting can lead to engine damage. For safety
reasons. never use start pilot simultaneously 8
;:0
with preheating systems.
....
1.1'
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-
84 85
n
......
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-;3 Maintenance Maintenance
~~
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AI
..'Po'" ~§
-i::>
" ,-
_AI Maintenance Chart*
"'"11
~= IMPORTANT!
a> (/I
-
0> ::>.
.
(.)::>
--400
0>1"
The Maintenance Chart displayed below is supplied as a self·
~ adhesive label along with each engine.
-•
-nUl
AlO
",a> Check that this label is stuck at a convenient location on the engine
N
_0'"
W'
,N
or driven equipment.
IDa>
$>$>
a>U> If necessary, ask for a fresh supply of labels.
N
N
a>
U>
""
.....
Stop engine Note:
Valid for routine maintenance work is the Maintenance Schedule on page 89.
~
~ before carrying out
< any maintenance work.
a
<:)
...,
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,.
~
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?
rn ,., CI Q
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8
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"-~ F2L 912

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2973629 II
. # .. $ DEUTZ o
o
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~
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0>::) Maintenance Maintenance Schedule Maintenance
~lG
~;:>
elll Engine Maintenance ",'''l>.

III
~~ • Check • Clean A Change V See Note
.." . ~~
-I::)
!.m.., The maintenance jobs described on the following pages ensure ready engine availability at all
• •• •
..
times and long life span . Job
lwr
t--........_.-
-
.. .---.--~- .. ~--
~=
~
0>111
~~
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00:>
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.. to
10
hours
ma • I Maintenance point
oojII Improvement of ~ . . . .O\!>
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93 94-96 97 Seepage
,
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0.
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hours . ~~ .. ~. '/
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0.0 Q) )( c: 0 98/99 100/101 102 Seepage
•
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W (/) (J (/)
(J W W (/) ..J
A Job
@ 0 0 0 0 0 (./,"~~
~
co 15mm
Every
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~\ ,.':.t
~ 250 '< Maintenance point
I~..
.~.
a
hours
\. J'
aL~ - -.. .. __ ..... _,.
<
~ -.-~ -.~.~--.
,..,
II>
Q
N 0 0 0 98/99 103/104 Seepage
~ A A .~~t~12~ Job
»
.... A~~
~'~j
~
:z 1ft CI 0 0 0 0 0 0 0 Every d~t~ !2
? 500
I~~f '(e:i4 Maintenance point
i Z~
<2 ()
hours . '" , 'ex •
~l ...•.. ..•..- ~ ... . -.. .. -_ _..

Co
e
~<
.-.--.~------- ..~.------~--
0 0 0
- 0 0
Fuel 98/99 105 106/107 Seepage
~CCl
" ",
••
• F2L912
•
r----'''''''-
f1j*a
~- .. -.--,-.. A
._--_ •.. _....
Job
O~ ~ 0 0 0 i,;:j~t ~
~
Every
1000 Maintenance point
\ I.Q
---
hours ' ! ex " • /1'.,) ...
~§z 0 0 106/107
108 109-111 Seepage
",
~ ••
I 0 0 0 0 0 0 0 0 Every Air intake and exhaust manifolds 112
1000
Cylinder-head temperature indicator 112
~O
hours
••
Every 113
/
Alternator
8~
0 0 0 0 0 0 0 1500
hours Starter motor 113 <
.."
Z
i.. •
Every
3000 114 o
Injectors o;:10
I \248661 hours
(I)
:! ..... 88 89 .."
...n
.....
W i
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n
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~;> Maintenance Maintenance
eW {l~
'" 0 The maintenance jobs duly completed can be recorded and certified in the schedule below.
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t!(; 6~
D The maintenance jobs duly completed can be recorded and certified in the schedule below
Ib -rt ~
-
:0
"<1> ~
"'C/l
'f' 0 6~
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(» :::!.
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.... <0
CD{/>
Completed Maintenance Jobs
-•
.~ Completed Maintenance Jobs
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"," '" Hours Date ! Signature Hours • Date t Signature Hours Signature Hours Dale Signature
w' :
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, - 6125 6250
6375 6500
• 50
.
",01 .-
'"
N
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125
375
i
250
500
6625
6875
6750
7000
..... 750
I
7125 7250
625
~ i
1000 7375 7500
875
~ I
a
1250 7625 7750
1125 iI 7875 8000
<
Q 1375 1500 - -.,-_.
V> I\) 8125 8250
,."
;0
1625 1750
8375 8500
".
r-
:z
0
rn C
1875
2125
2000
2250 8625 8750 o
R
Z~ .
2500 8875 9000
.,., 2375 0>
9125 9250
j 2625 2750
9375 9500
C 3000 .. - --
CJ .....
.."
N
2875 ~ ,.
lG /TI 3250 9625 9750

3125
O~
3500 9875 10000
3375
3750 10125 10250
3625
/TI 10375 10500
4000
;a~
i
3875
4250 10625 10750
:z 4125
/TI 4500 10875 11000
4375 -.
I 4625 4750 11125 11250
I
11375 11500
V>
V>
0 4875
5125
5000
5250 11625 11750 <
a~
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5500 11875 12000 :z
5375
c.. 12125 12250 o
>-
x 5625 5750 o
;0
c I i
....
6000 I 12375 12500
>- 5875 (./)
~ • See instructions on page 92 /TI
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g 90 91 ~
.-
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0>;) Maintenance Maintenance
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.(1)
Important: Commissioning New or Overhauled Engines Routine Maintenance
I~I
I»
-I=>
!!.if
~~
" ~
At the end of 15 minutes' running:
-
0>(1) C _ Oil Level In EngIne
CPo
OI::!
• Retenslon V-belts (Fig. 30).
w=> See pages 103/104.
....,00
0111'
• Engine must be in horizontal position and
-•
.0
» shutdown.
,,<0
1»0
,,0>
• Pull out dipstick 1 (Fig. 33).
IIJ"'" • wipe with clean. non-fraying rag.
~O
W'
,IIJ
,..,.
OlIO>
O>CJ\
• reinsert as far as it will go. and then
• withdraw again.
N
IIJ The oil level should be between the marks 2
0>
UI and 3 (Fig. 33). " the level is only up to or
." Fig. 30 even below the lower mark 3. top up with oil
~ Immediately. preferably up to the upper Fig. 33
@ At the end of 50 hours' running:
mark 2. in order to prevent serious damage
being caused to engine.
~ • Change 011.
a
See pages 98/99.
At the lirst oil change, the following jobs are Note:
~<:a
".
due In addition:
• Clean lube 011 filter
(item I, Fig. 31). See page 105.
Checking the oil level prior to starting the engine ensures a sufficient engine ol/Ievel for the start.
To check the 011 level accurately. It is necessa9!, to shut down the engine after about one minute 01
~ rn Q Note:
operation. The entire oil system will then be filled. The immediate 011 level check will then show
the 011 sump filling volume actually available during operation of the engine.
We strongly recommend to carry out this double check of the oil level before any prolonged 2
iZ~
With a view to matching the intervals for sub-
sequent oil changes and maintenance jobs to engine operation. particularly if the check prior to the engine start discloses an oil level in the o
()o
the total running time of the engine. we recom- vicinity of the lower or minimum mark on the dipstick. 8
:G
Hl 0 Q
~
" ,
mend. after the initial maintenance work at the
end of 50 running hours. that the ensuing
maintenance jobs be carried out after 125. 250
and 500 hours. etc.
Fig 31
.
Normally. new engines have a higher 011 consumption. During the running-in period (about 200
running hours) it is therefore essential to check the 011 level twice a day. After the running-in
period. one check per day Is sufficient.
O~
Where engines are Inclined. oil level should reach top mark of dipstick,
• Retighten engine mounting bolts.
• Retighten bolts securing air Intake and
~~:z
exhaust manifolds to the cylinder heads
(item 2, Fig. 32). See page 112.
• Check valve clearance readjusting if
", necessary. See page 106/107.
I
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I Fig. 32 :a
! .-. 92 93 '"
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<Dill
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OJ:>
0>1/1
0>C1>
~ .:> Maintenance Maintenance
• III
01
-t=> 2. Dry-type Air Cleaner (if mounted)
C1>-
-'" ~-
~4./.j. ~'ll C~ecking and Cleaning
~
C1>."
>< C1>
The life of the expendable paper cartridges in
-
en III ,..~ Air Cleaners dry-type air cleaners depends on dust collector
'flo
(Xl ~.
-'I 2 (Fig. 35) being emptied in good time. Failing
w=> this. the cartridge will clog up fast. Be sure,
-.;<0 therefore, to empty the collector not later than
001" Dust in the combustion air can cause prema- when filled half-way. Where the air is very
-•
.0 ture wear of the engine. Maintenance of the air dust-laden, this may require daily servic-
}>
cleaners is therefore essential to ensure long
.,,'"
",0 life. It is also necesary to check unions and
ing .
>< OJ connections of the intake manifold regu- If a special dust ejector 8 is prOVided, it is
"'-.; only necessary to clear the discharge slol
~O larly.
w'
./V
from time to time.
<0'"
The maintenance intervals for air cleaners
:.l> depend on the amount of dust fall-oul. No
",,,, 2.1 Emptying the Dust Collector
fixed intervals can therefore be given.
N
/V
en
• Stop engine. ..
'"
-
."
~ Fig. 34
• Release clip 1 (Fig. 35) and remove dust
collector 2 along with cover 3.
• Take off cover 3 and empty collector. Fig. 35
~ • Refit assembly, making sure that recess on cover mates with lug on collector (see arrows,
&
Fig. 35).
1. Oil Bath Air Cleaner (if mounted. otherwise see page 95)
<
C • Before checking. wait at least one hour after stopping the engine. so that the oil has had time to • When cleaner is installed in horizontal position, check that the "Top" mark is actually at top.
V> N
I'TI drip down from the cleaner element.
;0
i:
r-
z
?
rn cm
• Release the snap clips 3 (Fig. 34) and remove oil bowl 2.
• Remove element 4 by sidewise tapping with the hand or by inserting a screwdriver. Do not
damage rubber gasket I
2.2 Servicing the Cartridge
Where a service gauge (Fig. 36) is fitted and
keeps displaying the red warning signal 1
o
n
."
Z ....c:: • Renew oil in bowl 2 (for motor oil viscosity, see page 76). Note oil level mark (arrow) .
when the engine is stopped, Of where a
yellow warning light goes on With the
00
4!>
i N engine running, the cartridge is due for
-
• Rinse filter element 4 in diesel fuel (never in gasoline!) and allow to drip-dry thoroughly.
C servicing, (Also indicated by smoking exhaust
C
.."
N • Once or twice a year (depending on amount of dust). remove also the filter upper part 1 and and decreasing engine output.) It is not advis-
~ m likewise rinse in diesel fuel. Allow to drip-dry thoroughly. able to service the cartridge more frequenlly,
O~
as this may affect seal? (Fig. 35) between car-
• Following reassembly, check all connections for leaks. tridge 5 and housing 6.
Replace cartridge not later than at the end of
"'~
12 months or when soiled by soot. If no new
cartridge is to hand for replacement, the exist-
ing cartridge can also be cleaned for reuse
:z (see Section 2.2.1), but should then be replac-
m ed at the earliest opportunity.
I • Proceed by taking down dust collector 2
(Fig. 35) as described under 2.1.
;;:;
V>
0 (Where a dust ejector 8 is provided, unscrew
wing nut 9 and remove cover.)
Fig. 36
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..... 94 95
Fig. 36 (./l
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CTI;)
1» ..
CTlt1> Maintenance Maintenance
~?
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-4"
«,!.if
t1>."
• Unscrew hex. nut 4 and remove soiled
cartridge 5.
• Renew or clean cartridge.
I C···· f'll
,..
~
ChecklngW_Se_,
on Two-stage Fuel Filter
-
" t1>
CTI(j) (if mounted)
,~
lPl)
0> ;).
• After having serviced cartridge 5 five times.
W:J or after two years at the latest. renew
...,IQ Some engine versions use a two-stage fuel
together with safety cartridge 11 (secured to
o>JI' filter with water separator for protection of the
body 6 by nut 10). Enter the number of
.0 injection system. The water collects in bowls 2
-•
» servicings of cartridge 5 in the spaces pro-
and 3 (Fig. 37). In the transparent bowl 2. the
."ID vided on safety cartridge 11 .
",0 water is distinguished from the fuel above by
"CTI • Safety cartridge 11 may not be cleaned its lighter shade. Make sure that water level will
",""
~O not exceed the lower rim of bead 4.
W' and reused.
.'"
cg~ • Renewal of cartridge 11 is also required
The maintenance intervals for the water
separator depend on the amount of water con-
CTlI» when cartridge 5 is renewed because of
~ defects. etc., or when warning signal reap- tained in the fuel and cannot be stated definite-
Iy.lnitially. therefore. check daily whetherthere
'"CTI
-
pears although cartridge 5 has been
I»
..., serviced.
• Make sure that only genuine cartridges
are indications of water in the transparent
bowl 2 .
Draining off the water:
@ are used as supplied by the air cleaner
manufacturer. Cartridges of other make • Loosen knurled screws 5 and bowls 2 and 3
Fig. 37
~ usually do not fit and are a hazard to the through one or two turns.
a
engine. • Observe the flow of draining liquid and the
2.2.1 Cleaning the cartridge: transition from water to diesel fuel.
CI
~<
N a) by tapping (provisional): Tap cartridge 5 • Gently retighten knurled screws 5.
with its front end gently against the palm of Note:
: rn your hand or on a soft surface, to shake off

the dust. Take care not to damage the front Catch fuel in special receptacle to prevent
pollution of the environment.
iz ~
end of the cartridge. CI
b) with air: Apply air blast of max. 5 bar from (\
inside to outside until no more dust is com- 0>
- ing out. 00 not blowout housing 6. 8

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,..en
0
",
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I
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Fig. 36
3. Checking:
~O Prior to reassembly. introduce a lighted bulb

into filter cartridge 5 to see whether it suffered
a~ Lh damage (damaged cartridges must definitely

be renewed). Also make sure that gasket 7 is
not defective. If a service gauge with visual
<
IT1
Z
I~ I
Csution:
In no event use gasoline or hot liquids for
cleaning the cartridge!
sillnal is filled (Fig. 36). press push bullon 2:
thiS causes the red signal to disappear from
the window.
o
i
(I)
i .... IT1
-
96 97 (')
.....
'-I i
Maintenance Maintenance
.(Jl
AI
~\\~
.... :l
CD-
_AI
Change Oil
1\;1;
CD~
"CD Changing the Motor Oil while the engine is still hot, since the old oil will
0>(Jl run more easily in this condition.
-
CPo
QI :I.
t.):l
• Shut down engine.
.... 00 Important: • Unscrew drain plugs 1 (Fig. 38), after placing
till"
suitable receptacle underneath.
Should the engine run less than the hours stated in the following Table. the oil must be changed in
.~
-•
any case once a year. • When all old oil has run off, refit drain plugs 1
~U) complete with new sealing rings 2 .
... 0
,,0> 011 Change Periods • Fill in fresh oil through filler neck 3 (Fig. 39)
"' ....
~O Oil Change Intervals up to the upper dipstick mark (Max., Fig.
,'"
W'
,.,.
100>
Engine Applicalion
Category
of il
(running hours) 40).
Oil Grade Oil Grade • Following a short trial run. check oil level
0>U> Stressing
,(, A:'I~~9~~E API:CO/SE
orCD/SF
again. topping up to the upper mark (Max.)
if necessary.
'"
0>
U> Tractors. lift trucks. Oil capacity at refill approx. 4.5Iitres.
Fig. 38
.." Cranes. Construction machinery •
..... Rail traction units. Ships.
A 250 500
@ Base-load gensets. Pumps
~
Farm equipment (seasonal)
Underground mining. Road sweepers Lh
a
Winter service. Emergency gensets. B 125 250 Caution:
< C Emergency pumps

..,
II>
:0
N Engines with two-stage combustion
/FL!l12W)
Danger of scalding when draining off the hot
oil!
;:
r-
:z
f'
m CJ
Important:
The above intervals are based on the use of a diesel fuel containing max. 0.5 % b.w. 01 sulphur
Catch old oil in suitable receptacle to prevent
pollution of the environment!
CI
i Z~
and ambient temperatures above - 10 "C. R
Periods between 011 changes should be cut by half
Note: 0.
• when USing fuels containing more than 0.5 % up to 1 % sulphur or Upon changing over to a higher grade of oil
following a prolonged period of operation.
•
i C ~ • il the ambient temperatures are permanently below - 10 "C.
In the case 01 fuels containing more Ihan 1 % up to 1.5 % sulphur. the motor oil should have a
change oil at the end of 20 hours and clean oil
filter element.
F
Ig.
39
O~
TBN' 01 about 12 x % S-content. with the periods between oil changes being halved.
Typical exal)'lples:
1) Tropical climate. oil stressing category A. fuel containing 0.8 % sulphur. lube oil grade CO/SE:
"'~'"
Change oil every 250 hours.
2) Tropical climate, oil stressing category A. fuel containing 1.2 % sulphur:
z Change oil every 250 hours. USing CO/SE or CD/SF oil having a TBN' of about 14 mg KOH/g.
I Oil Grades
The responsibility for the grading of his particular oil product to API Specification is borne by the
supplier.
ElO
c:
a~ <
1""1
:z
I 8:0
=
i ....00
I TBN ~ "Total Base Number". expresses the neutralising capacity 01 the oil.
Ask your supplier to quote TBN. Fig. 40 U\
-
1""1
98 99 n
-f
i
~~
~8
IDUl
"0
'?l~
"':>
g::G Maintenance Maintenance
-;>
.Ul
AI g~ "" I"Z" ~.,. For inspecting and cleaning. proceed by un-
.~
.. ~ ' ' ' 1
..... :::1 doing the hel(. bolt 1 (Fig. 43) securing the air
<11-
-AI
<11."
,. <11
i§ ; "
Inspecting/Cleaning
the Cooling System
cowling hood 2 on the alternator side. and
removing the hood.
-
"'Ul
'flu
0>::1
§= / ;"
Cleaning methods:
1.1:::1
",to Cleaning the cooling system is most important
0>\1' since accumulation of dust on the cooling air • Dry cleaning by means of compressed air.
Start blowing through from the el(haust-air
.~ blower blading 1, on the COOling fins of the
-•
cylinder heads 2. cylinders 3 (Fig. 41) or oil side (Fig. 44).
."ID
~~ cooler 4 (Fig. 42) is liable to reduce cooling Any dirt blown into the air cowling space
/\,)'"
~O
efficiency substantially. especially where the
dust is retained by a film of fuel or oil.
(Fig. 45) must be removed afterwards. of
course.
W·
./\,)
ID'" Check the cooling system regularly for conta- • Use of cold cleansing agent (e.g. P 3 or
,."
",til mination in accordance with the following Nalfleet). After allowing an adequate soak-
N table. and clean if necessary. Please nole thai ing-in period. wash the engine with a power-
the inspection intervals can only be given as ful water jet.
'"'"
til
-
.."
I!
~
guide figures based on normal operating con-
ditions. and that in the case of abnormally con-
taminated cooling air -. check mounted cool-
ing air sieve boxes for correct seating and
good condition -. the inspection and cleaning
intervals may have to be substantially short-
• If a high-pressure jet is available. this
method of cleaning is preferable to any
other.
Note:
18It@D ~ ((r-'~1':'
"" .. c:.J \ ~\\
-.~ ~. -', I' '\\,(
a
ened accordingly.
> l- '.'
When cleaning the vehicle or engine by means
o
~<
N of cold cleansing agent or steam, cover up the
injection pump, alternator. voltage regulator
and starter motor as protection against direct
application of the jet.
~ftI After wet-cleaning, let the engine run until
iZ -=~
warm so that any water left behind will be !2
()
evaporated before rust can form.
0.
-
8
iC ",
CI) Lh
0
",
Caution:
r-
Always stop the engine before cleaning!
;
=a - G')
Z
",
Fig. 42
I Engine Application
Inspection Interval
(guide figures only)
I
~O
Run~ing ~~urs
2000 . i Ships. Gensets inclosed rooms. Pumps
c: 1000 Vehicles on paved roads _
a~ 500 Tractors. Lift ~rucks. Mobile gensets
<
ITI
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i;
I 250
125
Vehicles on building sites and unpaved roads.
Construction. machinery. Compressors. Underground mine units
Farm equiPm.e!'t •. Tractors doing harvesting work
g
::0
:! ..... '"
ITI
-
100 101
n
.....
--0 i
iU
~
!::!
.(Jl
1\1
I\~I
fa Ch_ng E-'I~
~::J
!.it Checking V-belt!
II..,
"II in Battery V-belt Tension "
\'"
-
0I(Jl
Ifo
~5 • Inspect V-belt over whole length for damage
-..100
Q)II'
• Remove cell caps 1 (Fig. 46).
or cracks. Renew damaged or cracked
• In some cases. electrolyte level testers 2
-•
.0 V-belts.
» are provided: the level should be high
"Tl 1O • Check by pressing with the thumb (Fig. 47)
enough to wet the bottom of these.
~~ midway between the pulleys to see whether
",-..I • An alternative method is to insert a clean the V-belt deflects inwards by max. 10 .o. 15
~O
W· wooden stick 3 into the cell until it touches mm (0.4 ... 0.6 in.).
.'"
1001
1>1>
the top of the plates. The electrolyte should
01'" wet the stick over a length of about 10 - 15 Retensioning V-belt with Alternator:
~ mm.
'"
• Slacken hex. bolts I, 2 and 3 (Fig. 48).
..
-
01 • If the electrolyte level is low. top up with • Pull alternator 4 in direction A until the cor-
'" ." distilled water only. rect belt tension is obtained .
• Replace cell caps. • Then securely retighten hex. bolts I, 2 and 3.
@ Fig. 46
• For hints on battery care in winter, see page Retensloning V-belt with Idler Pulley:
~ 84.
",,<0 Lh
a
• Slacken hex. bolts 1 and 2 (Fig. 49).
• Pull idler pulley 3 in direction A until the cor-
rect belt tension is obtained.
,.., N
:0:> • Then securely retighten hex. bolts 1 and 2.
;:
;lftc Caution:
When working on the battery, keep naked
Renewing the V-belt:
• Slacken hex. bolts I, 2 and 3 (Fig. 48) or 1 !2
I:"Z~
()
lights away. do not smoke! and 2 (Fig. 49).
N
Do not allow acid to come into contact with the
skin or clothing!
• Push alternator 4 or idler pulley 3 in direction
B against the engine. In this position, it is
do
..
~Dc Wear protective goggles! easy to fit the new V-belt.
• Tension V-belt as described above.
¥I - Do not place tools on battery!
""
O~ Note:
Retension new V-belts after running for 15 mi- 'j;
~!z
nutes. (Not applicable to cooling blower drive
with automatic tensioning pulley 1(Fig. 50). \\
When two V-belts are provided. always renew
both belts when only one is worn or damaged. ~ .. ' 1
I "" The difference in length of the new V-belts
may not exceed O. 15 %.
o.' i
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c:
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~~ J'TI
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}
Fig. 49 \ o
C
o
;:0
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g~ J'TI
-
102 103 n
o ~
i
-fD
~'"
~8
fD(fI
"'0
~iD
0>"
V'I/l
0><1)
~"
.(fI-;:~
I» 0 Checking V-belt Tension on Version
1i~
..... :J
equipped with Mechanical Shut-
<1) -
-I»
<1)..,
0::i
"
".. down system upon V-belt Breakage
,. <1)
6=
-
(Fig. 50)
cP
O>(fI
'0 z
CD::! On this version, it has to be ensured that the
.
w::> V-belt has the correct tension, since otherwise Cleaning the Oil Filter (Wash-finer')
..,,00
CDII' the shut-down device 2 will be actuated by the • Unscrew hex. bolt 1 (Fig. 52) .
~ swing movement of the idler pulley 1.
-•
• Remove cover 2 with gasket 3 and filter
..,fD II is therefore essential to tension the V-bell by element 4 .
~g swinging out the alternator so that distance A • Unscrew hex. nut 5 of hex. bolt 1, and take
",""
~O
between V-bell pulley 5 (Fig. 51) and idler off element 4.
w' pulley 1 measures 10 mm.
.'"
fDO>
",,,,
At every oil change, apply a drop of motor oil to
• Wash element 4 in clean diesel fuel and
allow to drip-dry thoroughly.
0>'" pin 3.
N • When reassembling, ensure correct posit-
IV
The shut-down device 2 must be so adjusted ioning of gasket 3 for cover 2 and gasket 6 of
0> that the shut-down lever 4 can be moved about
-S
element 4.
'" ."
3" further until reaching the stop .
Cleaning the Oil Filter (Edge Filter')
• To clean, turn handle 2 of plate-pack 1 (Fig.
~ 53) once or twice.
• The deposited sludge is thus carried out-
§<
a
wards and sinks into the sludge chamber of
C filter body 3.
N
• Drain off the sludge from time to time by
loosening filter body 3.
>
: III
iZ ~
0
Note: R
During trial run following reassembly, check do
-
oil pressure and tightness of filter mountings. 8
o
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&
" .,
CIt
0
".,
r-
Cautionl
-
~
I
Fig. 51 A small amount of oil runs out when screwing Fig 53
'"
en off the oil filter. .
z Danger of scalding in case of hot oil!
"., Catch old oil in suitable receptacle to prevent
I pollution of the environment!
~O
a~ <
".,
z
! I , "mounted.
o
o
::a
'"
:!~ ".,
-
104 105
..... n
~
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01::1
01",
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:::.
~~
elll ()~
r Maintenance Maintenance
AI 0
-1::1 J>~ Checking Decompression Clearance
!.At ~
<11"11 J>:5 --6-1.
i~'~'. ~I Checking (manually started engine)
'.n~: Valve Clearance
"<II ,.
~=
-
I Whenever checking valve clearance, be sure
cpl)
0I11l ~ I, ti· ex:· I also to check the adjustment of thrust screw 1
01 :3.
W::I (Fig. 55) located on the rocker arm and design-
'lit)
01'" • Valve clearance to be checked with engine ed for determining the clearance of the decom-
pression device, where provided. Proceed as
.~ cold.
-•
follows:
~:g Note: • Remove rocker chamber cover.
,,01 The valve clearance is the requisite gap 1bet-
11.)'1 • With valves closed, i. e. piston in compres-
~O ween the pads of rocker arms 2 and valves 3 sion TDC, press thrust pad 2 by hand
W'
,II.) (Fig. 54). Good engine performance and
,.,.
(001
power output depend on its correct selting
against the valve stem end.
• In this position of the rocker arm, the setting
0101 which may be carried out by a skilled mechanic
,;" according to the following instructions, but dimension "a" should be 59.7 + 0.2 mm.
II.)
-
01 preferably by a speCialist. • Setting the thrust screw 1: Loosen hex. nut 3
01 (Fig. 55) by 2 -. 3 turns with a 13 mm
"t'I • First remove rocker chamber covers. spanner.
• Tum crankshaft at front end until the valves • Adjust thrust screw 1 with a screwdriver so
@ of the cylinder in question are "overlapping" Fig 54 that the setting "a" stated above is obtained
~
(exhaust valve about to close, inlet valve . when hex. nut 3 is tightened.
about to open).
a
• Refit rocker chamber cover 1 (Fig. 56).
• Then continue turning the crankshaft through 360".
<
0 • After tightening the cover fastening bolts,
V> N • Check valve clearance: check that the decompression shafts 2 can
m Valve clearance 1 Is correct when a 0.15 mm feeler gauge can be inserted with a slight drag be turned easily through some 10".
'"
;;:
,....
between rocker arm 2 and valve 3.
"'Z
• Failing this, the valve clearance must be readjusted.
:z CI
~
• Readjust as follows: 52
~
Loosen locknut 4 by two to three turns. ("\
Adjust setscrew 5 with screwdriver so that, when locknut is retightened, the feeler gauge can be 0.
I"" N inserted and withdrawn with slight drag. iii
~CCl
" 1"1'1
O~
- • Check the valve clearances of each of the remaining cylinders and readjust if necessary.
• Do not change the setting of oil nozzle 6 unless required. With hot engine running at idling, an oil
flow to pad of rocker arm 2 must be just noticeable. An excessive oil flow can lead to higher oil
consumption.
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01" Maintenance
8::c Maintenance
-?
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F~ Renewing the Fuel Flne,

.,
-i::J JI::iiI
!.; c!l::i~ Cleaning Strainer of Fuel
Feed Pump
~'~
al!ll ~\) (~ Cartridge
"'" JI
-
"II> •
01 (/I
'f'-o
00 :J. z '"
W::J • In case of high-level tank. close fuel cock.
",10 • In case of high-level tank, close fuel cock.
00/1'
• Remove hex. bolt 1 (Fig. 57).
• Place receptacle in position to catch escap-
.~
-•
• Take off cover 2. ingfuel.
.,,11>
.,0 • Take out gasket 3 and strainer 4. • Screw off fuel filter cartridge 1 (Fig. 58) •
,,01 using special tool if necessary.
",--I • Clean strainer in diesel fuel.
_0
w'
,N • Following reassembly, check unit for tight- • Clean sealing surface.
11>01 ness.
,."
OIl11
• Apply a light film of oil to rubber gasket 2 of
the new filter cartridge.
N • Screw new cartridge in place by hand until
'"
01
III
Note:
Falling-off engine performance can be due to
gasket is evenly seated.
"'...."
• Give cartridge a final half tum.
contamination of this strainer.
Fig. 57 • Air-bleed fuel system (see page 74).
@ Fig. 58
~
~ Note:
§ <.2 Caution:
Falling-off engine performance can be due to clogged filter cartridge. If the filter cartridge clogs
up too quickly, check fuel for contamination, clean tank, check sealing of filler cap.
-
When working on the fuel system, keep naked
~.
> lights away, do not smoke!
~"'c Do not spill any fuel!
I:" Z ~
f"I
Caution:
When working on the fuel system, keep naked lights away, do not smoke!
c»8
N
Do not spill any fuel!
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Fuel Filter Cartridge
\1 ,
r.. ' , . Renewing the Two-stage

::".!~ ~ Fuel Filter Cartridge
:J~) . (2nd stage)
-
01 en <5 II!II (1st stage)
'Po zllW
m :3.
(.);)
.... to • In case of high-level tank, close fuel cock . • In case of high-level tank, close fuel cock.
ml"
• Place receptacle in position to catch drain- • Place receptacle in position to catch escap-
.~
-•
ing-off fuel. ing fuel.
T\<D
... 0 • Unscrew drain plug 2 (Fig. 59) . • Unscrew filter cartridge 1 (Fig. 60) complete
,,01 with drain plug by means of hexagon 2 at the
"'
_0
....
• Release clamping pin 3.
• Remove water bowl 5 and the two seals 4
bottom.
(.)'" • Clean sealing surface.
.o~ and 6.
• Apply a light film of oil to the rubber gasket of
~U1 • Unscrew cartridge 1 from bracket and re- the new filler cartridge and screw new car-
N place by new cartridge. tridge in place by hand until gasket is evenly
'"
01 • Refit water bowl in reverse sequence, taking seated, then give cartridge a final half-turn.
-
til
." care that seals 4 and 6 are properly seated. • Air-bleed fuel system (see page 74) .
• Air-bleed fuel system (see page 74).
@ Fig. 59 Fig. 60
~ Note:
a
Falling-off engine performance can be due to clogged filter cartridges. Ifthe filter cartridges clog
up too quickly, check fuel for contamination, clean tank, check sealing of filler cap.
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Caution:
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When working on the fuel system, keep naked lights away, do not smoke!
Do not spill any fuel!
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C?>. Workshop M~ntenance
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III.,
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-!If Inspecting Air Intake and Testing Alternator im.ml)mit:tl~ \ \ ' ':'~'i0~
~:l
(llii Exhaust Manifolds It is advisable to have the alternator 1 (Fig. 63)
Ii." tested in a specialized workshop.
-
" (II Check the connections of air intake manifold 1
OI(J) (Fig. 61) and exhaust manifold 2 to the cylinder
CPo
01 :l. heads for tightness and retighten if necessary. Notes on three-phase system:
W:l • When the engine is running, never discon-
...,to
0Ij11 nect the leads between battery, alternator
-•
and regulator. Where it is however neces-
-~
.,,10
sary to operate the engine without battery,
disconnect, before starting, the alternator
eg
,...,..., from the regulator.
_0 • Never interchange the battery leads.
,"'"
W'
1001 • Renew a defective charging pilot light bulb
,."
01111 immediately.
N • Before washing the engine, fit covers to
-
I\)
g: protect the alternator and regulator.
." • The common practice on a DC-system of
touching a lead against earth for checking Fig 63
whether the laad is live must under no cir- .
@ cumstances be adopted on a three-phase
;$I current system.
",<0
Testing Temperature • In case of electric welding, connect the
Indicator/Pilot Light earth terminal of the welding unit direct to
Unscrew sensor or switch 1, as provided (Fig. the piece to be welded.
", N 62), from cylinder head 2 and immerse in oil
::a heated to 150 .- 155·C (302 - 311°F). This
;:;
~ rn should cause the red sec10r to appear in the
window of the indicator or the lamp, if provided,
.I Z~
CI to light up.
N Note:
IG
HI
0 CI
-
",
The temperature elements 1(sensor or switch)
are always screwed into the head of the No. 1
cylinder.
Testing Starter Motor
It is advisable to have the starter motor 1 (Fig.
O~
64) tested in a specialized workshop.
=a~ ~
Caution:
Fig. 62 Note:
Cover up starter motor before washing engine.
~ Heat the oil in a container on a hot-plate (not

I with welding torch). Do not exceed the
specified temperature range. Danger of
EiO burns.
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-? Workshop Maintenance Trouble Shooting
.~
..... ;:, ~~
~§
~i» Testing Injectors If troubles should occur, these will be frequently due to incorrect
......
" .. • Remove injectors. operation, lubrication or maintenance of the engine. In such a
§=
-
a>(/l
CPu • Have the injectors tested in a specialized
01 :::!. workshop. For specified injection pressure, case, therefore, make a point of thoroughly re-reading the Sections
W::l
--110 see Specification Data. page 73. on pages 74 to 114.
01'" • When refitting the injectors. observe tighten-
.~ ing torque (see page 119)!
If you cannot identify the cause of the trouble or are unable to put it
-•
TIID
1»0
,,01 right yourself, the best plan is to contact your local DEUTZ distri-
",--I
_0 Note: butor.
.'"
W·
,.,.
IDOl
Inspection of the injectors between the times
stated on page 89 is unnecessary unless the
a>U\ engine displays unusual symptoms (e.g. black
N exhaust smoke, harsh combustion noises).
See Trouble Charts on pages 116 and 117.
I\)
-
a>
U\
A
."
@ Fig. 65
~ Cautlonl
a
To prevent personal injury, do not allow the pressurized spray-jet to come into contact with the
<
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-r Oil level too low ~
-:-:-.: !• :.:
i• i I Oil level tOO mgn ~
.!..! .:
-----.-.--
i. --_-=
Engine shut-down lever not in operating position
Speed control lever not in corre~ st~~ing pos~ion ~::> "' ....
II-------.;...-~-.L-r_.- . •..-i----'....:!!!'~~S~pe=ed~co='n:::;tr~oIlever_~t react:!ing full-load stop
. .:-; "" <C
- I :. 1 Excessive inclination of engine _ _ _ _ __
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wro.ng SAE-grade of motor oil and machine lube oil
FlI..el.!Ell'llpera_ture t()()hig,h
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•
•
•
Tank breather clogged
Air in fuel system
'Fuel fifier andlor lines fouled
Fuel feed pump defective (diaphragm) . - - - -
r-c-:--- . - - - .
Injector defective ._ _, ._.. .
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Commencement of delivery setting incorrect
Nozzle backleakage line clogged
en
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.....
to>
I. ;
Amount of fuel injected excessive ... __ _
, • ! Oil suction pipe strainer clogged

,• i Suction line leaky·---.---- - - - - -__ - -..- - -
Controlvalve-ciefective-- - - - - - - - . - - - - - - 2
Q
:• Lube oil pump defective .- .---------
2
~--~--~~--~~--~-!r-4------------------.=~~-------.~----·~~ ;:;:
:• Cooling fins soiled 00

_0
:• Air cowling plat-e'-s7'loo-s-e,-c-raCkedormiiSing-- - - - -
1-----+-.-:---'-,....-+--+:"".~I:---tTubeOiiCOOlerso;;ed-----·--·----·---·-·
I • Blower V-be~-IOOSe orbroken-- . - - - - - - - - - - - - -
j. BE05'-
en
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r-----,--=.~--~. Jf~~1-~:~~~~Jn E~
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• .:. • • Valve clearance incorrect/valves worn 00

--"'...2L_
• •.• ' •.• CompresslOnpreSsUietoo low--- - - - - - - - . - - --.
I ..... - ..........- .. - ... -.. .. f-.-..
o::J
d_ ------
• • :• . • • Cylinders and/or piston rings worn

1------
·• .
:• ' Plugsrri"cyfinder headSleaky-·-----
•• ;• : 'Oil meieriiig-screw'for'rocker armlu'tiricailon-incorreCtly set
m
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c
• •.• '
• : . 'Piston crown dear-ance excessive- .-.... -...-- -... .. .
vatVe'gUideswom- _ . - ---
Main and/or blg-endbeari'ngs defective----· ... - ..
to
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_._-- Engine'suspension defective-and/or ii-icorrect-
Flexible engine coupling defeCtive - - ..- r==.-- m
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Workshop Information Workshop Information
.(/1
AI
... :J The Workshop Manual dealing with the Tightening Table for Bolts and Nuts
!.Di engines described in this Operation Manual
(11"11 bears the number 2911842 and can be ordered Pre· Tightening
)( (II
-
from our headquarters in Cologne, Depart- DeSignation loading
00(/1
'flo
00 :::I.
W::J
mentMZA. "" \
Cylinder head 2101681
Nm
30
1st slage 2nd Slagel3rd slaqe 141h siage \
45" 45" I 45" ! 30"!

Total
165"
"410
0011'
Tightening Heavy-duty Bolts Connecting rod M 12 x 1.5 x 55 30 30" 60" - I.. 90"
-•
.0
» and Nuts
"11 10 Bearing cap M 14 x 110 30 45" 60''-\ f lOS"
.. 0 1
)(00 To prevent faulty assembly, the following
1\)"'"
~O information includes instructions on the tighten- Rocker bracket
- ._.-. __._----_ .. -
M8 x 55 I 28Nm
w'
,I\) ing of heavy-duty bolts, because the procedure ... - .... '.--- -_._.-
1000 differs from that normally employed. The Balance weight M12 x 70 30 30" 30" SO"
,"l>o
001ll tightening angle is particularly important and, --_._----_ .._-. -"
N for this reason, Fig. 66 indicates how various Flywheel 50 90" 90" 180"
I\)
00 angles can be readily obtained by comparison
UI with a clock face. 25Nm
Injectors Ml0
""....
(FL 912)
- - . -••• - . _ •• - . ' + ..'-.--.-...'-- ..--.- ..
1. Wet threads and seatings with motor 011
@ before fitting. _
.... .. _-_ _
V-belt pulley
.... ...... - -.- ---_ .. _.
M 35 x 1.5
-_ ...-- .. --. - ..•
50 60" 60"
~ 2. Screw the bolts in until they are uniformly Cooling blower M12 x 140
..-_... _--_.- ..
30 30" 60" 90"
a
positioned ready for pre-loading. - - - - - - - _ • • • -*. - _ .
3. Pre-load the bolts to the value stated i n - - - · Adapter housing 2164062 30 60" 90" 90" 240"
,..,
V>
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",
the "Tightening Table forBolts and Nuts" on
page 119.
4, Tighten the bolts according to the Table, if
necessary in stages, in conformity with the
tightening angles specified.
Fig. 66 '
-----.-.... -
Oil filter cover
Note:
-
.... .. ... -.--.. ..---.
3371962
~
35Nm
!2
Z
()
~ When renewing main and big-end bearings or after piston seizures. be sure to renew the bearing 0.
I"" N bolts as well, 8
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Workshop Information Workshop Information
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III
.... :J The Workshop Manual dealing with the TIghtening Table for Bolts and Nuts
CIIi» engines described in this Operation Manual
Ci-n bears the number 291 1842 and can be ordered Pre- Tightening
-
" II> "'''. Designation loading
from our headquarters in Cologne. Depart- ,
~~ Nm 1s1 slage 2nd slaqej3rd stage 4th siage: Total
mentMZA.
0> :J.
Col:J Cylinder head 2101681 30 45" 45" 45" 30" 165"
.,,<0
0>11'
Tightening Heavy-duty Bolts Connecting rod M 12 x 1.5 x 55 30 30° 1600 90"
.~
-•
-nCO and Nuts Bearing cap M 14 x 110 30 45" 60" 105"
1110 .. - .. - - .. __ .
,,01 To prevent faulty assembly. the following j
",'"
... 0 information includes instructions on the tighten- Rocker bracket M8 x 55 28Nm
-'. -_.... _--- '-
.'"
W·
,.,.
COOl
ing 01 heavy-duty bolts. because the procedure
differs from that normally employed. The Balance weight M12 x 70 30 30" t 30" 60"
-- ... -.--.------
0101 tightening angle is particularly important and.
Flywheel 50 90" I 90" 180"
'"'"
for this reason. Fig. 66 indicates how various
angles can be readily obtained by comparison
01
01
.,...... with a clock face. Injectors Ml0
._" .. ,_... - "-_.. --
25Nm
(FL912)
1. Wet threads and seatings with motor 011
@ before fitting.
V-belt pulley
_..... - .. ,_._ .._--- .. _. --
_, --
M 35 x 1.5 50 60" 60"
~ 2. Screw the bolts In until they are uniformly Cooling blower

-_ .. "--- _... __ ._. -- -- _ M 12 x 140
... _---_....-
30 30" 60"
j
90"
a
positioned ready for pre-loading.
C 3. Pre-load the bolts to the value stated in flffi!) Adapter housing
..-- _.....
2164062
_.. _. __ .. _..-..__ ... __ .-
30 60" 90" 90"
I 240"
~<
..
N the "Tightening Table for Bolts and Nuts" on ~--.-.-
page 119. Oil filter cover 3371962 3SNm

4. TIghten the bolts according to the Table. if Fig. 66
:rn
>-
~
necessary in stages. in conformity with the
tightening angles specified.
52
iz ....=~
Note:
()
When renewing main and big-end bearings or after piston seizures. be sure to renew the bearing 0.
bolts as well. 8
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ode Workshop Information
-.' Engine Preservation
..
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AI
-4'
!,M If your engine is to be shut down for a major period (e. g. over the winter). we recommend the
." following preservation measures against rusl formation .
"
-
0>1Jl 1. Clean the engine. including the cooling system, with commercial detergent and a water-jet or.
CPo
01 ::I.
better. a high-pressure jet (see page 101).
.
W'
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OIjII
~
2. Run engine up to working temperature and then shut down.
3. Drain the motor oil from the sump when still hot and fill in anti-corrosive oil .
-•
4. Pour the oil out of the bowl of the oil bath air cleaner. clean bowl and fill up with anli-corrosive oil.
~:g 5. Drain fuel from tank. mix well with 10 % anti-corrosive and fill back into tank. Instead of adding
,,01 anti-corrosive oil to the fuel. the tank can be filled up with injection pump testing oil having
",-.j
_0 corrosion inhibiting properties (e. g. Calibration Fluid B).
w'
,'" 6. Run engine for about 10 minutes, so that pipes. filter. pump and nozzles are filled with the
IDOl
~,. preservative mixture and the mixture is distributed to all parts.
01111 Fitting Valve Springs
N 7. After this run, detach the rocker chamber covers and spray the rocker chambers with a mixture
Be sure the close-coil end is at the bollom (Fig. of diesel fuel and 10 % anti-corrosive or with injection pump testing oil. After this. refit the
g:'" 67).
-
covers .
." 8. Now turn the engine over several times without firing in order to spray the mixture into the
combustion chambers.
@ 9. Remove V-belts and spray the grooves of the V-belt pulleys with anti-corrosive. Before reus-
~ ing the engine. wipe off the anti-corrosive.
10. Close intake opening of air cleaner and exhaust opening tightly.
a
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10
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7
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0.
•
-
N FL 912 (Direct Injection)
CI When filling a new piston, make sure that the
~a ,.., stamped-in arrow pOints to the exhaust-air

side of the engine (Fig. 68). Fig. 68 6 6
~
....
0
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I
-~
en
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Fig. 70
Note:
12504'1
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These preservative measures will give the engine a protection of 6 to 12 months, depending on
weather effects.
<
:~ Before reusing the engine, replace the preserving miKture by regular motor oil' to API Specifica-
tions.
/'T'I
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g
I
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I
FL 912 W (Two-stage Combustion)
When fitting a new piston. make sure that the
stamped-in arrow points to the exhaust-air
side of the engine (Fig. 69). Fig. 69
The anti-corrosive oils used should conform 10 MIL -L· 21260 B or TL 9150-03712 specifications or
NA TO Code C 6401642.
• Seepage98 '"
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~
ROL-SEAL® MOTOR
ROLLING ABUTMENT TYPE
MODELS RSA,
WASHINGTON SCIENTIFIC INDUSTRIES, INC.
POWER COMPONENTS DIVISION RSB
2605 West Wayzata Blvd. PO Box 340
Long Lake, Minnesota 55356 AND Rse
Telephone: (612) 473·1271 TWX: 910-576-2742
MAINTENANCE AND
PARTS MANUAL
NOTE
ONLY FACTORY OR QUALIFIED DISTRIBUTORS ARE AUTHORIZED
TO OVERHAUL AND REPAIR WSI EQUIPMENT. ALL FACTORY
WARRANTY IS CANCELLED UPON DISASSEMBLY BY UNAUTHORIZED
PERSONNEL.
FOAM 201FM
ROL-SEAL MOTOR MODELS RSA. RSB AND RSC
TABLE OF CONTENTS
TITLE PAGE
INTRODUCTION
HOW TO AVOID REPAIRS _ ••• : •...••••.•••••••.•.•.••••..... 1
TOOLS FOR DISASSEMBLY .•••••••..••.•••••.•..•.•••..•••.• 1
DISASSEMBLY ..•••..••...•••••••••..•..••••.••.......•.. 2
REASSEMBLY .•.•••.••.••..•••••••...••...•••..•.•....... 5
SEAL REPLACEMENT •••••.••••••.••.••••.•••••••.......•.. 6
TROUBLE SHOOTING •..••..•••••.•..••••..•••••••....•.... 7
ROL-SEAL MOTOR EXPLODED VIEW •...•••.••.••.••••..•..... 8
REPLACEMENT PARTS LIST •••••••••••.••..••••.•..•..••.... 9

ROL-SEAL MOTOR MODELS RSA, RSB AND RSC
INSTRUCTION MANUAL
INTRODUCTION Remove the key. Carefully remove all burrs from the
shaft. Make sure there are no sharp corners around the
The ROL-SEAL® Motor was designed to give both high keyway, to prevent the shaft seal from being cut upon
volumetric and high torque efficiencies. It is man- removal of the end cap. If there is any rust present,
ufactured with good quality workmanship and a design remove using 180 grit emery cloth.
concept that allows it to be mass produced. Because of its
low breakaway and low leakage characteristics it is under-
standable why this motor is desired in this energy
conservation time. The tools that are recommended for a successful repair
job are as follows:
"A" AND "B" FRAME MOTORS
HOW TO AVOID REPAIRS 1. Soft face hammer or mallet.
2. Torque wrench with at least 50 ft. Ibs. capacity.

Maintain cleanliness in your system. Be careful when
adding to the reservoir that clean oil is added and the
3. 5/1. " Allen wrench adaptable to torque wrench.
container being used is clean. Proper filtration does not
guarantee a contaminate-free system if the filters aren't
4. No. 03 internal snap ring pliers.
serviced at regular intervals. Make sure that pro'per care is
taken when installing the motor. If a flexible coupling is
5. 3 / 18" Allen wrench for gear cover.
used, alignment must be within the coupling range. Do
not exceed radial or t~rust load ratings of the shaft.
For hydraulic surge pressures applied to or by the motor,

a close-coupled direct-acting relief valve must be provided
"C" FRAME MOTOR
in the circuit. The motor must be protected from any
pressure surges that exceed twice the pressure rating of 1. Soft face hammer or mallet.
the motor.
2. Torque wrench with at least 175 ft. lb. capacity.
3. l/Z" Allen wrench adaptable to torque wrench.
4. No. 06 external snap ring pliers.

DISASSEMBL Y
5. No. 05 internal snap ring pliers.
Cleanliness is extremely important when repamng the
ROL-SEAL Motor. Before you remove the motor from 6. 3/1," Allen wrench for gear cover.
the system, clean as much debris off of the exterior as
possible. The area around the ports is most important. A bench vise is very helpful in the disassembly and
Upon disconnecting use something to plug the ends of the assembly of the ROL-SEAL Motor. Our instructions will
hydraulic lines to prevent contamination of the system. be based on the assumption that this item is available.
PAGE 1
DISASSEMBLY
3.1 Using the soft-faced hammer or mallet, tap upward on
the ear of the SAE mounting flange. (Fig. 2.1 By putting
the heel of your hand over the output shaft and your
fingers on the opposite ear you can keep the front end
cap from falling back down after each successive rap.
When you get beyond the dowel pin engagement there

should be no further requirement for the hammer. Simply
lift the end cap off of the assembly.
FIGURE 1
1.1 Place motor in vise as shown in Fig. 1, tightening vise

enough to prevent motor from rocking out. Excessive
clamping pressure could damage the inlet and outlet
ports. Normally the standard jaws will not contact spot-
face of ports.
2.) Unfasten the nine cap screws holding the end caps and
housing together. (Fig. 1.) Remove the cap screws completely
from the assembly.
FIGURE 3
4.) Removal of the displacement housing, (Fig. 3) the

dark center portion of the assembly, is carried out similar
to step 3. There are two scallops in the rear end cap. It is
this area that you tap to remove the housing. (Fig. 3.1 Do
not ever use any screwdriver or pinch bar to remove this
part. It is extremely easy to damage the end cap faces.
The dowel pins will remain in the displacement housing.
Unless you are replacing the housing, leave them intact.
The dowels are a press fit.
NOTE
The remaining steps can be performed on a
FIGURE 2 bench.
PAGE 2
ROL·SEAL MOTOR MODELS RSA, RSB AND RSC
DISASSEMBLY
7.) Unfasten the seven socket head cap screws which hold
the Model Code and Serial No. plate on the rear end cap.
FIGURE 4
FIGURE 6
5.) Remove seal plates (Fig. 4).
B.) The previous step exposed a set of timing gears.
Before removing these parts you must mark them (Fig.
6). The two small gears should also be marked left and
right.
FIGURE 5
FIGURE 7
6.) Remove seal rollers (Fig. 5). The motors have two sizes. The
seal rollers In the rotor tip are about 1/32nd dla. larger than
those behind the seal plates. 9.) Remove the snap rings that retain the gears, (Fig. 7)
and remove the gears.
PAGE 3
ROL-SEAL MOTOR MODELS RSA, RSB AND Rse
OISASSEMBLY
FIGURE 8
FIGURE 10
10.) By positioning the rotor as in Figure 8, you can lift
one of the abutment valves out. Rotate the shaft and
remaining abutment until the paddle of the rotor leaves 12.) Remove the snap ring which retains the shaft and
the abutment cavity. You now can remove this abutment. thrust bearing. (Fig. 10.)
FIGURE 9
AGURE 11
11.) Lift the rotor up, which will expose the drive key.
Remove the drive key. (Fig. 9.) . 13.) Remove the shaft from the rear end cap. (Fig. 11.)
PAGE 4
ROL-SEAL MOTOR MODELS RSA, RSS AND RSC
DISASSEMBL Y
14.) The step bearing that remains in the front end cap
should be taken out and inspected. There is an O-ring and
Teflon back-up ring under this part. (Fig. 12.)
15.) Check all mating metal-to-metal parts for scratches

or burrs which could cause leakage. Replace all parts on
which excessive damage is found. Use the following pro·
cedure to be sure that all these surfaces are perfectly
smooth:
Place a piece of 240 grit paper on a flat, smooth surface.
Place the part on the grit paper and stroke gently in a

figure eight motion several times. Excessive removal of
material should not be done as the parts may not
reassemble with proper clearances.
16.) Clean all parts in solvent and let them air-dry. All
O-rings and shaft seals should be replaced. If conditions
are such that you have to use the old seals they should be
FIGURE 12 washed in a mild soap and water solution.
REASSEMBLY
1.) Install shaft with thrust bearing and races through the 9.) Proceed to assemble the snap rings to retain the gears
back of the rear end cap. assembled in the previOUS step.
2.) Install snap ring to retain shaft. 10.) Set the assembly back on the rear cover face. Install the
seal plates and the seal pins in the rotor.
3.' Put spacer over shaft end, and assemble the large
timing gear to the shaft. 11.) Place the new O-ring in the groove of the end cap. A light
film of gun grease will help keep the O-ring from slipping out of
4.' Assemble snap ring to retain gear. the groove.
5.) Turning this subassembly and setting it on the rear 12.) Install the housing. If binding occurs take a soft faced
cover face, you can install one abutment valve. Install hammer and tap on the housing to free it.
new back-up ring and O-ring first. A light film of oil
should be applied to all new seals. 13.) Install new O-rings and back-up rings in the front end cap.
Put the step bearings in place. Apply a light film of gun grease
6.) Reassemble the round drive key in the key seat and to the large static seal, and place it in the groove.
slip rotor over key.
14.) Install the front end cap by slipping It over the shaft and
7.' Set the subassembly on its side and proceed with the watching the static seal to make sure it stays in place. Tap-
alignment and timing of the abutment and rotor. Either ping lightly with a soft face hammer may be required to seat
one of the abutments can be assembled. the front end cap.
8.) Rotate the shaft so the second abutment can be Installed. 15.) Set the body cap screws in place and tighten to recommend-
Align the timing marks. If the shaft can be rotated one com- ed torque values using a crisscross pattern. Torque settings are
plete revolution, it is likely that the proper assembly has been for lubricated threads. (see chart on following page)
carried out. NOTE: When properly timed, the rotor tip will pass
directly through the center of the abutment cavity.
PAGE 5
ROL-SEAL MOTOR MODELS RSA, RS8 AND RSC
REASSEMBLY
16.) Assemble Model Code and Serial No. plate to back of the
FRAME motor along with new static seal.
SIZE DISPLACEMENT TORQUE
17.) Before installing new shaft seal, make sure that shaft
500 in 1# turns. Then proceed to instali new seal and replace snap ring.
"A" and "8" 2·
(56 N-M) NOTE: Remove any burrs or raised edges from shaft keyway as
not to damage seal lip.
500 in 1#
"A" and "8" 3
(56 N-M)
18.) Replace motor in the system and run unit through normal
500 in 1# operating cycle.
"A" and "8" 4
(56 N-M)
.,cu 150 ft #
6
(203 N·M)
"Cit 150 ft 1#
8
(203N·M)
175 ft #
"Cft 10
(237 N·M)
SERIAL
125 in #
COVER ALL
(14 N·M)
PLATE
SEAL REPLACEMENT
1.) Clamp the motor in a vise. Remove the key and all 6.) Apply a thin film of grease to the lip of the new seal.
burrs or sharp edges which may have developed. Use 400 Slide over shaft to face of end cap.
w-it emery cloth to remove all rust from the shaft.
2.) Remove the snap ring.

7.) The seal must be installed without cocking it. The
best procedure is to obtain a short piece of tubing or pipe
3.) Remove front end cap as in steps 1·3 of the disassem-
which is square on the ends and will contact the outer
bly procedure.
shell of the seal. If the tubing is too small it will damage
the seal.
4.) Turn end cap with sealing face up. Use a large
screwdriver blade inserted between the seal lip and shell.
Proceed to pound out seal alternating from side to side so
as not to damage the end cap bore. 8.) Press seal in just far enough so the snap ring will stay
in the seal bore. Using the snap ring to seat the seal will
5.) Replace end cap and torque body bolts to recom· prevent you from pressing the seal in too deep. When the
mended torque, (see ctlart above.) snap ring pops into the groove the seal is properly seated.
PAGE 6
ROl-SEAl MOTOR MODELS RSA, RSB AND RSC
TROUBLE SHOOTING
The following chart lists the possible troubles that may be
encountered, the probable cause and the remedial action
recommended.
TROUBLE-8HOOTING CHART
Trouble Probable Cause Remedy
No pressure 1.) loose coupling. 1.) Repair or replace coupling.
2.) System relief open. 2.) Clean, adjust, or replace

if necessary.
Noisy system 1.) Cavitation at pump. 1.) Check for inlet air leaks.
Check pump inlet for restriction.
2.) Reservoir low. 2.) Fill to recommended level.
Motor will not 1.) System relief unloading. 1.) Disassemble, clean, adjust.
develop torque.
2.) Worn out. 2.) Repair or replace.
3.) High temperature operation. 3.) Change to fluid with higher

viscosity index.
Blown rear cover 1.) Drain restriction. 1.) Drain directly to tank.
2.) High case drain. 2.) Repair motor.
leakage around shaft. 1.) Shaft seal worn out. 1.) Replace.
Motor turns in wrong 1.) Hose connection wrong. 1.) Reverse connections.
direction.
PAGE 7
FIGURE 13. ROL-SEAL MOTOR EXPLODED VIEW

PAGE 8
ROl-5EAl MOTOR MODELS RSA, RSB AND RSC
PARTS LIST
REPLACEMENT PARTS LIST - ROL-SEAL ® MOTOR
NOTE
When Ordering Replacement Parts, Give Model Number, Serial Number, Item Number, Description and Quantity.
Item Description Quantity
1 Key, Woodruff 3
2 Pin, Drive 1
3 Ring, Retaining 2
4 Gear, Drive 1
5 Spacer 1
6 Ring, Retaining 1
7 Race, Bearing Thrust 2

8 Bearing, Thrust 1
9 Bearing, Roller 2
10 Seal, O-Ring 3
11 Cap, Rear
12 Pin, Rotor Tip 3
12A Pin, Seal Plate 18
13 Rotor 1
14 Plate, Seal 3
15 Valve, Rotary Abutment 2
16 Bearing, Needle 4
17 Bearing, Step 4
18 Seal, O-Ring 4
19 Ring, Teflon Backup 4

20 Pin, Dowel 2
21 Screw, Cap 9
23 Seal, Shaft 1
24 Cap, Front 1
25 Housing, Displacement 1
26 Ring, Retaining 4
27 Gear, Timing 2
28 Shaft, Power 1
29 Cover, Gear 1
30 Screw, Cap 7
31 Ring, Retaining 1
32 O-Ring, Front Cap Seal 1
PAGE 9
ROl-SEAl MOTOR MODELS RSA, RSB AND RSC
PAGE 10 PRINTED IN U.S.A. FORM 201FM

ROL·SEAL® BRAKE
REAR-MOUNTED, MULTI-DISC
TYPE FOR RSA AND
RSC MOTORS
WASHINGTON SCIENTIFIC INDUSTRIES, INC.
POWER COMPONENTS DIVISION
Long Lake, Minnesota 55356
Telephone: (612) 473-1271 TWX: 910·576·2742
MAINTENANCE AND
PARTS MANUAL
NOTE
ONLY FACTORY OR QUALIFIED DISTRIBUTORS ARE AUTHORIZED TO
OVERHAUL AND REPAIR WSI EQUIPMENT. ALL FACTORY WARRANTY IS
CANCELLED UPON DISASSEMBLY BY UNAUTHORIZED PERSONNEL.
10/84 FORM304FP
304 FP 10/84 ROL·SEAL® BRAKE
TABLE OF CONTENTS
PAGE
TITLE ...................................................... 1
INTRODUCTION ............................................. 1
HOW TO AVOID REPAIRS ..................................... 1
REAR MOUNTED BRAKE ASSEMBLY ........................... 2
TOOLS REQUIRED ........................................... 2
DISASSEMBLY .............................................. 2
REASSEMBLy .............................................. 3
PARTS LIST ................................................. 4

304 FP 10/84 ROL·SEALIID BRAKE
INSTRUCTION MANUAL
INTRODUCTION CASE DRAIN
This Wet Disc Type Brake was designed to fit on These units are provided with a case drain con-
the W.S.1. Rol-Seal®Motor to provide either dynam- nection. A line must be provided to return case
ic braking, or as a mechanical means of locking drain flow to the reservoir at no more than 250 PSI
the motor shaft to prevent motor drift due to surge pressure. Cross port check valves are op-
overhanging loads. The number of disc brake sets tional for internal drain but should not be used
provide for a higher static torque loading than the where instantaneous shock pressures occur,
dynamic torque rating of the hydraulic motor. such as in dynamic braking.
HOW TO AVOID REPAIRS OTHER BRAKE SPECIFICATIONS
Maintain cleanliness in your hydraulic system. Be WK2 of brake ....................... 2.6 lb. in. 2
careful when adding to the reservoir that clean oil Volume of oil to release brake ........... 0.6 in. 3
is added and the container being used is clean. Torque holding
Proper filtration does not guarantee a contami- capacity. . . . . 2 in.3 3 in. 3 4 in. 3
nate-free system if the filters aren't serviced at 940 lb. in. 1410 lb. in. 1880 lb. in.
regular intervals. Caution should be used when
connecting the brake release pressure port to the
brake housing inasmuch as the drain port is adja-
cent to the pressure port.
PAGE 1
304 FP 10/84 ROL·SEAL® BRAKE
DISASSEMBLY
Pressure Port c'P"
,----Return to Tank Port "T"
2
8
10
11 12 13
FIGURE 1. SECTIONAL VIEW, ROL·SEAL® BRAKE
REAR MOUNTED BRAKE ASSEMBLY 4. Remove remaining brake components.
TOOLS REQUIRED: 1f4 allen wrench (To remove brake piston (10), it may be
necessary to inject shop air (80 PSI max.) into
NOTE: If it is necessary to remove adapter plate pressure port "P". PLEASE NOTE: If air is used,
(8), a ~8 allen wrench and centering fixture (avail- precautions must be taken to retain piston so
able from factory) will be required. as to eliminate the possibility of injury!)
5. Remove the back-up rings (11,15), and O-rings

DISASSEMBLY (Figure 1) (12, 14) from the housing (1).
1. Thoroughly clean the exterior of the assembly 6. If it's necessary to remove the adapter plate (8)
and hydrauliC lines before attempting removal. from the motor, remove the seven cap screws (7).
2. Disconnect hydraulic lines and cap them to pre- 7. Clean all components in solvent and dry.
vent loss and contamination of fluid.
8. Inspect all components for wear and damage.
3. Remove the eight cap screws (13), and separate Replace components unfit for service. Note
the brake housing (1) from the adapter plate (8). quantities of friction discs (3) and drive plates
Discard O-ring (5). (4) in parts lists on following pages.
PAGE 2
304FP10/84 ROl·SEAl® BRAKE
REASSEMBLY
(See Figure 2)
3. Lubricate all components with clean hydraulic

fluid.
4. Position the spacer rings (2) in the housing (1).
NOTE: Spacer ring thickness varies with motor

size. See parts list.
5. Locate friction disc (3) in the housing; then a

driver plate (4); then another friction disc (3);
and so on depending on model, making sure
driver plate splines are aligned.
6. Carefully install the pressure plate (10) in the

housing so as not to damage the O-rings
(12, 14). Place the eight die springs (9) in the
pressure plate.
FIGURE 2. CENTERING FIXTURE
7. Position a new O-ring (5) in the housing using a
little grease to hold it in place.
1. If adapter plate (8) is removed, reassemble on
the motor using a centering fixture available 8. To assemble motor to brake, carefully drop
• from factory. Install capscrews (7) with shaft while engaging the plate drivers (4) with
I
washers (6) including O-rings (16) for RSC the splined motor shaft.
brake and torque to 150 in. lb.
9. Secure the housing to the adapter plate with
2. Install new O-rings (12, 14) and back-up rings (11, the eight cap screws (13). Tighten and torque
15) in the housing (1). Make sure the ends of the the cap screws to 300 in. Ibs.
back-up rings are flush and not overlapped.
10. Connect the hydraulic lines.
NOTE: Backup rings (11, 15) must be in posi-
tion as shown in sectional view. 11. Test the brake for operation and leaks.
PAGE 3
304 FP 10184 ROL·SEAL® BRAKE
PARTS LIST
REPLACEMENT PARTS LIST-REAR MOUNTED BRAKE ASSEMBLY
MODELS RSA02, RSA03, RSA04, RSB02, RSB03, RSB04, BRAKE
NOTE
When ordering replacement parts, give model number, serial number,
item number, part number, description and quantity.
.-- -- -- --
r- -- -- --
I
I
I
I
I
FIGURE 3. EXPLODED VIEW

RSA AND RSB SERIES BRAKE
Item Part No. Description Quantity
1 C·63086 Housing 1
2 A-63095 Spacer Ring 2 Cubic Inch 1
3 B-62308 Friction Disc 2 Cubic Inch 3
3 Cubic Inch 4
4 Cubic Inch 5
4 B-631 00 Plate Driver 2 Cubic Inch 2
3 Cubic Inch 3
4 Cubic Inch 4
5 A-63097 C-Ring 1
6 A-60709 Brass Washer 7
7 A-60955 Cap Screw-Socket Head 7
8 C-63087 Adapter Plate 1
9 A-62298 Die Spring 8
10 B-63093 Pressure Plate 1
11 B-62303 Back-Up Ring 1
12 B-62301 C-Ring 1
14 B-62302 C-Ring 1
15 B-62304 Back-Up Ring 1
PAGE 4
304 FP 10f84 ROl·SEAl® BRAKE
PARTS LIST
REPLACEMENT PARTS LIST
RSC MODEL ROL·SEAL® BRAKE
NOTE
When ordering replacement parts, give model number, serial number,
item number, part number, description and quantity.
FIGURE 4. EXPLODED VIEW

RSC SERIES BRAKE
Item Part No. Description Quantity

1 C-63086 Housing 1
3 8-62308 Friction Disc 6 Cubic Inch 7
8 Cubic Inch 9
10 Cubic Inch 12
4 8-63099 Driver Plate 6 Cubic Inch 6
8 Cubic Inch 8
10 Cubic Inch 11
5 A-63097 O-Ring 1
6 A-60709 8rass Washer 6
8 C-63089 Adapter Plate 1
9 A-62298 Die Spring 8
10 8-63093 Pressure Plate 1
11 8-62303 8ack-Up Ring 1
12 8-62301 O-Ring 1
.( 14 8-62302 O-Ring 1
" . 15 8-62304 8ack-Up Ring 1
16 A-60846 O-Ring 2
PAGE 5
304FP 10/84 ROL-SEALIIJ BRAKE
I
~ i
~I
PRINTED IN U.S.A. FORM 304FP

Torque-Hut> Final Drives
Service Manual
WI
·s'
DRIVE
Fairfield Manufacturing Company, Inc.

South Concord Road. Lafayette. Indiana 47902. U.S.A. 317/474-3474
II II
Introduction
This Service Manual is a step-by-step
guide designed for the customer or shop
mechanic who is servicing or repairing a
particular model of Torque-Hub Final
Drive. (The model covered by this copy of
the Manual is specified on the Manual
cover.)
Included are -
1. assembly and exploded view drawings
2. disassembly procedure
3. main assembly procedure (assuming
all sub-assemblies to be intact)
4. sub-assembly procedures.
At the time of printing, this Manual was
complete for the specific Torque-Hub
model designated. However, Fairfield
Manufacturing Co., Inc., reserves the right
to update and improve its products at any Safety
time. All specifications and procedures Standard safety practices should be
are therefore subject to change without followed during the disassembly and
notice. assembly procedures described. Safety
glasses and safety shoes should be worn;
heavy, heat resistant gloves should be
used when heated components are
handled. Be especially alert when you
see a caution symbol (&J. This symbol
indicates that a particular operation could
cause personal injury if not performed
properly or if certain safety procedures are
not followed.
W1A-W1B
Disassembly Procedure
1. Loosen all 16 Cover Bolts and drain 1O.To remove the Cluster Gears from the
the oil from the unit. Carrier, drive the anti-roll pin into the
Planet Shaft of the Cluster Gear. After
2. Remove the 16 Cover Bolts and lift off the Planet Shaft is removed the roll pin
the Cover Sub-Assembly. Discard the should be driven out of the Planet Shaft.
'0' ring Seal from the Cover
counterbore. WARNING: When rebuilding the unit, the
'0' rings and Retaining Rings should
3. Lift out the Carrier Sub-Assembly and always be replaced.
the top Thrust Washer. The Thrust
Washer may stick inside the Cover.
4. Pry the Ring Gear loose and remove it.

Discard the '0' ring Seal from the Hub
counterbore.
5. Remove the Input Shaft, Input Gear,

and the Thrust Spacers that are on the
Input Shaft.
6. Lift out the Internal Gear and Thrust

Washer. The Thrust Washer may stick
to the bottom of the Carrier.
7. Remove the Retaining Ring from the

Spindle and discard; then lift the hub
off the Spindle.
8. The inside Bearing Cone and the

Bearing Shim can now be removed.
9. The Seal can be pried out of the Hub

with a screw driver or pry bar. This
will also allow the outside Bearing to
be removed.
Note: If bearing replacement is

necessary, the Bearing Cups can
be removed with a "slide
hammer puller" or driven out
with a punch.
Main Assembly Procedure
1. Using an arbor type press if available,

press Bearing Cups with large inside
diameters facing out, into Hub
counterbores. Cup #JLM506810 will
go into small end of Hub, and Cup
#JM205110 will go into large end of
Hub. If Studs are being used, they can
be pressed in at this time. Solid
support must be used in this operation.
2. Place Bearing cone #JLM506849 into

Bearing Cup in small end of Hub.
3. Press Seal into Hub counterbore with

flat metal side facing in. Use a flat
object to assure that Seal is pressed
evenly and is flush with Hub face.
4. Lower Hub onto Spindle with large

open end up.
5. Place Bearing Cone #JM205149 over
end of Spindle and into Bearing cup.
6. Place Bearing Shim over end of

Spindle and against Bearing Cone.
7. Secure Retaining Ring completely into

Spindle groove and against Bearing
Shim. Be sure that Retaining Ring is
entirely in groove.
&Eye protection should be worn

during Retaining Ring installation.
8. Place Internal Gear onto end of

Spindle.
9. Place Input Shaft Assembly into

Spindle bore with unsplined end facing
out.
10.Place narrow Thrust Spacer over Input
Shaft with counterbore side facing
Spindle.
11.Place '0' Ring into Hub counterbore.

Use petroleum jelly or grease to hold
'0' Ring in place. Slight stretching of
the '0' Ring may be necessary to
insure proper seating.
12.Place Carrier Assembly on a flat

surface with the large gears up an.d
positioned as shown. Find the punch
marked tooth on each large gear and
locate at 12 o'clock (straight-up) from
each planet pin. Marked tooth will be
position
located just under the Carrier on
punchmarks
upper two gears.
at 12 o'clock
13.With shoulder side of Ring Gear facing

down, place Ring Gear over (into mesh
with) large gears. Be sure that punch
marks remain in correct location
during Ring Gear installation.
14. Turn over Carrier Assembly and Ring

Gear while keeping gears in mesh.
Place Thrust Washer into Carrier
counterbore. Use petroleum jelly or
grease to hold washer in place.
'/1.., r A ... -c . .. r.,.,

15. While holding Ring Gear, Input Gear and
Cluster Gears in mesh, place small side of
Cluster Gears into mesh with the Internal
Gear. On the Ring Gear locate the hole
marked "X" over one of the counterbored
holes in Hub. Mark these holes on
outside diameter for later use.
Note If gears do not mesh easily or Carrier Assembly does not rotate freely, then remove
the Carrier and Ring Gear and check the Cluster Gear timing.
16. Place Thrust Washer into Carrier

counterbore.
17. The Input Gear is now installed into the

carrier meshing with the large diameter
cluster gear. The counterbore in the bore
of the Input Gear must be to the inside of
this assembly.
'/1'
19.Place '0' Ring into Cover Assembly
counterbore. Use petroleum jelly or
grease to hold '0' Ring in place.
20.Place Cover Assembly over Ring Gear

with oil level check plug in Cover
located approximately 90 0 from oil fill
plug in Hub.
21.Locate four Shoulder Bolts with flat

washers, 90 0 apart into counterbored
holes in Hub marked in step 16.
Torque Shoulder Bolts to 23-27 ft. Ibs.
22.Use standard grade 8-5/16-18x21;4

bolts with flat washers in remaining
holes. Torque to 23-27 ft. Ibs.
i,~
.. 23.Place Coupling into Spindle and onto
Input Shaft.
This completes the Torque-Hub
Assembly. The unit must be filled one-
half full of EP90 lubricant before
operation.
Assembly Procedure
For Sub-Assemblies
Input Shaft Sub-Assembly
1. Place Washer, Spring and Washer, in
that order, onto Input Shaft.
ow-too
2. Install Retaining Ring into Input Shaft

groove to secure Spacers and Spring to
shaft.
~.... ~ & Eye protection should be worn

during Retaining Ring installation.
Carrier Sub-Assembly
,. Apply a coat of grease or petroleum
jelly to Cluster Gear bore.
"'., 4 • f.t ....
2. Place sixteen Needle Rollers into

Cluster Gear bore.
3. Place Spacer washer into opposite side

of Cluster Gear and against Needle
Rollers.
4. Place second set of sixteen Needle

Rollers into Cluster Gear.
5. Apply grease or petroleum jelly to the
tang side of two Thrust Washers. Place
Thrust Washers against bosses in
Carrier with washer tang fitting into
slot in Carrier outside diameter.
Note: Some old style Carriers will not
have slots and tangs should be
located inside boss relief.
6. While keeping Thrust Washers in

place, slide Cluster Gear into Carrier
with the larger gear on the side with
the small pin hole.
7. line up Cluster Gear and thrust

Washers with hole in Carrier arid slide
Planet Shaft through. line up
chamfered side of hole in Planet Shaft
with pin hole in Carrier.
8. Drive Anti-Roll Pin flush into Carrier

hole, thereby locking Planet Shaft into
place.
Repeat these steps for remaining two

Cluster Gears to complete Carrier Sub
Assembly.
Cover Sub-Assembly
1. Screw Pipe Plug into Cover.
2. Slip '0' Ring over Cover Cap

and against face.
3. Place '0' Ring into Cover Cap internal

groove. The Disconnect Rod may be
used to push '0' Ring into groove.
4. Place Cover Cap into Cover with large

hole located over Pipe Plug. Secure
Cover Cap to Cover with two %-20x%
bolts. Torque bolts to 70-80 in. Ibs.
5. Place Disconnect Cap over Cover Cap
with nipple facing out. Secure
Disconnect Cap to Cover with two
%-20x 3A bolts. Torque bolts 70-80
in.lbs.
6. Turn Cover over and push Disconnect

Rod into Cover Cap. Rod will be held
in place by friction from the '0' Ring.
Cover Sub· Assembly

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THE ;;:Rri/E ':>EoPLE
DRIVE 1.... '."'£r"E. "OIAJ11A
H.P.I. PROPORTIONAL CONTROL VALVE
INSTALLATION &MAINTENANCE
GENER"AL:
• Fluid Viscosity: 35 SSU to 1750 SSU
• Temperature:. -40°F to +180°F
• Seals: Buna N standard.
• Return Line Pressure: 500 psi maximum
INSTALLATION:
• Tie Bolts: Care should be taken to prevent stressing the
assembly by over-tightening the tie bolts. Always use a .
torque wrench to tighten. Torque to 225 inch-pounds.
• Mounting: When mounting a valve be sure that the mounting
bolts or connection pipe-work do not overstress the assembly.
• Sealing Compounds: No sealing compounds are required as
all ports are SAE straight thread o-ring ports.
• Port Preference: If one of the user ports (A or B) will
be handling a higher return flow, it is preferable to
connect the higher flow to the B port. This will provide
a more direct path to the tank port.
• Solenoids: The voltage should be checked against the
solenoid nameplate before wiring. (12 Volt D.C.)
START-UP:
• Bleeding: Air in.the system will impair control and may
cause dangerous movement of a load. At start-up the
hydraulic system should be bled at as many points as
possible.
OPERATION OF HPI PILOT VALVE
The pilot valve is not a conventional 4-way 3-position valve,

but a double pressure regulator. When one solenoid is energized,
the armature exerts a force on the pilot valve spool which is
proportional to the solenoid current. This force is balanced by
the output pressure, which is led to the opposite end of the pilot
spool. A given solenoid current will therefore generate a certain
secondary pressure (up to 200 psi approximately). It is this
secondary pressure which is applied to one end of the spool of the
main valve to displace the spool against an opposing (centering) .
spring, this displacement being proportional to the applied
pressure. The net effect is that the user speed may be controlled
by varying the solenoid current - independent of the load and any
load fluctuations.
This pilot valve does not require special filtration and required
flow rate is approximately 1 GPM.
I p
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TROUBLE-SHOOTING HPI PROPORTIONAL CONTROL VALVE
1. System pressure too low:

• Pump compensator set too low; adjust pressure
setting up.
2. Function pressure too low:
setting up.
• The functions compensator sticking or stuck; remove
and clean or replace.
• Shuttle valve leaking; locate leaking valve and
replace cut o-ring or complete assembly.
3. Load does not move:
setting up.
• Shuttle valve leaking; locate leaking valve and
replace cut o-ring or complete assembly.
• Stuck compensator; remove and clean or replace.
• Improper voltage; no voltage to solenoid or weak signal.
4. Function does not attain speed:
• Improper voltage; weak or not high enough voltage signal.
• Shuttle valve leaking; locate leaking valve and replace
cut o-ring or complete assembly.
• Wrong directional spool; replace with proper spool
(correct flow rate).
• Wrong compensator; replace with proper compensator to
attain correct flow rate.
5. Function speed too fast:
• Wrong directional spool; replace with proper spool
(correct flow rate).
• Wrong compensator; replace with proper compensator to
attain correct flow rate.
6. load moves erratically:
• Air in system; bleed at as many points as is possible.
• Faulty signal to solenoids; check solenoid input current
and correct if needed.
• Adjust compensator dampening screw to a position to
throttle pulsations.
• Fluctuating inlet pressure to the manifold; measure pump
outlet pressure and stabilize if fluctuating significantly.
• Excessive tank pressure; look for restriction in tank
line downstream of the valve.
7. Poor control:
• Adjust compensator dampening screw to a position at which
the function operates properly.
• Faulty signal to solenoids; check solenoid input voltage for
a smooth steady proportional signal.
• Air in system; bleed at as many points as is possible.
• Sticky pilot spool; remove and clean pilot spool of
contamination.
8. Interreaction between functions:
• Functions compensator stuck open; remove and clean or
replace compensator.
• Pump bias pressure too low; adjust bias pressure up.
9. Moving function no signal:
• Directional spool centering spring retainer has backed out;
screw retainer back in and lock.
10. Moving function:
• Check for electrical signal on valve.
,. ('
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MAINTENANCE INFORMATION
Fluids Be certain to fill the main pump housing with clean

hydraulic fluid prior to start up. Fill main pump housing by
Hydraulic fluids used with Sundstrand products should be pouring the filtered oil in the upper most case drain hole.
carefully selected wlth assistance from a reputable
supplier following the guidelines presented in the CAUTION
"Hydraulics Fluid Requirements" bulletin F-00.01.
The following types of fluids have been used successfully Operation of the pump with less than 160 PSI
in Sundstrand hydrostatic products: discharge pressure may reduce the life of
the unit.
1. Anti wear hydraulic oil.
2. Type F Automatic Transmission Fluid See machine operating manual for machine start up
3. Engine oils meeting the requirements of API procedures.
classification CD
4. Hydraulic transmission fluid of the type used by the On mobile applications, run at the lowest possible speed.
agricultural industry for combined transmission, hydraulic with a minimum of 160 psi until system pressure as been
and wet brake system. established. Oce system pressure is positive. increase he
speed to full RPM. On electric motor drives jog the motor
The fluid selected should provide a viscosity between 150 several times before initial start-up. In both cases if system
and 275 SSU at 100°F. pressure is not maintained. shutdown the system and
[...---..§~~ determine cause.
The hydraulic system should be operated for at least

As with any hydraulic system, a key to fifteen (15) minutes under light load conditions. .
successful operation and predicted life is
cleanliness of the various components and If control setting(s) is not per machine specifications refer
the fluid. Strict compliance with component to the control adjustment procedures in this manua\.
cleanliness recommendations and fluid
Shut down the system and remove the pressure gauge.
filtration requirements are a must. Failure to Check fluid level in the reservoir ~nd add fluid if
follow such recommendations and necessary.
requirements can result in excessive pump
flow loss and control valve malfunctions that The pump is now ready for operation.
can render a complete system inoperative,
or even cause catastrophic failure. System Maintenance
Installation For satisfactory service. regular maintenance of fluid and
filters must be performed. .
Prior to installing the pump. inspect for damage during
shipment and handling. Make certain all system Check fluid level daily. Change fluid more often jf it
components (reservoir, hoses. valves, fittings, heat becomes contaminated with any foreign matter (dirt.
exchanger, etc.) are clean prior to filling with fluid. water, grease. etc.)
The pump should be connected to the prime mover so Change Inlet and Return Filter whenever fluid is changed
that the centers of both drive shafts are aligned. Incorrect and whenever filter indicator shows a change is
alignment may result in eventual damage to the drive necessary. Replace all fluid lost during filter change.
shaft, drive shaft bearings, or the drive shaft seal which
can cause external oil leakage.
Start Up Procedure
Fill the reservoir with recommended hydrauliC fluid which
should be passed through a 25 micron (nominal) filter
prior to entering the reservoir. Never reuse fluid.
The inlet line leading from the pump to the reservoir must
be filled prior to start up. Check inlet line for properly
tightened fittings and be certain it is free of restrictions
and air leaks.
TABLE OF CONTENTS
DESCRIPTION PAGE
SERIES L PUMPS: BASIC OPERATION 1

Specifications and Requirements 1
PERFORMANCE CHARACTERISTICS 2
Open Circuit Pump Design 3
Basic Pump Operation 3
OPTIONAL CONFIGURATION 4
Rotation 4
System Ports 4
Auxiliary Pump Mounting Pad ·4
Quiet and Super Quiet Pumps 4
CONFIGURATION: CONTROLS 5
Pressure Compensator Control (PC) 5
Flow and Pressure Compensator Control (FP) 5
Remote Control Pressure Compensator Control CRC) 6
Horsepower Limiting Control (TP) 6
Combination Controls (CS and CP) 7
Dual Range Pressure Compensator Controls (DR) 8
Power Matching Control (PM) 8
MAINTENANCE INFORMATION 9
Fluids 9
Installation 9
Start Up Procedures 9
System Maintenance 9
TROUBLESHOOTING 10
Excessive Noise or Vibration 10
System Operating Hot 11
System Response is Sluggish 11
Low Pump Output Flow 12
Compensator Valve does not Operate 12
High Inlet Vacuum 13
CONTROL ADJUSTMENT 14
Maximum Row Adjustment 14
Pressure Compensator Control 15
Row Compensator Adjustment 17
MINOR REPAIRS 18
Introduction 18
General 18
Shaft Seal 18
Control 19
Control Disassembly 20
MAJOR REPAIRS 21
Introduction 21
Disassembly 21
Assembly 28
GENERAL PARTS IDENTIFICATION 35
Model L15 35
Model L23 36
Model L38 37
Model LSO 38
Model L70 39
SERIES L PUMPS: BASIC OPERATION
The Series L family of open circuit pumps consists of five
different frame sizes with displacements ranging from
.913 cubic inches per revolution to 4.26 in. 3 •
The variable displacement pump can be operated with

fixed or variable output flow between 0 and maximum flow
in one direction only.
A variety of controls are available to provide the most

efficient means of matching output flow and pressure to
the job requirements. These are further described in the
"Configuration: Controls" section of this manual.
The standard flow adjusting screw enables the maximum

TYPICAL L 15.23, 31 FRAME CONFIGURATION
pump delivery to be externally adjusted to match precise
system flow requirements. During normal operation the
swashplate will automatically vary from its deadhead
position to maximum displacement. Varying the
swash plate angle provides a means of varying the pump
flow. The pump will always produce a volume of fluid in
proportion to the angle of the swashplate at any given
input speed. For personnel and hydraulic sy,tem
safety reasons, a relief valve In the system is al!'ays
recommended.
Specifications and Requirements

The Sundstrand Series L pumps have certain pressures
that must be maintained as well as some requirements
TYPICAL L50. 70 FRAME CONFIGURATION and limitations which should be observed.
It should be noted that operation of L Series pumps not in

accordance with pressure and speed ratings, and system
requirements. can significantly reduce the expected life of
the pump from that which is published in other manuals
and brochures related to L Series pumps. Depending on
the degree of excess and the specific application. sudden
failure could occur.
SYSTEM REQUIREMENTS
MINIMUM
SPECIFICATIONS INLET 5"HG. 125 MM HG.
PRESSURE (1) VACUUM VACUUM
MAXIMIlIA SPEED
MAXIMUM ~UPEA gUIET
QUIET PUMP Case 10 PSI Max. .70 BAR Max.
MODEL DISPLACEMENT PRESSURE
Pressure
IN3/REV CC/REV PSI BAR RPM RPM
Fluid 1800F Continuous 820C Continuous
US .913 15 3000 210 1800 3600 Temperature 2000F Intermittent(2) 930C Intermittent(2)
L23 1.41 23 4000 280 1800 3200 Inlet
Filter 150 Mesh
L38 2.30 38 3000 210 14300 3000
L50 3.15 50 3000 210 1800 2400 Return

Line 25 Micron
L70 4.26 70 3000 210 1800 2200 Filter
(1) Applies at reduced speed. Pressure is higher

Above ratings pertain to continuous maximum pressure (positive) at maximum speed.
and continuous maximum speed.
(2) Not to Exceed 5 Min.
1
BASIC OPERATION
Performance Characteristics
L·15 L·50
VOWIlllETRIC E~NCY,
lOG VOL~METRIC E~FICIENCY
-
lOG
I I to to I I
OVERALL EFF1C1ENC~...
-..... ~ OVERALL EFFICIENCY

10
, -. fI'"
I 10
7
/ DELIVERY , _ RPM
/
I / DELIVERY - 1100 RPM
j DELIVERY
1200 RPM / I .--
~
'r/-DELIVERY -
1200 RPM
~ ~
30
r1IN~ S~
~/ 20
....
~
3
~
, -"~
". ,1 10 .P- ~~,,-
~OI'SE
2
--:::::::: ~
~ ~. .i o
500 1000 '500 2000 2SOO
DEADHEAD HP ..
~ i"""'" PRESSURE (PSI,
o
500 lOGO 1500 2000 2500 JOOO
OUTLET PRESSURE - PSI
L·70
VOLUME'TRIC EFFIC~ENCY _ lOG
L·23 , I
j. OVERAll EFFICIENCY 90
'OG 25
40 10
DELI~ERY -
".
to
...
:I
35 ~
l.!o RPM 7o~L70
,,
80 20£ I
__ \fPD;:'~~ 60 H60
.-. ..
:. "
..
~ 25
30
I SOtrSO~
u 60
12 .51... ~20 >fiE" ..,.
~
4O;~4O~
z
~~" L ...
~
......
!:!
'"
so
40
10
If i. 10
CIl :!! 15
10
V'
\,,~~ ~ : S~: i
!:!
30
20
DEUVERY-
1200 RPM I"" ...
4
0
C 5
::J
~
5
0
~ DEADHEAD HORSEPOWER
': t':
$00 lOGO 1500 2000 2SOO 3000
10 2 OUTLET PRESSURE - PSI
0 0
0 $00 lOGO 1$00 2000 2SOO 3000
PRESSURE (PSI,
L·38
V~UMETR':: EFFICIEky lOG
~LlVERY 1100 RPM Note: Performance curves based on 12()O oil temp and ISO
II to t SO
L OVERALL EFFICIENCY
t VG46 oil and are representative of this series size.
,
I J
~LIVERY!ZOO RPM
I
V
10
70....
60 ~~
.ao
It
I /' :~ 30 i
so ~I ~
k/ , / ' INfUT'Y z
., !:!
~ :..
I
#( 30'"
:::
20 0
:t
4
fI"',~
10
~
",
I
2
o
~
tOGO
DEA~ADHP
1500 2000 2SOO
- JOOO
10
o o
OUTLET PRESSURE - PSI
2
BASIC OPERATION
Control Control Cyll_

Open Circuit Pump Design
Sundstrand open circuit hydrostatic pumps are an axial
piston, slipper pad design. There are nine pistons
mounted in the cylinder block. As the cylinder block
rotates, these pistons are forced in and out of their bores
by the angle of the swashplate. This results in a specific
amount of fluid being displaced for every revolution of the
cylinder block.
The slipper pad attaches to a spherical ball on the end of

the piston forming a ball and socket joint. This allows the
slipper pad to tilt at any angle and make contact with the
swashplate. The face of the Slipper pad slides on a
hydrostatic fluid film which uses fluid pressure to balance
internal forces.
Basic Pump Operation

The variable displacement pump uses a tiltable
swashplate to vary displacement (output flow) .. The
swashplate is mounted on trunnion bearings and is spring
To
&.;.,
loaded from the back side toward its maximum angle
System position when the control is deactivated. . .
~~~+---~--~
The pump receives fluid directly from the reservoir without
~-¢ the requirement of a charge pump. Fluid is then pumped
From
Sy._ under pressure to the system and returns directly to the
reservoir.
The speed of the actuator (cylinder. hydraulic motor, etc.)

depends on the volume of fluid being pumped. The
operating pressure depends on the machine load.
If the actuator is to be reversed, a directional control valve

is necessary as the pump swash plate operates on one
side of neutral only and the pump is unidirectional.
When the pump's automatic control is activated, fluid is

ported into the destroking cylinder. This action destrokes
the swashplate (reduces pump displacement) to obtain
the desired pump flow.
The control can position the swashplace at any angle

between its maximum and zero displacement to provide
the pump flow necessary to .maintain the setting of the
control.
A variety of controls are available for the Series L which

regulate pump displacement in response to pressure,
flow, horsepower requirement or dual range pressure
settings. However, all the controls operate on the same
principal that when activated they port fluid to the
destroking cylinder.
3
OPTIONAL CONFIGURATIONS
CONTROL VALVE LOCATION
The pressure compensator may be factory selected with
1000, 2000 or 3000 PSI springs. The maximum
adjustment is limited internally to approximately 25%
above factory setting. Standard units are shipped from the
factory with the pressure compensator set at 500 PSI.
To meet the requirements of various applications, the

Series L pumps are available with various options which
change the configuration of the unit.
Rotation
SIDE PORTING (X) END PORTING (Y) Series L pumps can be either right hand or left hand
1.625-12 SAE STR THO 1.625-12 SAE STR THO rotation as viewed from the shaft end. A plate located on
O-RING BOSS O-RING BOSS the top of the pump shows rotation.direction. Right hand
or clockwise rotation is the standard configuration with
counter-clockwise rotation optional. The direction of
rotation can not be changed without changing the end cap
and valve plate.
Direction Perts
Rotation Inlet Outlet
System Ports
CW A B
CCW B A The Model L 15. L23 and L38 open circuit pumps are
designed with end ports as standard. Side ports are
optional for applications where space is limited. The
Model LSO and L70 are available with side ports only.
Auxiliary Pump 'Mounting Pad

The model L38 and L70 are available with an SAE "A"
auxiliary mounting pad for installation of an additional
hydraulic pump on the rear of the unit. This option can be
used to reduce the overall hydraulic system space
requirements as well as costs. since the auxiliary pump is
driven directly off the main pump shaft.
Quiet and Super Quiet Pumps

Quiet pumps are general purpose units capable of higher
speeds and recommended for open loop mobile
applications.
Super Quiet pumps are aimed more at the industrial 1800

rpm market and are identified by a "K" at the end of the
ordering code as well as part number. Example: Order
Code L 15-RBKY-PCX3XX-XK or Part Number
L15-7026K.
The Super Quiet version also has modified kidney slots

on the cylinder block. valve plate. and in most cases,
journal type bearings on the trunnion.
4
CONFIGURATION: CONTROLS
STANDARD CONTROLS
Pressure Compensator Control (PC)

The pressure compensator control automatically adjusts
pump delivery to maintain volume requirements of system
at a pre-selected adjustable operating pressure.
Maximum pump delivery is maintained to approximately
50 PSI below the pressure control setting. before being
reduced. The pressure compensator control has an
adjustment range that must be specified. Standard factory
range is 500 to 3000 PSI. Other optional ranges are
250-1000 PSI and 250-2000 PSI. Maximum adjustment is
limited internally to approximately 25% above nominal.
PRESSURE
Flow and Pressure Compensator

Control (FP)
PRESSURE COMPENSATOR CONTROL (PC) The flow compensator function matches output flow to
system demand. The control will automatically adjust the
pump displacement to match the flow requirement
necessary to maintain the constant flow sensing pressure
differential signal received from the system.
When system flow is not required, the pump standby

pressure will equal the selected flow sensing differential
pressure. When the system demands flow, the pump
supplies only the volume necessary at the pressure
required to operate the load.
This flow sensing pressure differential can be factory

selected at 100, 200, 300, 400 and 600 PSI.
I
t
;---~
t
I L
FLOW AND PRESSURE COMPENSATOR CONTROL (FP)
II,-.-.LP-RE-SS....JUL"RE:::--..l.--.
5
Remote Control Pressure'

Compensator Control (RC)
The remote control pressure compensator provides tor
remotely varying the compensator setting. The control will
automatically destroke the pump at a preselected remote
pilot relief valve setting. The remote pilot relief valve
setting is directly prOportional· to the pressure
compensator "tting. The spring in the control is
adjustable from 200 to 1200 PSJ. Note: Pumps prior to the
following SIN were not adiuttable; L15. 23. 38. SiN
84-36XXXX; LSO., 70 SltF8+48XXXX. Thus a simple
solenoid valve in the sense line. when vented back to tank.
allows the pump to attain the spring setting on the control
creating a control function for use in high-low pressure
applications.
REMOTE CONTROL PRESSURE COMPENSATOR CONTROL (RC)
1-- r--- ......- - +
,
I
L
'o!:---:P:-RE-S.L..SU-R-E-.I....-
OPTIONAL CONTROLS
Horsepower Limiting Control (TP)

The horsepower limiting control is designed to limit flow at
high pressu:e and is particularly suited for applications
where the pump horsepower is greater than the available
input horsepower. The control consists of a pressure
control valve whose setting increases at decreasing pump
displacement. Hence· the valve controls discharge
pressure and discharge rate at a specific RPM as
illustrated below.
HORSEPOWER UMITING CONTROL (TP)

I
I
I
I
I
I
OL--_ _ _ _....L-_
: I
~=-==--~
• PRESSURE
6
Combination Controls (CP and CS)

The installation of a combination control enables a single
pump to operate at two pressures and two flow settings.
This permits two performance capabilities as follows,
depending on the working cycle. .,..
• High volume flow at low pressure when the actuator is

unloading
• Low volume fJow at higt\ pressu!8 when the actuator is

loading.
There are two models of combination controls available.

The model CP is controlled automatically by system
pressure. The model CS uses a solenoid valve on the
•..
pump which allows the performance characteristics to be
changed by switching the solenoid valve.
COMBINATION CONTROL WITH SYSTEM PRESSURE (CP)
,
........-.-i!'!'i"--+---i..~_
"
~ ~ ---- ~,---~ I
·o~-~---....J"""
PRESSURE
COMBINATION CONTROL WITH SYSTEM PRESSURE (cp)
"1---.. . SOL "on-'
COMBINATION CONTROL WITH SOLENOID VALVE (CS)

•
.
'----!---~
~ "
COMBINATION CONTROL WITH SOLENOID VALVE (C$)
7
Dual Range Pressure Compensator

Control (DR)
The dual range pressure compensator control operates in
a manner similar to the combination control except that it
operates within a given pressure range but at two
separate pressure ranges. The control basically consists
of two separate compensator sections each being set to
the desired maximum pressure. A solenoid is used to
select which section is in control at a given time.
Available pressure ranges are the same as are available

on the standard pressure compensator control.
DUAL RANGE PRESSURE COMPENSATOR CONTROL (OR)
,I
L._ - .- -f--f---I
• .'--PR-----ES..LSU-R-E-....a.......-
Power Matching Control (PM)

The power matching control consists of a remote pressure
compensator valve whose setting is controlled by a
solenoid operated proportional relief valve (integral to the
control) along with a flow compensator control. The flow
aP options available are the same as those for the Flow
Compensator (FP) Control.
POWER MATCHING CONTROL (PM)
01..---1_--1_--1_
a PRESSURE
8
MAINTENANCE INFORMATION
Fluids Be certain to fill the main pump housing with clean

hydraulic fluid prior to start up. Fill main pump housing by
Hydraulic fluids used with Sundstrand products should be pouring the filtered oil in the upper most Gase drain hole.
carefully selected with assistance from a reputable
supplier following the guidelines presented in the CAUTION
"Hydraulics Fluid Requirements" bulletin F-OO.01.
The following types of fluids have been used successfully Operation of the pump with less than 160 PSI
in Sundstrand hydrostatic products: discharge pressure may reduce the life of
the unit.
1. Anti wear hydraulic oil.
2. Type F Automatic Transmission Fluid See machine operating manual for machine start up
3. Engine oils meeting the requirements of API procedures.
classification CO
4. Hydraulic transmission fluid of the type used by the On mobile applications. run at the lowest possible speed.
agricultural industry for combined transmission, hydraulic with a minimum of 160 psi until system pressure as been
and wet brake system. established. Oce system pressure is positive, increase he
speed to full RPM. On electric motor drives jog the motor
The fluid selected should provide a viscosity between 150 several times before initial start-up. In both cases if system
and 275 SSU at 100°F. pressure is not maintained, shutdown the system and
.[.........-...~~~
determine cause.
The hydraulic system should be operated for at least

As wi.th any hydraulic system, a key to fifteen (15) minutes under light load conditions.
successful operation and predicted life is
cleanliness of the various components and If control setting(s) is not per machine specifications refer
the fluid. Strict compliance with component to the control adjustment procedures in this manual.
cleanliness recommendations and fluid
Shut down the system and remove the pressure gauge.
filtration requirements'"are a must. Failure to Check fluid level in the reservoir and add fluid if
follow such recommendations and necessary.
requirements can result in excessive pump
flow loss and control valve malfunctions that The pump is now ready for operation.
can render a complete system inoperative,
or even cause catastrophic failure •......, System Maintenance
'.
Installation
- -~;.~
. ..,~
For satisfactory service. regular maintenance of fluid and
- --t:~ filters must be performed.
Prior to installing the pump, inspect for ~e during
shipment and handling. Make ceriaj"."" system Check fluid level daily. Change fluid more often if it
componeAtl (reservoir, hoses, varves~ ftttilgs, heat becomes contaminated with any foreign matter (dirt.
exchangeri etc.) are clean prior to filling wi1tf1lIid. water, grease, etc.)
The pump should be connected to the prime mover so Change Inlet and Return Filter whenever fluid is changed
that the centers of both drive shafts are aligned. Incorrect and whenever filter indicator shows a change is
alignment may result in eventual damage to the drive necessary. Replace all fluid lost during filter change.
shaft. drive shaft bearings, or the drive shaft seal which
can cause external oil leakage.
Start Up Procedure
Fill the reservoir with recommended hydraulic fluid which
should be passed through a 25 micron (nominal) filter
prior to entering the reservoir. Never reuse fluid.
The inlet line leading from the pump to the reservoir must
be filled prior to start up. Check inlet line for properly
tightened fittings and be certain it is free of restrictions
and air leaks.
9
TROUBLESHOOTING
The information co!'tained in this section provides a guide
0-_.,
for troubleshooting Sundstrand Series L pumps. It is a
problem solving tool aimed at reducing unnecessary
~-=--
machine downtime. Following the fault-logic approach will SYSTEM PReSSURE
t
assist in the expedlant correction of system problems. iI
~:
- - .. ITee. 5.000 or 10.000 PSI GAUGE
:~! INTO OUTI.£T HOSE)
\ -f:l/ -.
, . / <" INLET VACUUM
Various pressure and vacuum gauge readings can be a -..,...--"" . \. / ' /• ~,
J ,TEE VACUUM GAUGE
'Ii!:' '-....? INTO INLET HOSE)
great asset in troubleshooting problems with the pump or ~
support system.
~ ~ (,
U .....
~
It will be necessary to tee a high pressure gauge into the
system pressure line to check the setting of the system
relief valve as well as control settings.
Measuring the inlet pressure will help locate restrictions in

the inlet lines. filter. etc.
Note
Snubbers are recommended to protect
gauges. Gauge calibration is also necessary
to insure accuracy of readings.
A. EXCESSIVE NOISE ANDIOR VIBRATION
CHECK OIL AIR CHECK PUMP INSPECT INSPECT

LEVEL IN -OK- IN OK .. INLET !-OK" SHAFT ~OK" SHAFT
RESERVOIR SYSTEM PRESSURE COUPLING ALIGNMENT
Jw LOOSE IFITTING
IN SUCTION LINE
Jw DEFEbTIVE DEFElTIVE
OR RETURN LINE
1 l 1 1 1
FILL TO
PROPER
LEVEL
PURGE
AIR AND
TIGHTEN FITTING
B REPAIR
OR
REPLACE
ALIGN
SHAFTS
10
TROUBLESHOOTING
B. SYSTEM OPERATING HOT
CHECK OIL INSPECT CHECK SYSTEM CHECK PUMP CHECK

LEVEL IN OK" HEAT OK" RELIEF VALVE f-OK" INLET t-OK. CONTROL OK
RESERVOIR EXCHANGER SETTING PRESSURE VALVE
1 DEFLTlvE LoLCD Jw ®
1 ! ! !
B
;
FILL TO REPAIR ADJUST CORRECT

PROPER OR SETTING (REFER TO F) I
LEVEL REPLACE !
CHECK FOR
INTERNAL
<D If System Relief Valve is set below the Pressure SYSTEM ~
Compensator Control. the valve can open prematurely LEAKS
and result in heat buildup. The relief valve should be
+
set at least 300 PSI above desired pressure
compensator setting.
® In the same manner. if the compensator is inoperable

the relief valve will open in response to excessive
pressure and create heat in the system. REPAIR
AS
REQUIRED
c. SYSTEM RESPONSE IS SLUGGISH
CHECK
CHi:::K SYSTEM CHECK CONTROL DEFECTIVE INTERNAL
RE.lEFVALVE OK'" CONTROL -OK'" SIGNAL OK'" CONTROL t-OK'" SYSTEM LEAKS
SETTING SETTING PRESSURES
LOW INCORRECT
INcorECT
I
HIGH LEAKAGE
1 J J
ADJUST
SETTING
ADJUST
SETTING
B REPLACE
CONTROL
(REFER TO E)
REPAIR
AS
REQUIRED
11
TROUBLESHOOTING
D. LOW PUMP OUTPUT FLOW
CHECK OIL CHECK SYSTEM CHECK PUMP CHECK PUMP CHECK

LEVEL IN OK. RELIEF VALVE OK .. CONTROL OK. INLET OK- INPUT OK
RESERVOIR SETTING SETTING PRESSURE SPEED
Jw Jw INCoiRECT Jw Jw
1 I I I 1
FILL TO
PROPER
LEVEL
ADJUST
SETTING
ADJUST
SETTING
CORRECT
(REFER TO F)
B CHECK
MAXIMUM
FLOW I-
ADJUSTMENT
INC+E~
ADJUST
SETTING
E. COMPENSATOR VALVE DOES NOT OPERATE
CHECK INSPECT INSPECT INSPECT INSPECT

CONTROL -DK- COMPENSATOR "Vf\- FOR OK- COMPENSATOR ~OK'" FLOW CONTROL
SETTING SPRING LEAKAGE SPOOL CYLINDER
INCOLECT WR::>_NG
PRESSURE RANGE
DAMtGED
OR
CONTAMINATED
DAJAGE
OR
CONTAMINATED
1 l l l
ADJUST
SETTING
B B REPAIR
OR
REPLACE
REPAIR
OR
REPLACE
12
TROUBLESHOOTING
F. HIGH INLET VACUUM
CHECK OIL INSPECT CHECK INSPECT

TEMPERATURE -OK'" INLET t-OK- OIL OK- INLET
FILTER VISCOSITY PIPING
CLOGlED OR AS!VE TOO !ONG

clD TOO SMALL OF 150-275 SSU OR SMALL
I
MESH AT 1000F DIAMETER
! l l
ALLOW SYSTEM
TO WARM UP
REPLACE
FILTER
REPLACE
OIL
B
COMMON CAUSES OF WEAR AND PART DAMAGE
AFFECTED PART PROBLEM PROBABLE CAUSE
Shaft Broken A. Pump is used at higher than

maximum working pressure.
B. Seizure is due to lack of
lubrication.
-!--------- -------------------
Wear Needle bearin~ wear on L-15
Excessive sha end play on
L23, L38. L50, L70 models
Cylinder Block r- - §~~uLe_ - - __~~~~~~~~n ______

Valve Plate Wear A. Excessive oil temperature
B. Cavitation
C. Improper case drain filting
D. Excessive speed
E. Excessive pressure
Slipper Pads Wear A. Oil contamination
B. Excessive speed
C. Excessive pressure
Bearings Damage A. Improper shaft alignment

B. Abnormal pres~ure
C. Insufficient end play on L23,
L38, L50, and L70 models.
Oil Seals Damage A. Excessive case leakage

B. Excessive case pressure
C. Improper shaft alignment
Control Cylinder Wear A. Oil contamination

Cylinder rod
13
STANDARD CONTROL ADJUSTMENT
--- Maximum Flow Adjustment
•
"
COU .. rERCLOCI(WISE Maximum volume or flow from the pump can be varied to
...z TURNING
match the application requirement by turning the flow
...:Ii adjusting screw located on the back of the pump .
w
(.)
C
•
-'
Q.
III
is , CLOCI(WISE
TURNING
Using appropriate wrenches. loosen the locknut and turn
the adjusting screw clockwise to decrease maximum pump
flow or counterclockwise to increase maximum flow.
\ The flow rate will be increased or decreased by

_ PRESSURE approximately the following amount for each complete turn
of the adjustment screw .
l15 .091 in.Jlrev. per turn
END CAP L23 .123 in.Jrev. per turn

CYLIND~R ROD
FLOW
CONTROL CYLINDER L38 .15 in.Jirev. per turn
ADJUSTING SCREW
L50 .25 in.3Irev. per turn
L70 .31 in.3!rev. per turn
Stops are provided to limit both minimum and maximum

/ positions of the screw within the foHowing angle and
$WA$HPLATE
displacement per revolution range.
PUMP SWASHPLATE DISPLACEMENT I

SIZE ANGLE
I
L15 20 to 150 0.135 in J rev. to .913 in 3 rev
L23 5° to 17° 0.378 in.l·rev. to 1.41 In] rev.
L38 7° to 18° 0.9 in.3 rev. to 2.3 in.J rev.

!
L50 o to 18° o to 3.15 in.J'rev.
L70 2° to 18° 0.4 in.3rev. to 4.26 in.J rev.
After adjustment. hold the screw in place and torque the

10ckJlut to 12·16 ft. Ibs.
~
Excessive torque may damage threads and
FLOW ADJUSTMENT allow setting to change during operation.
14
PRESSURE COMPENSATOR
CONTROL (PC)
...z
~ The following adjustment procedure is applicable for the
w
U
C
pressure compensator function on the pressure
compensator control, the flow and pressure compensator
~
is control and the remote pressure compensator control.
l The standard pressure compensator adjustment range is

500 to 3000 PSI (35 BAR to 210 BAR). The following
optional ranges are available.
_PRESSURE
250 - 1000 PSI (15 BAR to 70 BAR)
TYPICAL PRESSURE COMPENSATOR CURVE
25C - 2000 PSI (15 BAR to 140 BAR)
It is necessary to refer to the machine specifications for

specific control settings and any procedures peculiar to
adjusting the control on each machine.
1. The system relief valve should be set at least 300 PSI

(20 BAR) higher than the desired pressure compensator
setting.
2. The flow compensator function, if present, must be

disabled prior to adjusting the pressure compensator using
one of the following procedures:
a. Connecting system pressure to the flow compensator

feedback port will disable the flow compensator function.
CUTAWAY VIEW OF PRESSURE COMPENSATOR CONTROL
b. The flow compensator may also be disabled by

SYSTEM PRESSURE
CONTROL loosening the locknut on the flow compensator section and
SETTING turning the adjustment screw clockwise until solid.
3. Using an appropriate adapter, connect a high pressure

gauge (10,000 PSI) into the pressure line from the pump.
To set the pressure compensator requires

deadheading the pump. Take necessary
SYSTEM RELIEF VALVE
SET 300 PSI ABOVE
precautions of securing the work function so
CONTROL SETTING no movement of the load occurs, and also
TYPICAL SYSTEM SCHEMATIC USING that the system high pressure relief valve is
PRESSURE COMPENSATOR CONTROL
properly adjusted as noted earlier in
paragraph (1).
4. Start the prime mover and allow fluid to reach normal
operating temperature.
5. Note the high pressure gauge reading which is the

pressure setting of the pressure compensator. Refer to
machine specifications for proper pressure setting.
6. To adjust the pressure compensator loosen the locknut.

Then, using appropriate hex wrench, turn the adjusting
screw clockwise to increase setting or counterclockwise to
decrease setting.
15
\
If the pressur~ setting does not increase in response to

turning the adjustment screw clockwise, the system relief
valve may be Improperly adjusted.
7. Once the desired pressure setting (shown on the

pressure gauge) is obtained, hold the adjustment screw in
place and torque the locknut to 16-20 ft. Ibs.
NOTE
Cycle pump 2 or 3 times to insure pressure

setting is maintained.
PRESSURE ADJUSTMENT ON THE FLOW PRESSURE CONTROL
L 15, L23, & L38 L50 & L70

210 3000r------,-----,.----'T'----, 210 3000~--~--~---r-----~~
(>
175
175 ~~
w
t$
a: ~
;:) ~
D'
w 140 VI 2000 t;)(S
~2OOO
VI ftj
140 w
VI a:
Q"
VI
W
, a: ~
Q" 105 z
~
i=
105 <I:
z VI
i= zw
<I:
VI 70 Q" 1000
Z :IE
w 0
70 Q,,1ooo
:IE
u
0
u 35
35
0
0 1 2 3 4
a: PRESSURE ADJUSTING SCREW

<I:
enQ" (REVOLUTIONS)
o CD
o 1 2 3 4
a: PRESSURE ADJUSTING SCREW
<I: (REVOLUTIONS)
CD
16
FLOW COMPENSATOR 5. Turn the flow compensator adjustment screw in until

system pressure equals the desired flow compensator
ADJUSTMENT (FP) pressure.
The flow compensator control also contains a pressure
compensator function which must be adjusted separately
as outlined on the previous page.
Before adjusting the flow compensator control, it may be

necessary to refer to the machine specifications for
specific control settings and any procedures peculiar to
adjusting the control for your machine.
E3
Adjustment of the pressure compensator
requires deadheading the pump. Take
necessary precautions of securing the work
function so no movement of the load occurs,
and also that the system high pressure relief
valve is properly adjusted as noted earlier in
paragraph (1).
1. Using an appropriate adapter, tee a high pressure gauge

into the high pressure line from the pump.
I,
The .l pressure setting is adjusted with the top adjustment

screw. The bottom adjustment screw is for the pressure
compensator. '
6. Once the desired .l pressure setting (shown on the

pressure gauge) is obtained, hold the adjustment screw in
place and torque the locknut to 16-20 ft. Ibs.
~~~~~~--~
SYSTEM
LU
2. Start the prime mover and allow fluid to reach normal

operating temperature.
3. Using appropriate wrenches loosen the adjustment

screw locknut and back the screw out (CCW) until spring
pressure is relieved.
4. A. If a closed center valve is used in conjunction with the

pump, read system pressure with the valve in the closed
pOSition.
B. If a closed center valve is not used, disconnect the

feedback line at the control and leave the control port
open. Plug the feedback line, bottom out a cylinder or
stall a motor function, and read system pressure.
17
MINOR REPAIRS
INTRODUCTION
"'t. o
The areas of repair indicated are classed as minor repairs
and may be performed, following the procedures In this
section. without voiding the unit warranty. Although
specific units are illustrated. these procedures apply to all
series and types of units in the Series L Family.
GENERAL
Cleanliness is a primary means of insuring satisfactory
pump life, on either new or repaired units. Cleaning parts
by using a solvent wash and air drying is adequate.
providing clean solvent is used. As with any precIsion
equipment, the internal mechanism and related items
must be kept free of foreign materials and chemicals.
REMOVAL Of' A STANDARD CONTROL
Protect all exposed sealing surfaces and open cavities

from damage and foreign material.
It is recommended that all gaskets and o-rings be

replaced. All gasket sealing surfaces must be cleaned
prior to installing a new gasket. Lightly lubricate all o-rings
with clean petroleum jelly prior to assembly.
SHAFT SEAL
L1S. \.50, L70 STYLE SHOWN
Removal
Two types of shaft seals are used on the L Series pumps.
The L 15. LSO and L70 models each utilize a seal retainer
and O-ring. The l23 and L38 models. however. use a
replaceable seal and retaining ring only. Refer to the
appropriate instructions which follow for seal
replacement. Please note: The seal retainer on the L50
manufactured after seriel no 84-50XXXX has been
eliminated.
Using retaining ring pliers. remove the retaining ring from
the shaft end of the pump.
L1S, L50. L70 MOOELS L.23 AND L.3I MODELS
[...--~!---.,~J
The retaining ring holds the shaft in the
housing on the L 15 model. Do not pull on the
shaft afte.r the retaining ring has been
removed. In the event the shaft is pulled
from the housing, do not attempt to slide it
back into the unit. .
The shaft aligns all cylinder block
components, which have probably now
become misaligned. Reinstalling the shaft
by sliding it back in will damage the cylinder
block assembly. Once the shaft has been
removed, it becomes necessary to remove
the end cap and cylinder block. Refer to the
major repair section of this manual.
18
MINOR REPAIRS
L15, L50 and L70 Models

Install a screw into each of the two threaded holes in the
face of the seal retainer. (The screws which hold the
control onto the end cap will fit.)
Pull or pry the seal retainer from the housing. The retainer
will. not come out easily as it is held in place by a large
a-ring.
Using a seal driver or similar tOol. remove the seal from
the seal retainer. Discard the seal when removed.
Remove and discard the a-ring from the outside of the
seal retainer.
I
L23 and L3S Models
'-.;4
Using a punch. or some type of sharp instrument.
puncture the shaft seal and gently pry it out of the
housing. Remove the old seal from the shaft and discard.
Installation
L15, L50 and L70 Models
Use a seal driver or similar tool to press a new seal into
the seal retainer. Make certain the seal is bottomed on the ~
counterbore within the retainer.
§3
Do not use excessive force as seal will be
damaged. '
Install a new o-ring on the outside of the seal retainer.
lubricate the o-ring with oil and slide the seal retainer over
the shaft and into the housing. Press the seal retainer into
the housing until the retaining ring groove is exposed.
Install the retaining ring with the beveled side out. Make
certain the retaining ring has snapped into the groove
completely.
L23 and L3S Models

lubricate the new seal with oil and carefully slide it over
the shaft. Make sure the shaft is covered or other
measures have been taken to protect the seal from
damage by the shaft keyway.
Press the seal into place and securely install the retaining
ring in the groove within the housing.
CONTROL
Using an internal hex wrench, remove the four socket
head screws which hold the control on the end cap.
Remove the control and gasket from the end cap.
Remove the a-ring from the groove in the mating surface
STANDARD COfiITROL REMOVAL
of the control.
19
MINOR REPAIRS
It is suggested that a new o-ring be installed on the contrOl

and a new gasket placed on the end cap mating surface.
Make certain the large hole on the gasket will mate with
the o-ring on the control when assembled.
Place the control on the end cap and reinstall mounting

screws. Tighten to 61-69 in. Ibs. torque.
NOTE
The standard controls, which include the
NOTE ORIENTATION OF GASKET WITH RELATION TO ().RING pressure compensator, remote pressure
compensator and flow and pressure
compensator controls, for the L15, L23 and
L38 are interchangeable between the three
models. Likewise, the standard controls are
SPAtNG
interchangeable between the L50 and L70
RETAINER
models. All other controls are not
interchangeable.
STANDARD CONTROL
DISASSEMBL Y
LOCKNUT
If the control is not performing properly because of a
sticking or contamination, it can be further disassembled
for cleaning or repair.
Using appropriate wrenches, loosen the adjustment

screw locknut and remove the adjustment screw. The
control spring and spring retainer can now be removed
from the cavity.
Using an internal hex wrench remove the threaded plug

from the opposite end of the control and remove the
control spool.
Flush the control cavity with clean solvent and wash all
WHEN REASSEM8UNG CONTROL 8E SURE SPOOL IS NOT REVERSED
parts in solvent and air dry. Examine spool and cavity
surfaces for nicks or scratches and replace any parts
found to be defective.
Replace spring and spring retainer in cavity

from adjustment end and reinstall
adjustment screw and locknut. Install control
spool in opposite end of control and install
plug. Insure that orientation of spool is
REMOTE PRESSURE {J~ '-F'~~:~~'~PRESSURE
z ~::,
correct.
G-' -
COMPENSATOR CONTROL ' • • _ COMPENSATOR
• '" - , ADJUSTMENT
FLOW AND PRESSURE . '.,

~ ~;;;-.r:-' FLOW COMPENSATOR
Reinstall control on pump housing replacing
o-ring and control gasket as part of the
COMPENSATOR CONTROL
PRESSURE COMPENSATOR
~: i;
CL - .; _..
• >,
' -oJ
,.'."
.. '.
ADJUSTMENT
PRESSURE
COMPENSATOR
procedure .
CONTROL ~ --- ADJUSTMENT Refer to control adjustment procedure in this

manual and set control for maximum system
pressure.
EXPLODED VIEW OF STANDARD CDNTROL

20
MAJOR REPAIRS - DISASSEMBLY
INTRODUCTION
The major repairs explained in this section will affect the
unit warranty; therefore, the equipment manufacturer
should be consulted prior to undertaking such repairs.
The following procedures have been written to cover all

Series L models. However, because of differences in
bearings and trunnions between the models, the
procedures are divided into various sections. Proceed
with disassembly and reassembly as follows, referring to
those steps which cover "All Models" or the model on
which you are working. Be sure to accomplish steps in the
order that appear in this manual.
Thoroughly clean the pump prior to disassembly.

Cleaning with a solvent wash and air drying is adequate,
providing clean solvent is used.
SHAFT SEAL REMOVAL
TYPICAL CONTROLS NEEDED FOR REPAIRS

L23, 38, 50 & 70 Only
Remove the shaft seal as outlined in Minor Repairs

procedures. The shaft seal must be removed before the
end cap screws are loosened to prevent the seal being
damaged.
SHAFT SEAL REMOVAL

L15 Only
Do not remove the shaft seal on the L-15 model at this

time. It will be removed at a later stage in the repair
procedures.
END CAP REMOVAUDISASSEMBLY

REMOVING RETAINING RING All Models
Remove the control valve as outlined in the Minor Repairs
section of this manual.
Using appropriate wrenches, remove the protective

locknut from the maximum flow adjustment screw.
Using the proper wrench loosen the four socket head bolts
which hold the end cap to the pump housing. Remove two
of the bolts OPPOSite each other.
END CAP REMOVAL
21
.J There is an internal loading on the end cap and as the last

two screws are loosened. it should begin to separate from
the housing. Loosen the screws alternately until the end
cap has separated from the housing. then remove the
screws entirely.
The end cap can now be lifted off the pump. However. be
certain that the valve plate does not fall and become
damaged. If the valve plate tends to lift off with the end cap.
hold it in place and remove both parts together. If the valve
plate remains on the bearing plate. remove it at this time.
REMOVING THE END CAP
All surfaces exposed are critical and caution

must be used to avoid damage. Surface
damage will cause low efficiency or even a
totally inoperative pump.
Remove the control cylinder by sliding it off the cylinder
rod .
CONTROL CYUNOER BEING REMOVAL OF VALVE PLATE

Do not attempt to remove the tube around
REMOVED which the control cylinder was fitted. The
tube was pressed into the end cap during
manufacturing and is not replaceable.
Remove the valve plate from the end cap.
Remove the valve plate locating pin.
Using an internal hex wrench, remove the maximum flow

adjustment screw by turning it clockwise through the end
cap. The adjustment screw may be pulled through the
cylinder rod once the threaded portion of the screw has
surpassed the threads in the end cap.
THE ADJUSTABLE VOLUME UMIT CONTROL MUST IE REMOVED BY Remove and discard the o-ring from the adjustment screw.
SCREWING IT THROUGH THE END CAP -
BEARING REMOVAL
Model L-15 Only
Inspect the needle bearing in the end cap. If the bearing is
not damaged, worn or contaminated it is not necessary to
remove it from the end cap.
If the needle bearing needs to be replaced. a bearing puller

will be required to remove it from the end cap.
ADJUSTABLE VOLUME UMIT MOOEL L15 ONLY USES A

CONTROL ROO AND ()'RING REAR NEEDLE BEARING
22
BEARING REMOVAL
L23, 38, 50 and 70
Remove the bearing race from the end cap. The race is
installed with a slip fit. Note that there may be shims
installed between the bearing race and the cap to adjust
end play. Retain these shims for reassembly. Loss of
these shims will result in improper end play causing
reduced bearing life and possibly reduced pump
performance.
Using a clam type bearing puller, remove the tapered

roller bearing from the shaft. Care must be taken not to
BEARING SHIM END CAP GASKET
damage the cylinder block surface or contaminate the unit
during this operation. A spacer is also required to protect
the end of the pump shaft from damage by the puller
screw.
ROTATING GROUP REMOVAL

All Models
Remove the end cap gasket from the pump housing.
With the pump laying horizontally, slide the cylinder block

assembly off the shaft while holding the external end of '
the shaft.
REMOVAL OF SHAFT CYUNDER BLOCK KIT
BEARING BEING REMOVED If the cylinder block assembly does not remain together
during removal, it can be reassembled at a later time. The
rotating group consists of a retainer. retainer guide,
washer (on L 15, L38 and L70 only), three pins, nine
pistons and the cylinder block.
Remove the thrust plate from its counterbore in the

swashplate. The thrust plate may be difficult to remove
due to the oil between the flat surfaces of the thrust plate
and the swashplate. Avoid damaging all critical surfaces.
RETAINER
TRUNNIONS
RETAlNERou:O <4-WASHEA
-'(USED ON L15. L38
AND L70 MODELS ONLy) Dependent upon the particular pump model there are four
different trunnion types which may be encountered. In the
disassembly and assembly instructions these will either
SWASHPLATE
be designated as bolt style or pin style.
Figure 1
JOURNAL --t--t Figure 1 is a bolt style trunnion which uses a journal

BEARINGS
bearing. The outer journal is pressed into the swashplate.
This design may be found on all current L 15, L23, l38
models.
ALL CURRENT L15. L23 AND L38 MODELS
FIGURE 1
23
Figure 2
~SWASHPlATE Figure 2 is a bolt style trunnion which uses two separate

JOURNAL~
BEARINGS -- ! journal bearings. The inner Journal bearing is pressed
onto the trunnion. The outer journal is pressed into the
L-_ ; i swashplate. The design may be found on L50 and L70
Super Quiet (Industrial) models.
L-- TRUNNION
LSO AND L70 SUPER QUIeT (INDUSTRIAL) MODeLS
FIGURE 2
Figure 3
TAPERED ROLLER BEARING
Figure 3 is a bolt style trunnion which uses a tapered roller
bearing. The bearing cone is pressed onto the trunnion
and the cup is pressed into the swashplate. This design
may be found on L50 and L70 Quiet (Mobile) models.
LSO AND L70 QUIET (MOBILe) MODeLS
FIGURE 3
Figure 4
Figure 4 shows a pin style trunnion. A needle bearing is

fJ.--SWASHPLATE
pressed into the pump housing. The trunnion shaft is
ROLL PIN---I~~§c5 connected to the swashplate by a roll pin. This design
may be found only on early model L 15 and L38 units.
SEAL
TRUNNION REMOVAL
Pin Style (Early L15 and L38 Models)
eARLY L 15 AND L38 MODeLS Note: The pump shaft on the Model L 15 may be removed
prior to trunnion and swashplate removal if desired. On
FIGURE 4 this model only, the shaft is removed from the front and
can therefore be removed at anytime.
This will allow for additional access for removal of the

trunnion shafts. The model L38 has a front roller bearing
and requires swashplate removal in order to remove the
shaft.
Using a small flat blade screwdriver. remove the retaining

ring from both trunnion shafts. These retaining rings are
the spiral type which may be reused later if not distorted
during removal.
Remove the washer from both trunnion shafts.
24
Using a round flat point punch. tap each spring pin which
fastens the trunnion shaft to the swashplate until the pin is
inserted into the trunnion shaft.
S TOP RING TRUNNION Do not attempt to drive the spring pin completely through.
as the bottom side of the swashplate is not drilled.
~"""."
SPRING PIN
TRUNNION PIN REMOVAL
Using a rubber or plastic hammer and a soft blunt object

(such as a wooden dowel) tap each trunnion shaft into the
housing to remove it.
REMOVAL OF TRUNNION SHAFT
Once the trunnion shafts have been taken out, remove

the spring pins by tapping the completely through the
shafts.
Lift the swashplate out of the pump housing.
Lift the spring retainer and bias spring out of the pump
housing.
SWASHPLATE AND BIAS SPAING BEING REMOVED
.,'
I,'
, . Using a hammer and a small flat point punch, remove both
trunnion seals by tapping them to the outside of the
housing. 00 not damage the trunnion needle bearings if
they do not need replaced. Discard the seals when
removed.
Removal of the trunnion needle bearings should be done

with an arbor or other similar type press. Press the bearing
through the trunnion bore toward the inside of the housing.
A spacer must be used between the press and the
bearings.
The bearing should not be driven out of the bore, as this

may result in damage to the bore.
REMOVAL OF TRUNNION SHAFT SEAL AND NEEDLE BEARING
25
MAJOR REPAIRS· DISASSEMBLY
2iS$lAiQ . '.- TRUNNION/SWASHPLATE REMOVAL

\ Roller Bearing Style (L50 and L70 Quiet
(Mobile) Models)
With a punch or metal scibe, mark right and left trunnions to
insure reassembly to the correct side of the housing.
Using a wrench remove the three hex head screws from

each trunnion.
MARKING TRUNNION REMOVING TRUNNION SOlTS

lOCATION
With a slide type puller, remove trunnions from the

housing.
The trunnion may also be removed by using a soft blunt

.
• object to drive it out of the housing from the inside .
Be certain to keep the plastic shims with the proper

trunnion to insure satisfactory bearing adjustment after
reassembly. .
After both trunnion assemblies have been removed. the

swashplate can be removed from the pump housing.
TRUNNION REMOVAL ON lSO/70 UNITS

housing.
TRUNNION/SWASH PLATE REMOVEL

JOURNAL BEARING STYLE
(All Models)
With a punch or metal scribe, mark right and left trunnions
to insure reassembly to the correct side of the housing.
Using a hex or internal hex wrench as needed, remove the

three cap screws from each trunnion. .
Remove each trunnion by using a soft, blunt object to drive

MARKING TRUNNION REMOVING TRUNNION
LOCATION BOLTS it out of the housing from the inside.
Remove o-ring seal from each trunnion and replace with

new o-ring prior to reassembly.
After both trunnion assemblies have been removed. the

swashplate can be removed from the pump housing.
housing.
GENTLY TAP OUT THE TRUNNION ANO O-RING

TRUNNION REMOVAL
26
SHAFT/FRONT BEARING REMOVAL

L15 Only
Using a pair of retaining ring pliers, remove the shaft seal
retaining ring.
With a rubber or plastic head mallet. tap the pump shaft

on the end cap end so the shaft and seal assembly are
removed from the pump housing.
Slide the seal off the shaft after it has been removed from
the housing.
If the shaft bearing requires replacement. remove the

retaining ring from the bearing end of the shaft.
The bearing can now be pressed off the shaft using an

arbor type press. Use care not to damage any area of the
shaft.
DRIVE SHAFT AND BEARING REMOVAL
SHAFT/FRONT BEARING REMOVAL

L23, 38, 50 & 70
Once the swash plate has been removed, the shaft can be
easily removed from the end cap side of the housing. The
front bearing is pressed onto the shaft and will be
removed with the shaft. However, the bearing race will
remain in the housing .
<
.
~
•
.
The tapered bearing can be pressed off the shaft if
.-'/;)~ft/\- ~ necessary. Be careful not to damage the seal diameter of
the shaft whiie removing the bearing.
,.. ':.'~...:ii,:b-~.~ ..
ALL MODELS
Thoroughly clean and inspect all parts. Examine for nicks,
burrs, scoring discoloration, etc. Replace all damaged
parts.
EXP\.OOEO VIEW OF PUMP SHOWING PUMP AND THE

THREE STANDARD CONROLS
27
MAJOR REPAIRS - ASSEMBLY
Assembly
Make sure all parts have been thoroughly cleaned pnor to
assembly. Cleaning with a solvent wash and air drYing is
adequate, providing clean solvent is used. Reassemble
with new a-rings and gaskets. Lubricate all a-rings pnor to
installation with clean petroleum jelly.
SHAFT BEARING INSTALLATION

All Models
Press the bearing onto the shaft if previously removed.
When pressing on the shaft bearing for the L 15 model.
make sure the writing on the bearing is toward the seal
end of the shaft. The bearing must be pressed on until It
rests on the shoulder of the shaft as illustrated.
On L 15 models, install the retaining ring on the shaft

ahead of the bearing. Make certain the ring is completely
seated in the groove.
SHAFT INSTALLATION
L23, 38, 50, & 70
Press new bearing race into the housing if it was
previously removed or if a new bearing cone was mstalled
on the shaft.
Insert the shaft and bearing into the housing.
Replace shims in the end cap if removed upon

disassembly and install the bearing race.
If a new bearing was pressed on the shaft, a new race

must also be installed.
Refer to page 32 about shim thickness if drive shaft.

bearings, housing or end cap are being replaced .
.:
' .=...__.._~'~
11__
1- ~
BEARING SHIMS
28
"- 4 P ~ When properly installed the bearing race will protude

approximately 7/64" above the surface of the end cap. It
functions with the small pin installed in the end cap to hold
the valve plate in the proper pOSItion.
Shaft and play must also be checked after complete

assembly to insure proper setting.
END CAP ASSEMBLY

All Models
Install the valve plate locating pin in the end cap. The pin
will protrude from the housing approximately .050-.094".
CHECKING PROPER BEARING RACE PROTRUSION
Install the end cap gasket onto the housing being certain
the locating pins are in place.
Install a new a-ring on the maximum angle adjusting

screw. The a-ring must be well lubricated prior to
installation. .
END CAP/HOUSING O-RING INSTALLATION ON

GASKET ADJUSTABLE YOLUMI! UMIT
ROO
Install the maximum flow adjustment screw (threaded end
first) into the cylinder rod.
Using an internal hex wrench, tum the adjustment screw

counterclockwise until the screw is against the internal
thread stop. This is the maximum flow position.
Lubricate the end cap face with clean hydraulic oil. Then
install the valve plate so that the slot locates over the
locating pin and the center bore fits over the protruding
needle bearing or bearing race.
Lubricate the cylinder rod and the inside of the control

cylinder with clean hydraulic oil. Slide the control cylinder
IHSTALUNG YOLUME UMIT POSITIONING YALVE PLATE
AND ADJUSTMENT ROO ON BEARING RAce AND PIN onto the cylinder rod.
TRUNNION/SWASHPLATE
INSTALLATION
Bolt Style
Install bias spring and spring retainer into the housing.
Insert the swashplate into the housing insuring that spring

retainer is completely inserted in the hole in the back side
of the swashplate.
BIAS SPRING AND THRUST PLATE AND

RET....NER INSTALLATION SWASHPLATE BEING INSTALLED 29
MAJOR REPAIRS - ASSEMBL V
Install the trunnions. insuring that each is Installed on the

correct side of the housing and oriented correctly. When
installing roller bearing style trunnions (on L50 and L70
Quiet (Mobile) models only) make sure all shims are
assembled with the correct trunnIons.
When installing journal bearing style trunnions make sure

a new o-ring has been installed on each trunnion shaft
and carefully drive trunnions into place.
Install cap screws in each trunnion and tighten to

specified torque.
JOURNAL SEARING STYLE
UNIT TRUNNION BOLT TORQUE

FT.-LB .
•. I.' • ."
L15 7-9 ft.-Ibs.
L23 7-9 ft.-Ibs.

L38 7-9 ft.-Ibs.
L50 16-21 ft.-Ibs.
L70 27 -37 ft. -Ibs.
ROLLER SEARING STYLE
TRUNNION/SWASHPLATE
l~
INSTALLATION
Pin Style (Early L15 and L3S Models)
Using an arbor type press, install a new trunnion needle
r-,/~~,3.
bearing in each trunnion if previously removed. The
. ~
bearing must be oriented so that the writing on the
bearing cage is toward the outside of the housing.
Press the bearing in until it is flush to .016" (.4mm) below

the counterbore for the trunnion seal.
NEEOLE BEARING STYLE

§3
Do not drive the bearing in with a hammer,
as this will result in damage to the bearing
and possibly the trunnion bore.
30
Install the trunnion seal in each trunnion. These are a

press fit, so care must be taken not to use excessive force
which might damage the seal. Press the seal in until it
touches the bottom of the seal counterbore.
Install the bias spring and spring retainer into the housing.
Prior to installing the swashplate, engage a new spring

pin in each spring pin hole in the swashplate. Do not tap
the pins too far into the swashplate or the trunnions will
not slip into place.
Insert the swashplate into the housing insuring that the

spring retainer is completely inserted in the hole in the back
side of the swashplate.
With the swashplate in place. slide the trunnion shaft

through the trunnion bore of the housing and into the
swashplate. Make sure the spring pin holes in the shaft and
the swashplate are in alignment. It may be necessary to
use a rubber or plastic head mallet for final positioning.
Once the trunnion shaft is in place. insure that the oil seal is
not damaged.
Use a round flat pOint punch to tap the spring pin into the
swashplate until the top of the pin is .060 - .125" below the
surface.
Follow the exact procedure for the other trunnion shaft

installation.
Install the trunnion washer.
Install the spiral retaining ring on the trunnion shaft. Make

certain the retaining ring is completely seated in the
groove.
Repeat trunnion washer and retaining ring installation on

oPPosite trunnion.
31
MAJOR REPAIRS - ASSEMBL V
SHAFT INSTALLATION
L15 Only
Install the pump shaft assembly into the housing,
Although this should be a slip fit. tapping the end of the
shaft with a rubber or plastic type mallet may be
necessary.
Install the shaft seal and retaining ring as outlined 10 the

minor repairs section of this manual.
ROTATING GROUP ASSEMBLY

All Models
Lubricate the thrust plate with clean hydraulic all and
install it into the counterbore of the swashplate. Make
certain the thrustplate lies flat against the swashplate
face.
or- Prior to assembly of the cylinder block: inspect the

pistons. retaining ring. retaining guide. washer and pins
for damage, contamination or excessive wear. Replace
any parts found to be defective. If one or more pistons are
found to be defective. it is necessary to replace the
complete cylinder block kit.
RETAINING GUIOE ______ .
Install locating pins in neck end of cylinder block.
WASHER "'-
---~~~~---,~
On L 15. L38 and L70 models place the washer on the
three pins. Install the retaining ring guide on the washer.
PIN:-Fl_~ Place retaining ring over retaining ring guide as

illustrated. The guide should protrude through the center
of the retaining ring. Make c;ertain the washer remains
centered under the retaining ring guide.
BLOCK
Note: On L50 and L70 models, after serial no.84-36XXXX

have brass cylinder blocks and a mating steel valve plate.
Lubricate each of the pistons with clean hydraulic oil and

install through the retaining ring and into the block.
Lubricate the slipper pads with clean hydraulic oil.
Then place the pump in a horizontal position and slide the

cylinder block assembly onto the shaft and against the
thrust plate. Use care that the washer and retaining guide
do not come off the locating pins.
32
When properly installed. a spring load can be felt when

pushing against the cylinder block.
Stand the unit vertically with the shaft seal down to insure
all parts remain in position. Then rotate the cylinder block
two or three times to confirm that the piston slippers are
completely in contact with the thrust plate.
END CAP BEARING INSTALLATION

L15 Only
Press a new needle bearing into the end cap if the old one
, was previously removed. The writing on the end of the
bearing cage should be visible when the bearing is
installed.
Press the bearing in to the point that it protrudes above

the end cap .088-.098"
END CAP BEARING AND BEARING

RACE INSTALLATION
L23, 38, 50 & 70
Install the tapered bearing on the ..:mp shaft with an
arbor type press for the most satisfactory results. The
bearing must not be driven onto the shaft. Press against
the inner race of the bearing and use care not to damage
the roller cage.
The bearing must be pressed on until it rests on the

shoulder of the shaft to insure adequate bearing
clearance.
An alternative method of installing the bearing is to use

the bearing puller bar and press the bearing onto the shaft
with the center screw of the puller bar. A spacer must be
used between the 'center 'screw and the bearing.
33
• Lubricate the valve plate and the cylinder block with clean
hydraulic oil. Install the end cap while holding the valve
plate in place so it does not drop off during assembly.
Install the four socket head bolts which attach the end cap
and tighten alternately until the internal spring has
compressed far enough for the end cap to rest on the
housing. Tighten bolts to the following torque value for
each model.
SIZE TORQUE
U5 35-45 It.-Ibs.
L23 62-80 It. -Ibs.
L38 62-80 It. -Ibs.
L50 35-45 ft.-Ibs.
L70 35-45 ft.-Ibs.
Replace the lock nut on the maximum angle adjustment

screw and torque to 12-16 ft. Ibs. Remember that the rod
will need to be correctly adjusted for the application after
the pump has been primed.
On L23. 38. 50 & 70 models. it is now necessary to install

shaft seal retainer and retaining ring as instructed in the
Minor Repairs section of·this manual.
Reinstall the control assembly as outlined in the Minor

Repairs section of this manual.
If any of the following components have been replaced.

the shaft end play must be checked.
Drive Shaft Housing

Bearings End Cap
All parts and gaskets must be assembled prior to

checking end play. If adjustment is necessary. the pump
must be partially disassembled and a shim of the proper
thickness installed under the bearing race in the end cap.
The shaft end play should be between .003 and .015" on

L23. L38. L50 & L70.
If the unit will not be installed immediately. cover all

openings (ports. fittings. etc.) to prevent oxidation and
contamination.
The pump housing and all hydraulic lines

must be filled with clean hydraulic oil prior to
start up.
34
GENERAL PARTS IDENTIFICATION
MODEL L15
Bulletin 9925
May 1985
NOlLTR DESCRIPTION QTY NOlLTR DESCRIPTION QTY
1 Lock Nut 1 26 Lip Seal - Shaft

2 Socket Head Bolt 4 27 Seal Retainer
3 Plug 1 28 a-Ring
4 End Cap 1 29 Retaining Ring
5 Locating Pin - End Cap 2 30 Key
6 End Cap Gasket 31 Shaft
7 Locating Pin - Valve Plate 32 Bearing - Front
8 Bearing - Rear 33 Retaining Ring
9 Valve Plate A End Cap Kit
10 Cylinder Block Kit B Control Valve Kit
11 Flow Adjustment Screw 1 48 a-Ring
12 O-Ring -1 49 Gasket 1
13 Control Cylinder 1 50 Socket Head Bolt 4
14 Thrust Plate 1
15 Swashplate 1 Early Models
16 Spring Retainer 1
17 Spring 1 40 Retainer. Ring Trunnion 2
18 Socket Head Bolt 6 41 Trunnion 2
19 Trunnion 2 42 Washer 2
20 O-Ring 2 43 Up Seal. Trunnion 2
21 Joumal Bearing 2 44 Bearing. Trunnion Needle 2
22 Housing 1 45 Housing 1
23 Name Plate 1 46 Swashplate 1
24 O-Ring 47 Swash plate Pin 2
25 Plug
35
~~~"!!ydro-Tra~~~ a BulletIn 9
III ..... • ,."e ~"'.e -- ."""., .,..... ....., 18 SERIES

OPEN C1RCU
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Iff. T-18-130 SUNOSTRANO CORPORATION RIIN OATE 03-1';-7A
tfVORO-TRANSHISSION DIVISION PARf I
~ - I~ WARRANTY PARTS SERVICING SfRVICE PARTS LIST
tOIlEL NO. - lA-l016 OESCRIPTION - PUMP VAH REVISION nATE - 00-00-00 AfVISION NO. -
fOR PART REfERE~CE IO[NTlfICATION SEE BULLETIN 9128
:, T KIT NUMOfR (JTV / PART PART NIIHAf.R IHY/ SIlPERCfOEO Rfv
:ff KIT NUM8ER DESCRIPTION ... OflEl. H€f PARt NII ... AER DESCRIPTION MOOEl PART NUMBER NO
012 Jl110216 HOUSI"'r, I
021 JI110218 END CAP LH I
0')0 Jll10281 SWASH PLATE I
028 JI120344 PLA TE VAL VF. lti I
022 JllZ04?Q StiAfT nRIVE I
011 JI110193 PLATE THRUST I
029 JI130394 CYL BLOCK KIT I
Oil
OIl
JI130391
JI130398
COVER SEAL
RETAIHER SPfHNG ,
I
008 JI130399 RASKET END C'P I
002
014
JI140691
JI140104
CAP
SPRING ,
1
014 JI140105 SHAFT TRUNNION 2

036 JI140106 WASHER 2
009 JI140101 CONTROL CYl I
001 JI140108 ROO CYLINDER I
001 JI140110 SCREW AD.JUST I
010 Jl140118 NAME PLATE I
019 JI140119 SEAL liP I
OZ4 J1140186 SOCKET HEAD ALf 4
015 JI140190 RING RETAINING 2
020 J114019? RING RETAININB 1
019 JI140196 PIN SPRING 2
018 JI140199 o RING 1
016 JI740800 PLATE ARROW 1
011 J1140801 ORIVE SCREW 4
005 JI140802 o RINR 1
018 9001465-0002 REARIHR NEEOLE 2
011
026
9004201-5000 .
9004800-1908
o RING
PI~ ST HOLS ,
I
021 9004800-2506 PIN ST HOLS 2

012 9005100-7500 PLUG Sf THO I
012 9008' 081 SEAL liP 2 9008000-
025 9510c .. 8E4f~INfl KIT I
Hff. T-IH-130 swmSTHA'''O CORPORATION RUN DATE 03-1~-lA
.. YHRO- TI~ANSM I S5 ION 01 VI S ION PARE 2
• - IN WARHANTY PARTS SERVICING SfHVICE PARJS LIST
HOf)fL NO. - 18-101h OfSCHIPTION - PIJMP VAH REVISION OATE - 00-00-00 A[VIS.ON NO. -
fOR PART ~Ef[HENCE IOENTlflCATION SfE AULLfTIN 9128
KIT KIT NUMAER C~TY PMH

/ PART NUMlifR tHY/ SlJPERCFOfO RfV
RF.f KIT NU~HER OfSCAIPTION MOOfL. H£f PART NUMOER IlESCAIPTION MOOFL PART NUMOfR NO
015 9510295 HEMUNG KIT 1
A Q510384-0002 KIT CONT VALVE 041 .Jl120378 HOUSING VALVf 1

046 .11740631' SPOOL 1
Olt*\ J17~0644 OtHflCE I
054 J)140692 SCHEW AOJUST ?
05l J174069'5 SPRING 1 )
osa; J1740691 LOCK NUT 2
OltO. J114069*\ GASKET 1
049 J)1401l3 AETAINfR SPklNG ?
OSO Jl1401l4 SPRING 1
044. J) 140111 SPOOL )
04?* J174078R SOCKET .. f.AO ALT 4
045 Jl140789 PLUG 2
043 J1140191 o RING 1
053 J114019A o RIMG ?
052 9004800-3110 PIN Sf ..OlS 1
047 9005415-0001 PLUG SPECIAL 2
CORPORAT~N
HYDRAULIC ROTARY COUPLING (Calavar Part No. 32554)

INSTALLATION PROCEDURE FOR TEFLON RINGS
• EQUIPMENT NEEDED:
1. Heating container (NESCO oven or equivalent).
2. One (1) pair of heat resistant gloves.
• OPERATION:
1. Insure coupling is free of foreign matter.
2. Place teflon rings in oven until 300 F to 350 F is
0 0
reached.
CAUTION---Do not exceed 500 F
0
(Rings should turn dark in color and become elastic.)

3. Grasp a ring (using gloves) and slip over end of
coupling to groove.
CAUTION---Do not stretch rings, as
they will NOT return to size.
Speed is essential before contracting occurs.
4. Insure ring is not twisted when installed in groove.
• NOTE: Rings that are loose on coupling can be sized by

compressing with suitable hose clamp.
HYDRAULIC ROTARY COUPLING
(CALAVAR PART NO. 32554)
MeV-ISO VALVE SYSTEMS
INSTALLATION
START-UP
&
TROUBLE-SHOOTING
GUIDE
5/9/86
MeV-ISO VALVE SYSTEMS
INSTALLATION ~ MAINTENANCE
General
Filtration: 25 micron, return line
Fluid viscosity: 35 to 1750 SSU
Temperature: -40 degrees F. to +180 degrees F.
Seals: Buna N standard .
Specify viton if required
Pressure: 3000 PSI maximum
Return Line Pressure: sao PSI maximum
Inlet Flow: 40 GPM max~um
Installation
Mounting: The MCV-ISO will function in any mounting
position. However, for optimum/long life
"", performance; mount so that the solenoids are
horizontal. When mounting a valve, be
sure mounting bolts or connecting pipe-work
do not overstress the assembly.
Sealing Compounds: Sealing compounds are not
recommended or required. All
ports are SAE straight thread
O-ring ports.
Solenoids: The voltage should be checked
against the imprint on the coil
prior to wiring (take care not to bend
the terminals).
Handle Position: The handle position may be
changed as follows: Remove four
mounting screws from the handle cap
assembly, lift handle cap upwards
(disengaging pinion gear from
rack), remove handle cap, and
rotate handle. Replace the
handle cap (engaging pinion gear
onto rack), and replace the four
mounting screws.
!vl~f1UL.;) rL.UUJ "'UWCt1
Page 2
Start-up
Pressure Setting: Before starting the pump, the relief
valve adjustment should be fully un-
screwed. Then, with the pump running
and one of the functions dead-headed,
adjust the maximum system pressure by
t~rning in the relief valve adjustment.
Note: For systems incorporating power

beyond, the power beyond circuit
must incorporate a maximum
pressure relief valve.
Bleeding: Air in the system will impair control and may
cause dangerous movement of a load. At
start-up the hydraulic system should be bled
at as many points as possible.
Dampening: (For systems incorporating the MUV
inlet only)
The dampening throttle is factory set. If
adjustment is required, remove the protective
screw cap and adjust the throttle screw
slightly. Keep in mind that the dampening
throttle will affect the response time of
the compensator. If the throttle is completely
closed, the compensator and the relief valve
will be completely eliminated from the circuit.
Nil"H(JL~ rLlJlU t'OwtH
Page 3
TROUBLE-SHOOTING
(1) System pressure too low

(2) Load does not move or moves at low speeds
(3) Load moves erratically
(system is oscillating)
(4) Poor control
(5) Pump does not destroke
(6) Pump does not unload
(7) Manifold shuttle valve locations
(8) Manifold shuttle valve removal/installation
instructions
:$!ffi !iJ ,
Page 4
1• SYSTEM PRESSURE IQQ LOW
For systems incorporating MUV inlet:
* Open dampening orifice, clean/replace as necessary.

* With dead-headed load, check relief valve setting,
adjust as necessary.
* Remove relief valve, inspect for damage. Replace

external o-rings or replace relief valve as
necessary.
* Remove MUV inlet spool, inspect, deburr, clean.

Replace MUV inlet as necessary.
For all systems:

* Isolate area of low pressure to all functions or
a single function.
If all functions are at low pressure, check
hydraulic circuit for additional relief valve{s),
check pump compensator setting. Adjust,
replace as necessary.
If a single function, check manifold shuttle
valve. (1)
(1) See Section 7 & 8
=£i:··5
NIf,.;HUL~ rLUIU I-'UWt:H
Page 5
2. LOAD DOES NOT MOVE OR MOVES AT ~ SPEEDS
FOR SYSTEMS WITH MUV INLET:
* Open dampening orifice, clean or replace

as necessary.
* Readjust relief valve using a pressure gauge.
For all systems:
* Check input signal electrical or hydraulic pilot.
* Return line flow may, be restricted, check

for correct plumbing.
* Manifold shuttle valve sticking/leaking. (1)

Clean, replace as necessary.
* Stroke controls preventing four-way spool shift.

Adjust as necessary.
* Output flow requirements exceed pump supply.

Make appropriate system design modifications.
'/(
Load sense bias pressure too low. Shim or
adjust per pump manufacturers recommendations
(typical load sense bias: 200 to 400 PSI).
'/(
Pilot valve spool, four-way spool, or solenoids
sticking: Swap with "good" section(s) to verify
problem. Clean, deburr, replace as necessary.

NI(.;HUL:::' rLUIiJ PUWcH
Page 6
Special Considerations:
Electric valves with auxiliary lever:
If four-way spool is sticking, check rack for
bending. Replace as necessary. Check for
proper engagement of the rack and pinion.
Adjust as necessary (refer to Page 8). Inspect
seals on pinion. If swelling or wear is present,
replace pinion/seal assembly. Do not use other
manual levers than those supplied with valve.
Heavy levers will cause the spool to drag
during electric actuation.
Electric valves:
When replacing solenoid assembly onto pilot valve,
care must be taken to prevent excessive
distortion of the flux tube: Torque four mounting
screws to 30 inch-pounds using a sequence of
torquing opposite screws (during mounting, end plate
distortion and subsequent effective torque increase
is acceptable. Effective torque should not exceed
45 inch-pounds).
NI("H(JL~ t-LUIU ~UWt::H
Page 7
3. LOAD MOVES ERRATICALLY AND/OR SYSTEM !§ OSCILLATING
* Air in system: Bleed at as many points as

possible.
* Electric valve pilot pressure collapse. Caused
.by light loads, negative loads, or holding
valves with high pilot ratios.
Artificially increase light loads with spring-
loaded check valve. Eliminate negative loads
with counter-balance valves, brake valves, or
pilot operated check valves.
Employ counter-balance valve, etc. with pilot
ratios of 3:1 or 4:1. High pilot ratios will
cause instantaneous pilot pressure collapse,
system oscillation, and associated noise.
Note: If load pressure of 200 PSI cannot be
assured, employ external pilot
pressure supply.
* If demand flow exceeds pump flow, pressure
compensation is lost. System design modification
is recommended.
Cartridge compensator (COM) may sustain damage
due to starvation. If suspected, remove COM and
inspect for spool breakage (if spool is broken
CDM cartridge will be in two pieces. The spool
may remain in the manifold when the CDM's
removed) •
* Severe load pressure fluctuations causing
oscillation/noise. Isolate and eliminate cause(s)
of pressure spikes. Dampen load sense signal to
MUV or load sense pump as necessary.
Page 8
4. POOR CONTROL:
Electric Valves
* Faulty input signal. Check controller
specifications. 55 to 70 Hertz pulse width
modulation (PWM) recommended for best
proportional control.
* Faulty solenoid. Swap with "good" solenoid to
verify. Replace as necessary.
* open pilot chokes (optional). Clean as necessary.
* Adjust controller threshold and/or maximum output
adjustment for best control from cracking to
full flow.
* Controller ramp adjustment should be set for
desired response.
Pilot Operated Valve:

* Check pilot supply pressure. Recommended
range: 50 to 200 PSI.
Manual (and auxiliary lever) Valves:
* Check proper engagement of rack and pinion. If
stiff, loosen lever cap, lightly tap lever cap up,
retighten screws. If sloppy, loosen lever cap,
lightly tap down, retighten.
* Check rack for bending.

Note: Rack is bent when large downward
forces are applied to lever. If
necessary, high pressure caps (option-G)
with rack support should be specified.
=-i9:. fj
Page 9
All Valves:
* Manifold shuttle valve sticking/leaking.
Clean, replace as necessary. (1)
* COM cartridge compensator damaged. Inspect,
replace seals, replace COM as necessary.
* Incorrect four-way spool (spool rated for higher
flow than required). Replace spool with one
of correct maximum flow (be sure COM flow rating
and four-way flow rating match).

Page 10
5. PUMP DOES NOT DESTROKE:

(Load-sinse/pressure compensated pumps)
* Four-way not in neutral position (verified

by seeing pressure at "Y" port or "L.S." port
when four-way is "in neutral").
Check rack and four-way centering spring assembly.
Both items are loc-tited and threaded into
four-way spool. If they work loose, four-way spool
may not find its true neutral position. If
necessary, place spool in soft vise, loc-tite
loose item and tighten onto spool.
Note: Four-way spool is not symmetrical.
Small load sense groove must be
located on "A" side.
* Load sense signal does not drain to tank.
Do not use auxiliary shuttle if "Z" port is
plugged. Remove auxiliary shuttle if
necessary. (1)
Manifold shuttle sticking. Clean, replace
as necessary. (1)
ii .19.::. !J
i .... /vjfUL~ t"LUIU I-'UhcH
Page 11
6. PUMP DOES NOT UNLOAD, PUMP UNLOADS AT HIGH

PRESS~DROP: -- --
(with all four-ways in neutral, fixed displacement
pumps will unload across the MUV at approximately
150 PSI).
Fixed Displaceme'nt Pump does not Unload:

* MUV spool sticking. Clean, deburr as necessary.
* Load sense signal does not drain to tank - see
pump does not destroke.
Fixed Displacement Pump Unloads at High PSI Drop

* Return line flow restricted, high return line
pressure. Check for correct plumbing.
* Four-way spool not in neutral - see pump does
not destroke.
NI("HOLS fLU/&) tJOWtk
Page 12
7. MANIFOLD SHUTTLE VALVE LOCATIONS

(drawing attached)
A. Two-function manifold
B. Three-function manifold
C. Four-function manifold
All drawings show optional auxiliary shuttle

valve location.
NICHOLS FLUID POWER
Page 13
8. MANIFOLD SHUTTLE VALVE INSTALLATION INSTRUCTIONS

(refer to attached drawing)
To Remove Shuttle Valve from Manifold:

(1) Remove appropriate construction plug
from manifold (see shuttle valve
locations).
(2) Screw threaded rod (4/40 NC-2B) into
shuttle valve (maximum thread depth
is .25").
(3) Pull rod and shuttle valve out with
pliers.
(4) If left in manifold, remove back-up ring.
To Install Shuttle Valve into Manifold:

(If possible, disconnect tank line from valve
to prevent back flow during assembly).
(1) Remove appropriate construction plug.
(2) Using pencil (eraser end) or similar
instrument, insert back-up ring (#1) into
bore, being sure back-up ring bottoms in bore.
(3) Same as step 2, insert o-ring (#2).
(4) Pre-assemble o-ring (13) onto shuttle valve.
(5) Insert shuttle valve into bore.
(6) Apply firm pressure until the o-ring and back-up
ring slip onto shuttle valve.
(7) Reinstall construction plug.
CORPORATION
RETURN LINE SPIN-A-FILTER (Calavar Part No. 32522)
GENERAL INFORMATION
• Spin-A-Filter from AMBAC Industries Incorporated is designed
for fast and simple maintenance. Twist off the old element.
Twist on the new. No bolts to remove. No time-consuming
cleaning operations. Takes less than a minute to change a
Spin-A-Filter element.
• Disposable filter element pays for itself with lower maintenance
and downtime costs. Designed for return line applications up
to 20 GPM (76 L/Min.). For use with petroleum-based oils in
mobile equipment operations.
• Filter assemblies are furnished standard with a by-pass valve
in the cast aluminum housing head. The integral by-pass
valve protects element against line surges.
• 10 micron filter element is standard (Calavar Part No. 67408).
RETURN LINE SPIN-A-FILTER
FILTER ASSEMBLY (Calavar Part No. 3252~
REPLACEMENT FILTER ELEMENT - 10 MICRON (Calavar Part No. 67408)
DIMENSIONAL DATA '---
~-ZOl/NCx~ (13MMJP€E,P - -
TW&> M&>vNrINt:i H&>I..~.s
-, I
rr~·~Z"
eZMA1I
I
7- 50 "
(/~ IMM)
,
3·8/"
(70MM I
.--/
ENGINEERING DATA
Port sizes...................................... 111 NPTF
By-pass valve setting, factory set ..•........... 25 PSID (1.7 BAR)
Nominal size particle retention rating ........•. 10 MICRON
. Operating pressure ..•........•..............•... 100 PSI (6.9 BAR) MAX.
Operating temperature .....•....•....•..•........ +250°F (121°C) MAX.
Performance ........•.•....•..•.•....••.......... 160 SSU @ 100°F (378°C)
FLOW AVERAGE PRESSURE DROP

~PM L/MIN 10 MICRON
5 19 2.0 PSI 0.14 BAR
10 38 5.5 PSI 0.38 BAR
15 57 9.9 PSI 0.68 BAR
20 76 14.7 PSI 1.01 BAR
~
SUNOSTRAND
MCHXXX
~ Control Handle
BULLETIN 95-8956-4
APPLICA T I O N - - - - - -
The MCHXXX Control Handle is intended for use in
open loop systems or as a setpoint for analog or micro-
processor closed loop systems for controlling position,
speed, pressure, horsepower or other dynamic para-
meters.
The Control Handle is designed to provide remote elec-

trical actuation of the MCV101 Pressure Control Pilot
Valve or other pilots for pressure and flow control servo-
valves as well as directly controlling main spool valves.
It may also be used to power the V7058 Hydrotransmis-
sion Valve for Sundstrand and Eaton pumps/motors, or
other electrically-actuated pump strokers such as the
MCV104 Electrical Displacement Control. LOAD RESISTANCE
Customer specified. See Ordering Information.
SWITCH CURRENT CAPABILITY

FEATURES------------ 3 amps inductive at 28 Vdc.
• Shock and vibration resistant
MECHANICAL
• Choice of three mounting styles, with or without
watertight case HANDLE STROKE
±30° (±.52 radians)
• Rugged components designed for the construction
environment SPRING TORQUE
11 ±4 in-Ibs. (1.2 ±.4 N-m) at center breakaway
• High-torque handle actuation gives sure feel 18 ±6 in-Ibs. (2.0 ±.7 N-m) at full stroke
• Simple to install DETENT TORQUE (OVER AND ABOVE FRICTION

DRAG)
• Mechanical options include center lock, spring-return, 6 in-Ibs. (.7 N-m I
friction drag, unilbi-directionality and Packard con-
nector FRICTION DRAG
11 ±.4 in-Ibs. (1.2 ±.5 N-m). Friction is adjusted at
the brake with a 5/32 English Allen wrench and 3/8
• Electrical characteristics customized to the applica-
tion open end wrench.
ENVIRONMENTAL
SPECIFICATIONS,---- TEMPERATURE
_400 to 1700 F (-400 to n° C) operating
ELECTRICAL _300 to 1500 F (_340 to 660 C) storage
OPERATING VOLTAGE
HUMIDITY
11-15 Vdc (12 volt models)
22-30 Vdc (24 volt models) After being placed in a controlled atmosphere of 95%
humidity at 490 C (1200 F) for 10 days, the Control
POWER
Handle will perform within specification limits.
See Ordering Information. SPECIFICA TlONS (continued page 2)
Sundstrand Mobile Controls

SPECIFICA TlONS (continued from page 1)
RAIN DIMENSIONS
After being showered yom all directions by a high See Figure 1.
pressure hose down, the Control Handle will perform
within specification limits (applied to cased models
only). lhis test fulfills NEMA 4 specifications.
VIBRATION
Withstands a vibration test designed for mobile equip-
ment controls consisting of two parts: PERFORMANCE
1. Cycling from 5 to 2000 Hz in each of the 3
axes. NULL CURRENT
2. Resonance dwell for one million cycles for each ±5 ma maximum if not switched
resonance point in each of the 3 axes.
CENTER DEADZONE (OPTIONAL)
SHOCK ±3° nominal
50 g for 11 milliseconds. Three shocks in both direc-
tions of the 3 mutually perpendicular axes for a total
of 18 shocks. FULL STROKE CURRENT CAPABILITY
Customer specified. See Ordering Information.
LIFE
Greater than 1,000,000 cycles excluding potentiome- STEP CURRENT
ters. Potentiometers with greater than 1,000,000 Customer specified. See Ordering Information. Step
cycles available for most applications. current occurs at end of deadzone.
PANEL CUTOUT AND PANEL CUTOUT

....
149.1
(S.I7)
I'ftm
MOUNTING PLATE SO.• 1ft'"
P' -------_ . _. - .,:----.--rt

~::!,:,mm~ .... 7.0 ...'"
1275, 2S.4 ",m
(1.00,
..-..-.25.• "'1'1'1
:
.
IS.S "un; i
I
'
'
:
13.Jm'"
(I ]11'
f.O~O'r':::'mm
1
3
(1.12'
~O.I"'m ._~
(1 HI ~4)t----- ...__ . - - - ~e--1 6&.6" .."
\2.00) . 6.2 mm
"'i
V·
~ ---.J~'
1 (~M
, I-filL
I ___
~t-:..........-,,; -- --~ - .-? "EMOV£ BURRS FROM BOTH

SIDES OF PANEL TO AVOID
. (...., 1505''''''~ \ DAMAGING BOOT
• (5.;], ~ ~OUNTING
--.
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(10.')
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~::~:, mm (l.l.). I
MAlIC,
SURFACE MOUNT TOP ~OUNT PANEL MOUNT SIDE VIEW

OF ALL
&. DIMENSIONS FOA REF ONLY UNLESS OTH£AWISE SPECIFIED PANEL MOUNT
&. INDICATES MAJ(, OIMENSION WITH CASE OMITTED
FIGURE 1. Dimensions of the MCHXXX Control Handle in millimeters (inches).
2 Sundstrand Mobile Controls 95-8956-4

WIRING-------------------------------------------
Three wiring styles are available for most Control
Handles. If no external cabling is ordered, access to
power, ground and the potentiometer(s) is gained
through a barrier terminal strip inside the handle's case.
The customer should run a cable from the strip through A failure may cause an output vvhich could
the connector on the side or bottom of the case. See activate the valve or pump. If this occurs, the ap-
Figure 2. A clockwise ~ handle movement causes a paratus may move, possibly endangering people or
current flow from terminal 8 to A when the terminal equipment It is strongly recommended that han-
strip is facing you. dles be equipped with a neutral OFF switch to pre-
vent this eventuality. For cases in which an active
neutral is necessary, an emergency shut down and!
or braking system sufficient to stop the system or
vehicle immediately should be provided.
In most applications, center-off and other switches must
be customer-wired, as shown in Figure 2. When the
Figure 4 demonstrates how to assemble the mating
switch is used as a center-off, power is connected from
Packard connector (male sheH, female sockets) shown in
the common 12 volt supply to the terminal labeled
Figure 3. The necessary parts are shipped in a bag assem-
"normally open". The switch terminals are 3/16" quick-
connect. Figure 3 shows a pre-wired Control Handle bly (Part Number 12499703) composed of six sockets
and one plastic connector body. .
with center-off switch and Packard connector, exhibiting
the handle phasing and color coding of the wires. WIRING (continued page 4)
n
-
( )
{ }
l J
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( 1
~ ~
@ @
@ DRIVEN MOTOR
~ 0 v=-. " jJ
~ ~OMNc;.~
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+12 VDC
- • A +
yo f 'Jt ?f" ~<?>IO I~ ~ :t 1 1\
GND 1U)
FIGURE 2. Center-off switch assembly and wiring connections for the Control Handle. If no center-off switch is used
the power lead should be wired to the "+" terminal on the terminal strip. Ground and A, B wires are attached through
the connector, at right.
95-8956-4 Sundstrand Mobile Controls 3

WIRING (continued from page 3)
~--- BLUE - POWERED WHEN HANDLE IS CENTERED
RED - I 2 VDC SUPPLY
YELLOW - POWERED WHEN HANDLE IS OFF CENTER
GREEN - VALVE DRIVE. HAN OLE FORWARD
WHITE- VALVE DRIVE. HANDLE REVERSE
BLACK - GROUND
& TOTAL LENGTH. I FOOT (WITH CONNECTOR) OR 5 FOOT (WITHOUT CONNECTOR)

& FUNCTIONS PROVIDED BY THE BLUE AND YELLOW WIRES ARE OPTIONAL.
FIGURE 3. Phasing and color scheme for handle with cable and connector.
TERMINALS (6)
12000232-00 I
(REF)
Figure 5 shows the location of the three trim potentio-
meters on the" L" handle. See the "Electrical Charact-
eristics" section of the Ordering Information.
In order to avoid damaging the Control Handle, a 1 amp

fuse wired in series is recommended for applications with
low current-drawing requirements.
& CRIMP BEFORE INSERTING TERMINAL INTO BODY
FIGURE 4. Packard mating connec:tor assembly.

I. MOUNTING (see Figure 1)
o 1. BASE, OR SURFACE MOUNT
Connection is via four screws to the flanges Cln the
bottom of the metal case.
o 2. TOP MOUNT WITH CASE

Connection is via two screws to an enlarged
mounting plate. Top mounting allows the entire
handle to be removed from above the panel. The
case is made of black nylon plastic.
o 3. TOP MOUNT WITHOUT CASE

STEP CURRENT AOJUST Same as 2, but without case.
FORWAR
REVERSE
J SPAN AOJUST,
OR
FULL CURRENT
OUTPUT
o 4. PANEL MOUNT WITH CASE
Connection is via four screws to the top plate that
holds the boot in place. The case is made of black
nylon plastic.
o 5. PANEL MOUNT WITHOUT CASE

Same as 4, but without case.
II. TYPE OF CONTROL KNOB

(see Figure 1)
o 1. NON·LOCKING
The non·locking handle has a standard ball knob.
The friction·held handle detents with a spring·
loaded ball to indicate nUll, while the spring·return
handle has a spring'preload indicating null.
FIGURE 5. Location of trim potentiometers on ilL"
Control Handles. o 2. CENTER·LOCK
The center·lock handle has a cylindrical knob and
ORDERING provides a positive center·lock that unlatches when
the operator pulls up on the knob.
INFORMA T I O N - - - - - -
A wide range of options to the basic Control Handle al· o 3. NON·LOCKING, AUXILIARY SWITCH
lows it to be custom·tailored to each application. The This knob is teardrop shaped, with an auxiliary
handle is specified by filling in each slot of the order momentary push·button switch on top. The
number, as is shown in Table 1. Other options are pos· switch is wired through the handle shaft to the
sible; consult Sundstrand with further questions. body with three wires (common, normally open
and normally closed).
TABLE 1. MCH Control Handle Order Number Matrix
III. HANDLE ACTUATION
MCH X X X X X X X X o A. SPRING·RETURN, BI·DIRECTIONAL
T T
This handle uses a torsion spring to return to the
mechanical center position, and has 30 degrees of
handle throw on either side of center.
DEVICE
SPECIFICATION
NUMBER
o B. FRICTION·HElD, BI·DIRECTIONAL
IDENTITY This handle has an adjustable drag, set with a
(See Section VII
clamp· type brake, that holds the handle at the
CONNECTOR set position, and has 30 degrees of handle throw
MOUNTING
(See Section II (See Section VI on either side of the center detent.
o C. FRICTION.HELD, UNI·DIRECTIONAL
TYPE OF CONTROL ELECTRICAL This handle has a high·resolution 60 degrees of
KNOB CHARACTERISTICS
handle throw, rotating on only one side of me·
(See Section III (See Section IVI
chanical nUll, which is at full stroke. It has no
HANDLE ACTUATION detent mechanism.
(See Section 1111
ORDERING INFORMA T/ON (continued page 6)

ORDERING INFORMA T/ON (continued from page 5)
IV. ELECTRICAL
CHARACTERISTICS
o A. PROPORTIONAL, NO SWITCHES, 12 VOLT
BI-POLAR
This handle's output curve is fairly linear (see
Figure 6), with output voltages a function of han-
dle stroke. The supply voltage is 12 volts, and
there are no auxiliary function switches.
o B. PROPORTIONAL, CENTER-OFF SWITCH,

12 VOLT, BI·POLAR
This handle has a center· off switch that ensures
zero output voltage over +3 degrees handle throw,
o C. PROPORTIONAL, CENTER-OFF SWITCH, FIGURE 6. Proportional Control Handle Output Cur-

24 VOLT, BI-POlAR rent vs. Control Handle Travel.
This handle runs on a supply voltage of 24 volts.
o D. PROPORTIONAL, CENTER-OFF SWITCH,

AUXILIARY SWITCH, 12 VOLT, BI-POLAR
This handle has a second switch that actuates at
+2 or -2 degrees.
o E. PROPORTIONAL, CENTER-OFF SWITCH,

12 VOLT, UNI-POLAR
This handle maintains a single direction of current
or voltage flow at all handle angles.
o F. STEP-PLUS-PROPORTIONAL, 12 VOLT, BI-

POLAR
This handle uses two switches to give the step-plus-
proportional output current on either side of nUll.
This is used to overcome dead bands in spool valves.
See Figure 7. Current beyond this step output is
proportional through the rest of the handle throw.
Full current output at 30 degrees handle stroke is
maximum of 250 mao Step current is a maximum FIGURE 7. Step-Plus-Proportional Control Handle.
of 50% of full current output.
o l. STEP-PLUS-PROPORTIONAL, FULL
o G. STEP-PLUS-PROPORTIONAL, 24 VOLT, AUXILIARY SWITCHING, 12 VOLT, BI-
BI-POlAR POLAR ELECTRONIC, PULSE WIDTH
MODULATED
Same as F, but 24 volt.
This handle uses a printed circuit board that makes
the step height and output current fully adjustable,
o H. SWITCHING accomodating high current applications. It also
This handle is non-proportional. Moving the han- has pulse width modulation, which "dithers" the
dle off null activates switches that power ON/OFF load to avoid stiction. Full current output at 30
devices (e.g., solenoid valves). degrees handle stroke is a maximum of 2 amps in-
to a 5 ohm load. Step current is a maximum 50%
of full current output. Typical dither frequencies
o J. STEP-PLUS-PROPORTIONAL, FUll (dependent on resistance of the load, specified in
AUXILIARY SWITCHING, 12 VOLT, BI·POlAR the suffix number) are: 60 Hz for the HPI solenoid
This handle uses the step switches for additional actuator, approximately 400 Hz for the V7058
secondary functions. Full current output at 30 de-
Hydrotransmission Valve and approximately 1000
grees handle stroke is a maximum of 250 mao Step
Hz for the MCV101A Pressure Control Pilot Valve.
current is a maximum of 50% of full current out-
put. ORDERING INFORMA T/ON (continued page 7)

ORDERING INFORMA TlON (continued from page 6) ORDER FROM
VI. SUFFIX NUMBER SUNOSTRANO MOBILE CONTROLS
3900 Annapolis Lane North
o 1. TERMINAL STRIP Minneapolis, Minnesota 55441
Electrical connections are made to a set of four (612) 559-2121
internal screw terminals.
o 2. PIGTAIL WITHOUT CONNECTOR

Four wires extend from the handle case. See Fig·
ure 3 for lengths. DEVICE REPAIR
For devices in need of repair, include a description of the
o 3. PIGTAIL WITH CONNECTOR problem, a copy of the purchase order and your name
The wires from the case terminate in a Packard and address.
environmental connector. See Figure 3.
V. CONNECTOR
These final three numbers are factory-generated. To RETURN TO
create the suffix number, the following information
must be supplied: number of additional switches SUNDSTRAND MOB I LE CONTROLS
needed and actuation angle of each with respect to Return Goods Department
null, full current output, resistance of the driven load, 3900 Annapolis Lane North
step current needed (if necessary). Minneapolis, Minnesota 55441

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LURING SCHEMATIC
---~
SYNCHRO-START D.C. SOLENOIDS
1. GENERAL
• Condor uses the Synchro-Start D.C. Solenoids for choke
and throttle control on the gasoline engines, and for
fuel on/off and throttle control on the diesel engines.
(See Table "A" for the list of Condor Models and the
solenoids used.)
• The solenoids used have the dual coil design, and may be
energized continuously without any duty cycle de-rating.
They have an extremely high work output for their size,
because of the high amperage "pull" winding and a separate
low amperage "hold" winding. These dual coils (one low
resistance, the other high resistance) permit safe
operation even in high ambient temperatures.
• The low resistance coil provides a high pulling force.

Upon completion of the plunger stroke, the heavy duty
double break self-contained switch automatically dis-
connects the high current pull winding within .040 seconds
of energization.
• All D. C. solenoids using dual coils must be installed

and adjusted so that the plunger always completes its
stroke, i.e., the plunger must bottom, disconnecting
the low resistance coil. If this does not occur,
excessive heat ensues, which in time (over 30 sec.),
does irreparable damage.
• CAUTION:
Proper installation is extremely important. Plunger
must "bottom" properly (Le., complete its stroke)
to actuate the pull-coil disconnect switch. If contacts
fail to open and circuit is not protected against over-
load, the pull-coil will burn out in 30 to 50 seconds.
Damage of this type is due to faulty installation and
is not covered by normal warranty.
2. ELECTRICAL DATA: SYNCHRO-START D.C. SOLENOIDS
LENGTH OF RATED D.C. PULL HOLD

SOLENOID PART NO. STROKE VOLTS AMPERES AMPERES
32111 1 IN. 12 24 0.5

40808 1 IN. 12 37 0.6
32239 H IN. 12 42 0.6
#32111 #40808 #32239
,
,
....._-- Contacts must

Open with Plunge
Bottomed
SYNCHRO-START D.C. SOLENOIDS - continued:
3. TEST PROCEDURE TO DETERMINE PLUNGER HAS BOTTOMED

• On units with an auxiliary terminal, connect a voltmeter
or appropriate light (voltage rating) between auxiliary
and1/+1/terminals. When the solenoid is energized and
-the plunger bottoms, the voltmeter will indicate the
battery voltage or the light is energized.
• Visual Method - Push the plunger to the full bottomed
position and measure the plunger extension length from
th.e solenoid body before the linkage is connected.
Connect linkage and energize the solenoid. If the plunger
has fully bottomed, the plunger extension lengths should
be the same.
4. TEST PROCEDURE TO DETERMINE ADEQUATE VOLTAGE

• Connect a D. C. Voltmeter across the solenoid terminals
and manually hold the plunger so that it cannot bottom.
Energize the solenoid just long enough to obtain a volt-
meter reading, then connect the same voltmeter across the
power source and manually hold the plunger so that it can-
not pull in just long enough to obtain a voltmeter reading.
The difference between the two voltmeter readings is the
voltage reduction due to wiring which should normally be
less than 7% of rated voltage.
5. CORRECTIVE ACTION
• If the power source voltage is low, check for partially
discharged battery, etc. If the solenoid voltage is low,
check for undersized hookup wire, high resistance connections
and underrated control device contacts.
TABLE "A"
LIST OF CONDOR MODELS & SYNCHRO-START D. C. SOLENOIDS USED
CONDOR SOLEt«lID
MlDEL ENGINE CONTROL FUNCTION PART f«).
36N Wisconsin
Ga.sol ine Choke 32111
I
! 46N Model VH4D, Throttle 32111
i
I
30 HP
;
I 36N Deutz
146N Diesel Fuel Shut Off 32239
Model
I
!
F2L511
,
!
160N Wisconsin Choke 32111
148 Gasoline
I 50
1 56 Model VG4D, Throttle 40808
; 58 37 HP
! 68
: 76
i 46Q8
60N
48 Deutz
50 Diesel
, 56 F2L912 Fuel On 40808
I 58
168
76
46Q8
CORPORATION
COUNTERBALANCE VALVE CARTRIDGE

CALAVAR PART NO. 32585
• Low leakage load holding ( 0 to 5 drops per minute, max. )

• Built-in free-flow check valve; cracking pressure = 4 psi
• Manual emerge~cy load release
• Pilot ratio 3:1
• Seals: Buna-N
• Pressure adjustment range : 1000 - 4000 psi
• Standard setting: 2900 psi (stamped on cartridge hex)
• Installation torque: 40- 45 ft-lbs.
----Locating shoulder
1~~~li~~~l
~ IN
. . COUNTERBALANCE
. (CYLINOER)
SCREW OUT 10 INCREASE

PRESSURE SETTING. IN
SCREW IN TO RELEASE LOAD. FREE FLOW (VALVE)
~~--------------~
CALAVAR PART NO. 32585
COUNTERBALANCE VALVE CARTRIDGE

SERVICE INSTRUCTIONS
Calavar #32585 cartridges are basic service items in themselves. They are
easily removed from their mounting for cleaning or replacement, but are not
designed to be disassembled or repaired in the field.
It is not necessary to remove an entire holding valve from the circuit
plumbing. Simply unscrew the cartridge from its body for troubleshooting
(below) or replacement.
If, for any reason, a cartridge does not perform as required, the trouble-
shooting steps given below may be taken. Following this, if the cartridge still
does not function, it should be replaced with a new factory-tested cartridge.
The non-functioning cartridge may be returned to Calavar through your local
dealer/distributor for evaluation if desired. A full report of our findings
will be issued on request.
TROUBLE SHOOTING
The most common cause of a cartridge failing to operate is dirt in .the
hydraulic fluid - dirt which lodges in the working parts and interferes with
their operation. Cartridges can be cleaned without altering their pressure
setting.
To check and clean a cartridge which is not functioning:
1) Remove the cartridge from the cavity.
2) Inspect for visible contaminants and carefully remove obvious
oarticles.
J) Through the nose of the cartridge, manually operate the inner
working parts several times. Use a wooden or plastic dowel to avoid
damaging soft seats, sharp edges or finished surfaces. All parts
should move freely. If possible, do this with the cartridge sub-
merged in clean mineral spirits.
4) After "flushtng", blow dry with clean filtered air.
5) Replace seals if indicated, using the appropriate service kit.
6) Reinstall cartridge, tighten to specified torque, and retest.
7) If this procedure does not eliminate the problem, replace with a
new factory-tested cartridge.
CARTRIDGE SEAL KIT: Calavar Part No. 93067
Kit contains quantity = 3 seals and quantity = 3 back-up rings.
install nos• •nd
bock-up ring
& seal as
C!T: SEAL
NOSE ENO
8ACK-UP
shown. e:.r RtNG
When replacing spiral back-up rings, take special care that the SPIRAL IS
WOUND LIKE A LEFT-HANDED THREAD, so that the back-up ring will follow the
cartridge into the cavity properly when being assembled.
INSTALLATION TORQUE: 40 to 45 ft. lbs.
CONIOAA noN
WATERPROOF LIMIT SWITCHES
Calavar Part No. 40207 (All Boom Machines)

Calavar Part No. 40208 (Model 86 and Truck Mounts)
Condor self-propelled aerial work platforms use waterproof limit switches

manufactured by Control Products, Inc. They are designed for rugged
military and mobile equipment applications.
These switches are really WATER-PROOF.· They are designed to operate
reliably under exposure to water, oil, humidity, sand, dirt, vibration
and shock. They do not rely on gaskets, O-rings, or diaphrams. The
neoprene jacket is bonded to the neoprene insulation on the leads, to
withstand temperatures from -65°F to +165°F.
The CPI waterproof switches meet or exceed Military Specifications
with exact ratings shown in Table I.
liIree aru actuat,nr button
accurately locates actuation
pOInt an snap actIon .pnnll .._ _
Plated steel 'Wltell
-'ti!:::----- case and cover.
Riveted snap action IIlade

mountlnc pOillts.
, . Fielillie waterproof
neoprene ,acket molded
- - - - - to lead .ires.
Eccentric adjustmlllt
for precise tensiollilll
of blad •.
Sine IIlado. _ _ _ _ _---'

• Carry!nl ••tonsioll I..,.,
CPt MEETS OR £XCEEOS Cpt MEETS OR £XCnDS

~IR[MENT MIL. SPEC. REQUIREMENT Mil. SPEC.
Constructton MS 39058 Mechanical Actualin, force - 1 to 2 pounds
Matenal: Actuation Release orce - 6 oz. minimum
Rubber Jacket MS 39058. Mil·R·3065 Release Time - 1/4 sec. .f
Wire MS 39058, Ord. =7722204 maximum at -65·
CorrOSion'
Resistance
MiI·Std.202
i Method 101 A
I 200 hrs .. Salt Spray Contact
Pretravel - .015 minimum
Overtravel- .015 minimum
Differential - .005 maximum ,
Mil·S·13484 B
I! Fungus
R€~lstance I, Mil·F 1392790 Days Voltage
Drop
28 V.D.C. 15 amp (resistivelload
VOltsae drop shall not exceed
I MiI·S·13484 B 1 millivolts
I Water ~
i
PrOCliness !6 PSI mternal pressure. 30 min. Overload Mil·S·13484 B
! 6 psi internal yac!;um. 30 min. 28 V.D.C. 22·1.'2 amp
i Immersed in Salt Water Solution (resistivel
I EXlre":;~!'AII.S.13484 B High
100 "make" and "break"
I TetT'p. Res.124 hrs. at - 65' = 5' F MII·S·13484 B
I 24 hrs at 165· =5'f Voltage 440 Volts (RMSI at 60 CPS
I
i
I
Operated 1000 cycles 28 V.D.C.
15 amp load
1 min. between leads
Open Mtl·S·13484 B
Shock 202A MII·Std 202A Circuit Open contacts not less than
!
, ReSIstance
I
100 gravity units "g's" ReSistance 1 megohm
28 V.D.C. 15 amp (resistive)
load during test. Endurance Mil·S·13484 B
28 V.D.C. 7·1/2 amp
Vibration 20 lA Mil·Std 202A (jnductivelload
Resistance 1 hr. of vibration 7·1/2 amp !lamp) load
3 major axes repeated in 25,000 "make" and "break" cycles
open position.
(Not less than 6 hrs. in vibration.! 115 V.A.C. 60 Hz
.06 inch double amplitude 113 H.P. motor load
frequency 10 and 55 CPS 5 amp.lamp.
10 amp. resistive
return to 10 CPS 25,000 "make" and "break" cycles
28 V.D.C. 15 amp resistive load
during test. 115 V.A.C. 60 Hz
4 amp. inductive l/R = .049
lead Subjected to a tensile force of 8 amp. resistive
Connections 25 pounds along axis of lead and 100,000 "make" and "break" cycles
perpendicular to axis of leads.
CPI Waterproof Switches

BRAKE TORQUE ADJUSTMENT FOR HYDRAULIC MOTOR
(Calavar Part #32762 - Braden Winch Co. Dwg. #0-03016)
Due to manufacturing tolerances of the brake parts (including the springs),

the number of brake plates may vary to obtain the required brake torque.
Nominally, this assembly will require:
5 friction plates
6 steel plates
3 brake plate spacers
5 springs
The brake should be assembled as shown on the cross-section Drawing 0-03016.

Using a torque wrench, the torque, where the brake starts to slip, should
measure 106± 10-ft/lbs.
If less torque is desired, reassemble the brake with:
4 friction plates
8 steel plates
5 springs
If more torque is desired, reassemble the brake with:

6 friction plates
10 steel plates
5 springs
or
7 friction plates
8 steel plates
5 springs
Please note that the number of brake springs could be adjusted to obtain the
desired brake torque. However, this would change the fully released brake
pressure and may be objectionable.
-t-:U4-1IfG- g.UlT NIIM6e~ DESCRIPffoN' QTV/P€~
03016 eEl 20 SWIIliG DB I~E
001 Z 5533 ~OUSING 1

002 2 S5 21 OUTPUT P IN ION 1
003 25582 OIL SEAL 1
004 25583 BE AB UIG CII e .l-
aos 2 S58 4 BEARING CONe 1
006 25585 BEARING CUP 1
._D.O.1- 25586 BE Alit IlliG CONE '--- -.------ -. .1.
008 25549 BEARING SPACER 1
009 25581 SNAP RING 1
.Jllil._ 25532 011 reur el ArliE I (ABIUEB 1
O.ll 25546 OUTPUT PLANET GEAR 3
Ol2 25545 OUTPUT PLANET GEAR SHAFT 3
-Oll- 210"9 R1 a-OIS-ROLI e IN 3
01t,. 2t,.115 ROLLER BEARING 6
015 24161 THRUST BEARING 6
-D.lA- 255"6 BE A.B HIG se AC ER 3-
011 25544 OUTPUT SUN GEAR 1
018 25588 S~AP itING 1
.J.U.9.._ 13023 1941006 S~Ae BIlliG 1..
020 25590 THRUST RACE 2
all 25531 PRIMARY PLANET CARRIER 1
_QZ2- Z 55 5 f: ee I~Aa:! PI AtIIEr GEAB 3..
023 2554 '3 PLANET GEAR SHAFT j:'
02~· 12025 R12-050 ROLL P IN 3
_02.5.- Z49lS aeAlH~C Roa L ER 11
026 24914 BEARING ~ACE -THRUS r 6
027 25547 PRIMARY SUN GEAR 1
-<lL'3_- 25551 [Neill SiiAE I .1
029 25589 SNAP RING t
030 25534 BRAKE CYLINDER t
-.0.3.1.- lQ4 ~Q lO450 {,} RING ..t
012 24916 B~AKE SPRING 5
033 2559'3 THRUST BEARING 1
..JiJ-'t__ ~ss 52 S2 BING eLAIE .1
0)'.) 25594 U-CUP SEAL 1
.11.3.6-- 2!j!j§1 -8R--Aif..€-.-cotJP LIN G 1
.0 BRAKE PLATE SPACER ,)
25550
038 255t,.0 8R AKE 01 s.c 6
039 ~§~4l -E..R-~I.oN.-O-l-S-C 5
040 10138 16262-249 a-RING 1
041 25535 MOTOR ADAP rER 1
042 21466 S+J.l--15PM5 CAP SCREw 6
043 1L1b1 S03l-l0PH5 CAP SCREW d
044 L1024 A031 LDCKWASHER l4
0"5 2:}OQ5 M37W PbUG Z
046 22314 EO lZA PIPE PLUG 2
041 10014 2558011l RELl EF VALVE 1
04~ 25403 --5)-4 IPP [NG PLUG HYO 1/l~ 1
049 23106 23106 G~SKET-~CTCR 2
050 21959 MU1-502DC, SHIELD OUST 1
-0.51-- --·~O9 ~~...o...s~H'.i c.A.I2~ue.w----· -.. -. ----~
\ 1
052 11020 A050 LOCKWASHER 2

Item Part No. N Description

1 WIB140 1 Hub-Spindle Subassembly
lA 1400703 1 Spindle
IB 1501301 1 Seal
lC 1500803 1 Bearing Cup (JLM506810)
10 1500804 1 Bearing Cone (JLM506849)
IE 1500805 1 Bearing Cup (JM205110)
IF 1500806 1 Bearing Cone (JM205149)
IG 1500603 1 Hub
IH 1900904 1 Spacer
1I 910006 1 Retaining Ring
1J 950002 2 Pipe Plug
IN 970004 9 Stud
2 1400066 1 Internal Gear
3 1200028 ..1 Carrier Assembly
3A 1200503 1 Carrier
3B 1200310 6 Thrust Washer
3C 1200803 96 Needle Roller
3D 1201002 3 Spacer
3E 1200101 3 Planet Shaft
3F 1300028 3 Cluster Gear
3G 920002 3 Roll Pin
...
4 1500073 1 Ring Gear
5 1940001 2 "0" Ri ng
6 1500406A 1 Cover Assembly
6A 1500406 1 Cover
6B 1900402 1 Cover Cap
6C 930004 4 Bolt
60 1900401 1 Disconnect Cap
6E 1900101 1 Disconnect Rod
6F 940001 1 "0" Ring
6G 940002 1 "0" Ring
6H 950001 1 Pipe Plug
6J 901201 1 ID Pl ate
7 1100104A 1 Input Shaft Assembly
7A 1100104 1 Input Shaft
TB 910007 1 Retaining Ring
7C 1901501 1 Spring
70 1201002 2 Spacer
8 1100017 1 Input Gear
(Cont'd.)
Item Part No. ~ Descri~tion
9 1901001 1 Thrust Spacer

11 1200301 2 Thrust Washer
12 930101 12 Bolt
13 1930201 4 Shoulder Bolt
14 1100203 1 Coupling
16 960201 16 Flat Washer
MCA100A
Multi-Axis Tilt Alarm
BULLETIN 95-8954-2
- ","-,
APPLICATION------
The MCA100A Multi-Axis Tilt Alarm provides a signal
to the operator of self-propelled aerial lifts, cherry pick-
ers, truck cranes, etc. that warns when the base vehicle
is off level. When the alarm is tilted 4.5 0 from null the
output signal activates both medium and high current
alarms, sirens, bells or lights. The warning alarm indi-
cates an imminent danger that must be rectified before
work continues.
The Mult-Axis Tilt Alarm is easily mounted in a conven-

ient location on the machine frame. It can be wired and
leveled quickly and will provide years of trouble-free
service.
Alarms used in rechargeable battery-operated elec-
trical systems will not sound if the system voltage
FEATURES------------- drops below the input voltage rating for the relay
• Complies with ANSI aerial lift standard A 92.5 to the alarm.
• High reliability with solid state load switching

OUTPUT CURRENT
• Easy to install .2 amps, nominal; .5 amps, maximum
• LED simplifies leveling of time delayed alarms OUTPUT LOAD INDUCTANCE

.5 henries, maximum
• Damped response ignores normal machine vibrations
SHORT CI RCUIT PROTECTION
• Operates in either 12, 24 or 36 volt systems Indefinite (output to ground or output to power
supply).
• Time delay option available
LOAD SWITCHI NG RATE
• Reverse polarity and short circuit protected 60 cps maximum at rated inductance and current
• Tough housing withstands the elements TIME DELAYED (OPTIONAL'

2.5 ±.5 seconds
• Spring-loaded base allows for operational tests
ENVIRONMENT AL
SPECIFICATIONS---- OPERATING TEMPERATURE
_340 to '+71° C (_300 to +1600 F)
ELECTRICAL
STORAGE TEMPERATURE
POWER SUPPLY _340 to +660 C (_30 0 to +1500 F)
11.to 30 Vdc (12124 volt model)
24 to 40 Vdc (36 volt model) SPECIFICATIONS (continued page 2)
Sundstrand Mobile Controls

SPEC/FICA T/ONS (continued from page 1) EMI/RFI
Radiated fields of 10 volts per meter from 30 MHz to
VIBRATION 200 MHz.
Withstands a vibration test designed for mobile equip-
ment controls that includes two parts: MECHANICAL
1. Cycling from 5 to 2000 cycles in each of the
three major axes. LIFE
2. Resonance dwell for one million Hz for each re- 10,000 operations at a single alarm point
sonance point in each of the three major axes.
DIFFERENTIAL
+1
SHOCK 9 _1.5° differential between diametrically opposite
50 g for 11 milliseconds. Three shocks in both direc- switch-on points.
tions of the three major axes for a total of 18 shocks.
For non-time delayed units, a maximum of 2.5 sec-
onds and a minimum of .15 seconds from null to 6°
HUMIDITY tilt angle over a temperature range of _30° to 160° F.
After being placed in a controlled atmosphere of 95%
humidity at 1200 F for 10 days the alarm will per- For time delayed units, 2.5 ±.5 seconds (0° to
form within specification limits. 160° F) and 5.0 seconds or less (_30° to 0° F) from
null to 6° tilt angle.
RAIN GENERAL
After being showered from all directions by a high
pressure hose down the alarm will perform within DIMENSIONS
specification limits. See Figure 1.
r=
~62gomm
28.0 mm 'or. ·28 ADJUSTING NUTS .1PL

f.l0
rl-----+--
I+- I
-----(\~1---L.1.I0
28.0 mm
56.00 mm
2.20
", \1
"
''--- OPTIONAL MOUNTING
l,Omm "PL 300mm MIN
HOLES IN BASE
.21
'!.I'l
1
83,18 mm MAX
1.21
ffi LEO ONI.. v ON TIME OELAYED UNITS
4,8m",
BASE .19
FIGURE 1. Dimensions of the MCA100A in millimeten (inches).
~.. nl'lctr"nl'l MnhU.. r.nntrnlc

THEORY OF O P E R A T I O N I - - - - - - - - - - - - - -
The Mult-Axis Tilt Alarm functions as a switch. It con-
sists of a molded nylon housing containing a steel ball
bearing, an incandescent lamp, a photo detector and a
printed circuit board. The ball bearing is free to roll in a
clear silicone damping fluid on a transparent, spherical In everyday use, some shaking of the machine's
basin. The bearing normally acts as an interruption be- frame is to be expected. To prevent an inter-
tween the lamp and the photo detector, but when the mittent alarm that would normally sound during
alarm is tilted 4.50 from horizontal the ball no longer use, the Tilt Alarm response is damped with
blocks the light. The detector then receives the light silicone fluid. The resulting lag can be several sec-
and switches a VMOS transistor from a high impedence onds. Therefore, the alarm should not and can
(OFF) to a low impedence (ON) state, activating the not be expected to give the operator sufficient
alarm. If the unit is time-delayed, an RC timing cir- warning time in dynamic movement situations.
cuit is allowed to charge towards a threshold voltage be- Angular boom and ground velocities should be
fore the transistor switches to the ON state. The timer kept to reasonable rates to ensure operator safety.
is reset when the alarm is releveled back to less than Nor should the alarm be expected to warn the op-
4.5°. Should the filament break, the circuit will close to erator in the event of machine lurches due to un-
warn the operator. tamped earth fills, ditches, drop-offs, holes, etc.
Good safety practices demand a thorough inspec-
tion of the ground surrounding the vehicle base.
When properly performed, this inspection should
preclude possibilities of unforeseen machine move-
ments.
INSTALLATION-------------------------------~
WIRING tern on the base (see Figure 1). If the device is welded,
the base should be detached from the housing and the
Three wires must be connected to put the Tilt Alarm in alarm assembled subsequent to the mounting. This will
the alarm circuit. The red wire is the high (positive) side avoid accidentally overheating the housing. Since the
of the alarm, the black wire is the chassis ground and the alarm is leveled after mounting, a smooth, flat weld is
white wire is the output lead. The Tilt Alarm and load not critical for correct operation.
are powered by 12, 24 or 36 volts.
In a very few applications, machinery equipped with the

Tilt Alarm will be subjected to the high accelerations
and decelerations associated with quick stops, starts and
turns. Since its sensing principle responds to gravity, the
alarm will also respond to these accelerations and trip The location of the mounting will vary from ma-
the horn or light. In order to avoid annoying the opera- chine to machine. In all cases it should be on a
tor with false alarms, the owners of tight-cornering andl level, horizontal area of the main frame. It should
or high-grounded-speed vehicles should interlock the op- also be isolated from the operator (outside of the
eration of the Tilt Alarm with the work (as opposed to cab) but accessible for day-to-day use, since the
travel) mode. If the alarm has the time delay feature, alarm should be field tested for proper working
this precaution is necessary. condition every day before the machine is run.
Two typical wiring schemes are illustrated in Figures 2

and 3. Figure 3 uses a separate remote horn as the load.
The horn should be a solid state device such as the
Mallory SC616N with a volume of 80 db or better. It
shquld draw no more than one-half amp. Figure 3 uses RED
the vehicle's own alarm system (generally the horn) as

the load. The horn relay should typically be from 200 111040V -
to 600 ohms. Also pictured is the interlock switch. TILT
ALARM
WHITE
REMOTE
HORN
RLACK
MOUNTING ~------I
1002
Three welds, one on each corner, are sufficient to mount

the base for the Multi-Axis Tilt Alarm. Or the device FIGURE 2. Wiring scheme using remote horn.
can be bolted to the frame through the four-bolt pat- INSTALLA TlON (continued page 4)

INSTALLATION (continued from page 3) o 2. Level the base of the alarm by tightening the three
flange nuts with a screwdriver·type socket wrench.
Each nut should be tightened through approxi-
mately one half of its spring's travel. During the
remainder of the procedure do not adjust the nut
INTERLOCl<
SWITCH
on the 90° corner.
HORN
RELAY o 3. With the electrical connections complete. slowly
tighten the nut on one of the two corners adjacent
RED
to the 90° corner until the circuit is closed.
For non-time delayed units. the alarm will sound.

TILT WHITE
ALARM For time delayed units, the LED on the underside
11 TOlO V
of the housing will turn on.
VEHICLE
HORN
o 4. Note the angular position of the· socket Loosen
the nut, counting the number of turns until the
HORN
BLACK BUTTON circuit is closed again.
'00' o 5. Divide this number in half. Tighten the nut by

this many turns. The line determined by this nut
and the nut on the 90° corner is now parallel to
FIGURE 3. Wiring scheme using vehicle horn. the ground.
o 6. Repeat steps 3 through 5 for the remaining nut.

The alarm is now level.
o 7. Individually push down on one corner at a time;

LEVELING there should be enough travel to cause the alarm
to trip. If the alarm does not trip in all three tests.
Use the following procedure to bring the Tilt Alarm into the flange nuts have been tightened too far.
gravitational null: Loosen the nut on the 90° corner and repeat steps
3 through 6. This push-to-test feature enables the
o 1. Park the vehicle on a flat surface. Be sure it is as operator to test the alarm without losing the alarm
level as possible, with tires filled to rated pressure. adjustment.
ORDERING INFORMATION---------------------------
SPECIFY DEVICE REPAIR
Model name (MCA 100A) For devices in need of repair. include a description of
Input voltage (12. 24 or 36) the problem. a copy of the purchase order and your
name and address.
Instantaneous or time-delayed turn-on
For non-standard trip angles. or different trip angles in

the X and Y axes, consult the Customer Service Depart- RETURN TO
ment.
SUNSTRAND MOBI LE CONTROLS
Return Goods Department
ORDER FROM 3900 Annapolis Lane North
SUNDSTRAND MOBI LE CONTROLS Minneapolis. Minnesota 55441
3900 Annapolis Lane North
Minneapolis. Minnesota 55441
(612) 559-2121
4 Sundstrand Mobile Controls

I. Oust Se.1
2. Wire Ring
3. Shim
4. Se.1
5. Housing
.. 6. SII' Carrier AllY.
10. Thrust Bearing
11. Shaft
12. Drive link
5 13. Wllr Plate
14. Seal 131
15. Roller Stator
16. Pin
17. End Cover
18. Bolt 141
10
11
12 II
13
14
IS
·NOTE: Earlier models have a leather backup in

seal carrier. Leather and old shaft seal
should be replaced by new shaft seal and 16
spring.
Figure 1
J1
..i'l;
!~; &1. 18 a.
SERVICE PROCEDURE 6. Assemble the drive link (12) into shaft (11). Care
must be taken to align mark at root of drive link
Disassembly Procedure ... tooth with mark on cupped end of shaft. See Fig.
Prior to removing roller stator motor from unit, 3. Fill drive link end with grease. Note. if markings
clean off all dirt. Disconnect hydraulic connections are indistinguishable the root of the drive link
and plug ports. Remove the motor from unit. After re- tooth should be placed with the deeper slot of the
moval, wash the motor with solvent to remove all output shaft to the right and 1/4" thru hole to the
excess dirt from outside of the motor. Remove the left. (Mark alignment as described on drive link
woodruff key from shaft (11), place the motor in a vise end with soft pencil if no marks appear.)
as shown in Fig. 2 taking care to clamp at port area of 7. Slide output shaft assembly (6. 10, 11 and 12)
t:lousing (see Fig. 2). Place newspapers or a sheet of into housing Fig. 4. (Shaft must be flush or slight-
cardboard on top of bench to obtain a clean work area. ly below housing.)
8. Place lightly oiled seal (14) in groove of housing.
9. Place wear plate (13) on top of drilled end of
DISASSEMBLY OF ROLLER STATOR housing. insuring alignment of seven feed holes.
See Fig. 5. Note alignment groove of wear plate to
(reference Fig. 1) be in direction of ports.
1. Remove four bolts (18) [9/16 socket or boxed 10. Install lightly oiled seal (14) into groove of roller
end] and end cover (17). stator (15). With seal side down place roller stator
2. Shift wear plate to clear end of drive link and lift (15) over drive link with mark on drive link root in
group (rotor assembly (15) and wear plate (13)] line with rotor valley (min. diameter). See Fig. 6.
from housing assembly (5). Mark on stator must be in line with slot in wear
3. Remove shaft (11) and drive link (12) from hous- plate. Note alignment of seven feed holes with
ing by pushing up on shaft end with palm of one wear plate and housing. See Fig. 7. Align four bolt
hand and lifting shaft with the other hand. Items holes with housing. Care must be taken to insure
6, 10, 11. 12 and 16 usually will come out from that seal stays in place. Note: Counterbore on
assembly. rotor is away from housing.
4. Remove housing (5) from vise and place u>[lp~siil'!deP.e----
down on work bench. This allows thrust bearing
(10) to fall free. Next place fingers through dust
seal (1) of housing and push seal carrier (6) out
the opposite end from the dust seal. Care should
be taken to keep the seal carrier from marring the
housing bore. This procedure will remove items LONG MILLED OR
6 and 10 from housing. ANGLE DRILLED
5. Mount housing assembly (5) in vise, using the SLOT
grip end of a large screw driver, tap dust seal (1)
until it falls free. Fig. 2
6. With small screw driver remove retaining ring (2),
seal (4) and shim (3).
Fig. 3
ASSEMBLY PROCEDURE
(reference Fig. 1)
IMPORTANT
Before assembling, wash all parts off in clean
solvent. It is advisable to use a new seal kit containing
items 1,3,4 and 14 (3 seals).
1. Place housing with mounting flange end up on
newspaper. install seal (4) in groove. Fig. 4
2. Install shim (3) into groove next to seal.
3. Push retaining ring (2) into position.
4. Place housing (5) in vise as shown in Fig. 4 with
groove side up clamping at ports.
5. Place thrust bearing (10) on shaft (11) followed by
the seal carrier assembly (6) with large diameter
of seal carrier towards thrust bearing. Fig. 5
11. Pllce lightly oited sell (14) Into end cover (17). , 6. Place assembly on side (portl up) In vise and
12. Place greale in recessed center of end cover flce. rotate shaft with key in place Ind check to inlure
Inltatt pin (16) into greased recess If recess Is the suction port Is In the same direction of
fltled with alt. wipe clean before loading with rotation.
greale. End cover of new models (built after
March. 1983) contains a pressed stee' ball and a
pin (16) with a concave end. Make sure concave
end 01 pin II Inserted into end cover (17) In these
modell.
13. Carefully Invert end cover assembly (17. 16 and
14) and place into position on top of roller stator
allembly. Take care not to dislodge sea' or pin
from end cover. .
14. Check Iides for leall that may be out of place.
15. Insert four bolts (18) and torque to 50 foot pounds.
Fig. 6 Fig. 7
6·8 SPLINE (SAE J489)
WHITE HYDRAULICS, INC.

TELEPHONE 502-885-1110
P.O. BOX 1127
z HOPKINSVILLE, KY 42240
A-18UNC"SO ..N 11ft,
1.1_.......... Attn: White Co.
TWX 157178
'-"""-- ,Hole.
"'-"Nlf(110 POO'..... '"'
1Iw.,.1ot:* ~
Mounting Dimensions
DIMENSION "A"
MOTOR DISPLACE ME NT
4 Hole Flange 2 Hole Flange
SERIES
Cu.ln.IRev. Cu.Cm./Re\l. In. mm In. mm
RS·AA·l 3 50 5.41 137.41 5.41 137.41
RS·AB·l 45 74 5.41 137.41 5.41 137.41
RS·AC·l 68 110 553 137.41 5.53 137.41
RS·AE·l 10 164 5.87 155.45 5.87 155. 4~
RS·AG·' 12 200 6.12 155.45 6.12 155 45
RS·AK·' 146 268 6.66 169.HI 6.66 169.16
RS·AM·l 18 295 5Ge 169.16 6.66 16916 I
RS·AP·l 24 393 7.37 187.20 7.37 18;_~
PARTS SECTION
INDEX
Figure Title
1 Final Assembly (2-Section Boom)
1 Final Assembly (3-Section Boom)
2 Safety Decal and Placard Location (2-Settion Boom)
2 Safety Decal and Placard Location (3-Section Boom)
2A Safety Decals
3 Carriage Assembly
4 Steering Assembly
4A Drive Valve Assembly
5 Hub Assembly - Non-Drive Axle
6 Torque Drive and Steering Hydraulics
8 Steering Cylinder
9 Rota ry Coup 1i ng
10 " Turret Assembly
lOA Power Module Assembly - Wisconsin Gas Engine
lOB Power Module Assembly - Deutz Diesel Engine
12 Pump/Drive Assembly - Wisconsin Gas Engine
12A Pump/Drive Assembly - Deutz Diesel Engine
14 Fuel Tank Assembly
15 Hydraulic Tank Assembly
16 Ground Control Console
17 Turret Rotation Speed Reducer
18 Muffler Installation (Gas)
18A Muffler Installation (Diesel)
19 Air Cleaner Installation
20 Electric Motor/Pump Assembly for Emergency System
21 Boom Assembly (2-Section)
21A Boom Assembly (3-Section)
23 Slave Leveling Cylinder Assembly
25 Master Leveling Cylinder
26 Boom Extension Cylinder Assembly (2-Section Boom)
26A Boom Extension Cylinder Assembly (3-Section Boom)
PARTS SECTION
INDEX (Cont'd.)
Figure Title
27 Topping Cylinder
28 Platform Rotation Cylinder
30 Platform Assembly
31 Platform Control Console Assembly
32 Platform Skirt
33 Pl atform Fork
35 180 0 Platform Rotation Assembly
35A Platform Non-Rotation Assembly
39 Four-Wheel Drive (Option 135543)
46QS-SO-15 Hydraulic Tool Circuit Installation
46QS-SO-16 Tool Circuit Assembly
(
46QS-SO-17 Oil Cooler Assembly
46QS-80-2S Diesel Engine Special Option
FIGURE 1 FINAL ASSEMBLY (2-SECTION BOOM)
11/85
1 Ti e-Down Ri ng 32536 1
5
7
'11 Hinge, Piano 33017-002 2
12 Rivet, Pop - 3/16 11 Dia. BOW34192 58
13 Screw, Hex Hd. Cap 3/8 11 x 3/4 11 Self-Tapping BOW31846 17
14 - Latch, Turret Cover LBL00200 2
16 Cover, Wraparound 36283 1
18 Hatch, Top 35061 1
20 Gas Spring 'Bracket Assembly 35377 2
22 Screw, Hex Hd. Cap 1/4 11 -2QUNC x 111 Lg. BOW30004 22
23 Flatwasher, 1/411 BOW31431 12
25 Clip, Speednut - 1/4 11 -20UNC BOW432 10
26 Washer, Fender 1/411 BOW32572 10
27 Washer, Neoprene 3/8" 35681 17
I'
')~
11/85
11/85

1 Ti e-Oown Ri ng 32536 1
5
7
11 Hinge, Piano 33017-002 2
12 Rivet, Pop - 3/16" Dia. BOW34192 58
13 Screw, -Hex Hd. Cap 3/8" x 3/4" Self-Tapping BOW31846 17
14" Latch, Turret Cover LBL00200 2
16 Cover~ Wraparound 36283 1
18 Hatch, Top 35061 1
20 Gas Spring Bracket Assembly 35377 2
22 Screw, Hex Hd. Cap 1/4"-20UNC x 111 Lg. BOW30004 22
23 Flatwasher., 1/411 BOW31431 12
24- Lockwasher, 1/4u BOW36725 22
25 Clip, Speednut " 1/4"-20UNC BOW432 10
26 Washer, Fender 1/4" BOW32572 10
27 Washer, Neoprene 3/8" 35681 17
11/85
FIGURE 2 SAFETY DECAL & PLACARD LOCATION (2-SECTION BOOM)
00
4/86
ZIS!1'
1 Decal - WARNING ~ 1
4 Decal - CO 21834-1 2
5 Decal - NO 21834-2 2
6 Decal - OR 21834-3 2
10 . Decal - DANGER 21882-2 2
12 Decal - DANGER 21882-1 . 2
13 Decal - 46 QUBIC-8 35040 2
14 Dec~l - TRANSPORTING DIAGRAM 35041 2
15 Dec~l - TIRE PRESSURE 65 PSI 21971-3 4
16 Deca 1 - LUBE FITTING FOR PINS 35773 1
19 Decal - DO NOT LIFT BOOM 21971-2 ~'8e·S'" 2
23· .Placard - HYDRAULIC FLUID 21850 1
24 Decal - MAD.E IN USA - 6-Inch 35656 2
25 Decal ,- LUBE LOCATIONS 35774 1
26 Decal - OPERATION AND SAFETY MANUAL 21384 1
4/86
4/86
't18 S'i-
1
2
Decal -
Decal -
WARNING
GENERAL OPERATING INSTRUCTIONS
....
"'"""""
35366
"'''' 1
1
4 Decal - CONDGR (small) 50277 2
5 Decal - MADE IN USA 35656 _. 2
6 Placard ~ HYD. FLUID 21850 1
12 Decal - DANGER 21882-1 - 2
13 Decal - 46 QUBIC-8 35040 2
16 Decal - LUBE FITTING 21079 2
19 Decal - DO NOT LIFT BOOM 2-1971-2 ~et>o) 2
23 Decal ~ CENTRAL LUBING FOR PINS 3577;3 .1
24 Decal - LUBE LOCATIONS 35774 1
25 Decal - OPERATION AND SAFETY MANUAL 21384 1
4/86
FIGURE 2A SAFETY DECALS
CAUTION
1. DO NOT OPERATE THIS MACHINE UNLESS YOU ARE A TRAINED AND

AUTHORIZED OPERATOR FOR THIS CONDOR MODEl. BE FAMILIAR
WITH UNIVERSAL SYMBOLS USED ON CONSOLES.
2. CHECK ALL MACHINE FUNCTIONS. INCLUDING BRAKES. PRIOR TO
EACH DAY'S USE.
CONDOR MODEL 46 QUBle-8™ 3. ALL PERSONNEL IN PLATFORM MUST WEAR APPROVED HARD HATS
PLATFORM CAPACITY 500 LBS. AND BOOY BELTS WITH LANYARDS ATTACHED TO DESIGNATED
POINTS ON THE PLATFORM ASSEMBLY.
INCLUDES PERSONNEL & EQUIPMENT 4. OPERATE ALL CONTROLS SLOWLY FOR SMOOTH PLATFORM
35045 MOVEMENT WATCH FOR OBSTRUCTIONS WHICH MAY STRIKE
PLATFORM. PERSONNEL. CONTROLS OR MACHINE.
5. DO NOT OPERATE THE CONDOR ON SOFT OR UNEVEN SURFACES OR
ON SLOPES IN EXCESS OF 5' (105" RISE IN 10 FEET)
6. DO NOT OPERATE THE CONDOR WHEN WIND VElOCITY EXCEEDS
25 MPH.
7. NORMAL TRAVEL POSITION IS WITH THE BOOM FULLY RETRACTED
AND "TURRET COUNTERWEIGHT" POSITIONED OVER THE ORIVING
(FRONT) AXLE. THE BOOM MUST BE ElEVATED TO PROVIDE
ADEOUATE GROUND CLEARANCE FOR THE PLATFORM ASSEMBLY
DIRECTION OF PLATFORM TRAVEL REVERSES IN RELATION TO
CONTROLLER MOTION WHEN THE BOOM IS OVER THEFRONT AXLE. DO
NOT DRIVE THE CONDOR WITH THE BOOM ELEVATED IF ANY PART OF
THE MACHINE IS WITHIN 6 FEET OF AN OBSTRUCTION.
8. THIS CONDOR IS EOUIPPED WITH A SLOPE SENSOR AND AN INDICATOR
LIGHT ON AERIAL CONTROL CONSOLE TO INOICATE A 5' OUT·OF·
LEVEl CONDITION. ALL BOOM FUNCTIONS ARE INOPERABLE WHEN
CONDOR IS MORE THAN 5° OUT·OF·LEVEl.
YOU MUST NOT OPERATE THIS MACHINE NOTE TO CORRECT THIS CONDITION. REVERSE/CHANGE DIRECTION
UNUSS YOU ARE QUALIfIED 8Y TRAINIIIG ANO EXPERIENCE
IN THE SAFE OPERATION OF THIS MACHINE.
OF GROUND TRAVEL UNTIL INDICATOR LIGHTS GOES OFF.
9. HIGH SPEED MODE FOR TRAVEL WORKS ONL Y WHEN SElECTOR
TRA'NIH& INCLUDES COMPl£TE KNOWlEDGE OF SWITCH IS IN "HIGH" AND BOOM IS BELOW HORIZONTAl. AERIAL
YOUR EMPLOYER'S WORK RULES, All GOVERNMENTAL FUNCTIONS DO NOT OPERATE WITH UNIT IN HIGH SPEED.
REGUlATIONS. AND MANUFACTURER'S OPERATOR
AND SAF£TY MANUALS RELATIVE TO THIS 10. IN CASE OF EMERGENCY. DEPRESS EMERGENCY "STOP" BUTTON
MACHINE'S SAFE USE. 35365
AN UNTRAINED OPERATOR SUBJECTS HIMSELF AND OTHERS TO
OEATH OR SERIOUS INJURY.
SIGNMAlIER 1
21882-3 TIRE PRESSURE 65 PSI~
DO NOT LIFT WHEELS

WITH BOOM 21971-2
THIS MACHINE IS NOT INSULATED
ELECTROCUTION HAZARD
MAINTAIN SAFE CLEARANCES fROM ELEClRICAlLINES AND
APf'AAATUS YOU MUST AllOW fOR 800M SIllY. ROCK OR
SAG AND ElECTR1CAlllN£ AND LOAD SY/iIYING.
THIS AER1Al WORK PLAtfORM OO£S NOT PROVIDE
PROTECTION fROM CONTACT WITH OR PROXIMITY TO AN
ELECTRICAllY CHARGfD CONDUCTOR
YOU MUST MAINTAIN AClEARANCE Of AT LEAST 10 fEET
ELEaROCUllON HAZARD
BETWEEN ANY PART Of THE WORK PLAtfORM OR LOAD AND
ANY ElEClR1CAlllNE OR APf'AAATUS CARRYtNq:IJP TO KEEP CLEAR
50.000 VOlTS ONE fOOT ADDITIONAl CLEAR~E IS
REQUIRED fOR EVERY ADDITIONAl 30.000 VOlTS OR LESS DEATH 01 SERIOUS INJURY UN RESULT fROM
DEATH OR SERIOUS INJURY Will RESULT FROM CO~TACT OR (ONTAG WITH TIllS EQUIPMENT OR VEHKlI
INADEQUATE CLEARANCE. If IT SHOUlD II BfCTlKAl.lY OfAIGED. 21112·'
2IIIa2-2
WARNING THIS UNIT IS NOT INSULATED AND MUST NOT BE OPERATED

WITHIN 10 FEET OF ENERGIZED POWER LINES. 32200
11/85
CALAVAR SELF-PROPELLED CONDOR

WARNINGS -
1. BEFORE OPERATING CONDOR, READ AND UNDERSTAND ALL OPERATING/SAFETY INFORMATION IN
THE OPERATION/MAINTENANCE MANUAL AND ON ALL DECALS/PLACARDS DISPLAYED ON THIS
UNIT.
2. BE FAMILIAR WITH THE UNIVERSAL SYMBOLS USED ON THE CONTROL CONSOLES.
3. BE SURE THAT CONDOR IS PROPERLY MAINTAINED IN ACCORDANCE WITH CALAVAR'S
REQUIREMENTS AS SPECIFIED IN THE OPERATION/MAINTENANCE MANUAL.
4. DO NOT OPERATE THIS MACHINE IF IT DOES NOT FUNCTION PROPERLY.
5. 00 NOT MAKE ANY MODIFICATIONS TO CONDOR WITHOUT WRITTEN CONSENT OF CALAVAR.
DAilY INSPECTION CHECKLIST BEfORE USING CONDOR -

(REFER TO OPERATION/MAINTENANCE MANUAL FOR FACTORY RECOMMENDATIONS)
1. CHECK FLUID LEVELS IN HYDRAULIC AND FUEL TANKS AND BATIERY.
2. CHECK ENGINE CRANKCASE OIL, AND COOLANT FOR WATER-COOLED ENGINES ONLY.
3. VISUALLY INSPECT CONDOR FOR LOOSE OR MISSING PARTS, WEAR, WELD CRACKS. DENTS. OR
OTHER SIGNS OF DAMAGE. .
4. CHECK TIRES FOR WEAR, CUTS, AND INFLATION PRESSURE (PNEUMATIC TIRES ONLY).
5. CHECK ALL VISIBLE BOLTS. NUTS. PINS AND FASTENERS FOR PROPER INSTALLATION.
6. CHECK HYDRAULIC COMPONENTS, FLUID LINES AND FITTINGS OR LEAKS.
7. INSPECT ELECTRICAL HARNESSES, CONNECTORS, CIRCUITS, AND BOOM MECHANICAL CABLES
(3-SECT10N BOOMS ONLY) FOR DAMAGE AND PROPER INST £\LLA110N.
8. CHECK 5° SLOPE SENSOR AND INDICATOR LIGHT FOR PROPER OPERATION.
9. CHECK TURRET ROTATION GEAR BOX, RING GEAR BOLTS AND LOCK-STRIPS FOR PROPER
INST ALLATION.
GENERAL OPERATING INSTRUCTIONS-

1. CHECK THAT TURRET LQCK-PIN IS REMOVED (APPLICABLE ONLVTO CONDOR MODELS WITH TURRET
ROTATION LOCKING FEATURE FOR TRANSPORTING).
2. TURN MASTER SWITCH "ON" AT GROUND CONTROL CONSOLE. START ENGINE/MOTOR AND ALLOW
UNIT TO WARM TO OPERATING TEMPERATURE.
3. POSITION SELECTOR SWITCH TO "GROUND CONTROL" AND TEST OPERATE ALL AERIAL FUNCTIONS
FROM THE GROUND CONTROL CONSOLE.
4. POSITION SELECTOR SWITCH TO ':AERIAL CONTROL", THEN ENTER THE WORK PLATFORM AND
ATTACH THE SAFETY BELT/LANYARD.
5. REFER TO WORK PLATFORM "CAUTION" DECAL FOR ALL OPERATIONS IN THE PLATFORM.
6. FOR TRANSPORTING, USE EXTREME CAUTION WHILE LOADING/UNLOADING THE CONDOR UNDER ITS
OWN POWER:
• TRAVEL IN LOW SPEED MODE ONLY. .
• MAKE SURE BOOM IS FULLY RETRACTED AND BELOW HORIZONTAL.
• ROTATE TURRET IN LINE WITH CHASSIS.
• 00 NOT EXCEED RAMP ANGLE OF 14° (2.5 FEET RISE IN 10 FEET).
35366
11/85
FACTORY RECOMMENDED
TRANSPORTING DIAGRAM
35041
NO STEP~
A. DANGER EXPLOSIVE GASES
Cigarettes, flames or sparks could cause battery to explode. Always shield eye. and face.
from battery. 00 not charge or UM booster cable. or adjust post connection. without
proper Instruction and training. KEEP VENT CAPS TIGHT AND' LEVEL
A. POISON CAUSES SEVERE BURNS
Contains sulfuric acid. Avoid contact with skin, eyes or clothing. In event of accident flush
with water and call physician Immediately.
KEEP OUT OF REACH OF CHILDREN
'35785
4/86
9200 S. Sorenson Ave.

Santa Fe Springs, CA. 90670
CONDOR MODEL-_ _ _ _ SERIAL NO-_ _ __
ASSEMBLY NO-_ _ _ _ _ _ _ _ _ _ __
PART NO-_ _ _ _ _ DATE OF MFG-_ _ __
MAXIMUM PLATFORM HEIGHT - _ _ _ _ _ _ __
MAXIMUM HORIZONTAL REACH-_ _ _ _ _ _ __
RATED WORK LOAD - LBS.

HYDRAULIC OPERATING PRESSURE - PSI
U.S. PATENT 4,506,480
THIS UNIT IS NOT elECTRICALLY INSULATED
THIS MOBILE UNIT CONFORMS TO ALL APPLICABLE
REQUIREMENTS OF ANSI A92.5-1980
16843F"
OPERATION AND :;
SAFETY MANUAL ~
4/86
FIGURE 3 CARRIAGE ASSEMBLY
.....
.-
M
.-
--'-\ll --
\
Oll"l
,.........
11/85
FIGURE 3 CARRIAGE ASSEMBLY
REF DES(RIPTION PART NUMBER QTY
1--+-Carri age We 1dment--------------il---- 35100 - - - - - - t - - l

2 Wheel Assembly* 35789 4
Ti re CJBOI001 4
Rim35790 4
3--+-Hub, T o r q u e - - - - - - - - - - - - - + - - - : 3 2 0 8 4 2
4 Weldment; Rear Spindle 3527B 2
5 Screw, Hex Hd. Cap 1/2/1-13UNC x 2-1/2" 19. BOW36110 12
7 Cover ,Rear Axle 35626 2
B Cover, Front Hatch 35269 1
9 Gear, Slewing Ring 21922 1
10 Capscrew, Hex Hd. 5/B II -11UNC x 3-1/4/1 19. BOW36154 B
11 Flatwasher, 5/B II (SAE) BOW31437 12
12 Lockstrip 6B226 9
13 Screw, Hex Hd. Cap 1/2"-13~C x 2-1/411 19. BOW36109 18
14 Nut, Lock Hex 5/B"-11UNC BOW469B5 8
15 Screw., Hex Hd. Cap· 5/BII-11UNC x 2" 19. BOW36149 4
16 Screw, Hex Hd. Cap 3/Bi' -16UNC x 1/211 19. BOW 300 50 8
17 Flatwasher, 3/B II BOW31433 8
.tB lockwasher, 3/8 11 BOW36727 8
19 ,Screw,·Hex Hd. Cap 1/4 11 -20UNC xI" 19. BOW30004 6
20 Fl atwasher, 1/4/1 BOW31401 6
21 .Lockwasher, 1/4" BOW31325 6
* Wheel Assembly, Foam Filled (Optional) 35794 4
5/86
FIGURE 4 STEERING ASSEMBLY
1 Knuckle Weldment, Steering - RH 35291 1

3 Knuckle Weldment, Steering - LH 35318 1
4 King Pin 3540 4
5 Pi n, Cotter 3p6 11 Dia. x 2" Lg. BOW38250 6'
6 Bushing, King in 35248 4
7 Lockwasher., 1/411 BOW.313.25 ·2
8 Cylinder, Steering 35087 1
9 Tie Rod 35331 1
10 Tie Rod End, RH 67497 1
11 Nut, Hex Jam 1-1/811 -12UNF - RH BOW 34240 1
12 Ti e Rod End,. LH 67495 1
13 Nut, Hex Jam 1-1/8"-12UNF - LH BOW34241 1
14 Pin Weldment, Steering Cylinder 35636 2
15 Nut, Castle 1 1/4 11 -7UNC 35448 4
16 Lube Fitting BOW7596 4
17 Screw, Hex Hd. Cap 1/4"-20UNC x 1/2" Lg. BOW 30000 2
18 Washer, Flat BOW36722 4
19 .Washer, Thrust 35405 4
10/86
FIGURE 4A . DRIVE VALVE ASSEMBLY
Drive Valve Assembly 32800 1

1 Valve, C h e c k - - - - - - - - - - - - - - + - - - 6 7 4 0 6 - - - - - - 4 - 2
2 Bushing, Reducer 67407 1
3 Valve, Positive Traction 92069 1
4 Valve, Flow Divider/Combiner 67401 1
5 Valve, Counterbalance 67405 2
1/84
FIGURE 5 HUB ASSEMBLY - NON-DRIVE AXLE
Hub Assembly (except #1) 35274 1

l-+--Spindle ' 35278----4--1
2 Cotter Pin, 1/811 x 1-1/211 Lg.---------'I-----92106 1
3 Seal, Grease 92101 1
4 Cone, Bearing 92098 1
5 Bearing Cup 92100 1
6 Cover, Dust 30289 1
7 Nut, Slotted 111-14UNF 92105 1
8 Cone, Bearing 92097 1
9 Beari ng Cup· 92099 1
10 Hub, Idler 35606 1
11 Lug Nut, 1/2 11 -20UNF BOW6460 9
12 Wheel Stud, 1/2 11 -20UNF x 1-15/16 11 Lg. 91111 '9
13 Washer, Keyed CHBOO101 1
6
FIGURE 6 TORQUE DRIVE AND STEERING HYDRAULICS
11 lOr::
FIGURE 6 TORQUE DRIVE AND STEERING HYDRAULICS
1--Motor, Drive (with brake) '. 36393 2

2- -Block, Drive Ref. Figure 4A 1
3- ~Bushing, O-Ring #8-#12 35336 4
4- r-Elbow, 90° Swivel #4-#4 02219 2
5- r-Elbow, 90° Swivel #8-#8 36085 4
6- r-Elbow, 90° O-Ring #4-#6 02875 5
7- r-Union, STR #8-#8 02685 4
8- r-Connector, STR O-Ring #4-#6 00456 5
9- r-Connector, STR O-Ring #8-#12 00303 6
10- r-Elbow, 45° Swivel #8-#8 02649 4
11- r-Tube Assembly #8-#8 35120 2
12- ~ Tube As semb ly #8- #8 35119 2
13- ~Hose Assembly, #8 STR-#8 STR x 14" 19.· 2
14-r-Hose Assembly, #8 STR-#8 STR x 15" 19. 2
15-r-Hose Assembly, #8 STR-#8 Elbow, 90° x 51 19. 2
16-r-Hose Assembly, #4 STR-#4 STR x 43" 19. 4
17-I- Hose As semb ly, #4 STR-#4 STR x 5 111" 19. 1
18-f--Hose Assembly, #4 STR-#4 Elbow, 90° x 5 19" 19 1
19-f--Cylinder, Steering Ref. Figure 8 1
20- f--Elbow, 90° O-Ring #8-#8 04523 2
21- r- Hose As semb ly, #4 STR-#4 STR x 41 11" 19. 1
22- I-Hose Assembly, #4 STR-#4 STR x 5 111" 19. 1
23- f--Reducer, #8-#4 00564 2
11/85
FIGURE 8 STEERING CYLINDER
Cylinder 35087 1
1 Gland 92041 1
2- Piston 92042 1
3 Collar 92043 1
4 Barrel Assembly 92044 1
5 Rod 92138 1
6 Locknut, Self-Locking 91011 1
7 Gland Static Seal 92047* 1
8 Rod Seal 92047* 1
9 Piston Seal 92047* 2
10 Rod Wiper 92047* 1
11 Rod Static Seal 92047* 1
12 Rod E:nd 92046 1
13 Jam Nut 111 - 14 UNS 93016 1
*Seal Kit (Contains Items 7 thru 11)
5 8
1
7
13 12
J
10
11/85
FIGURE 9 ROTARY COUPLING
19
20~_~V
18
21
16
- - - - - - -15
11/85
FIGURE 9 ROTARY COUPLING

,. Rotary Coupling 32554
1 -t-Spacer KVQ 01004 1
2 - f-Housi ng KVQ 01002· 1
3 -I- Elbow, 90 0 #4 JIC-#4 O-Ring 02236 3
4 - I-E1 bow, goo #8 JIC-#12 O-Ring 02664 4
5 - t- Reducer #8 JIC-#4 JIC 00492 1
6 - t-Tee, Run #4 J IC-#4 JIC 00344* 1
7 - t- Cap #6 JIC 04012 1
8 - I-Reducer #8 JIC-#6 JIC 00388 1
9 - t- O-Ri ng ** 1
10-I-Plate, Keeper KVQ 01005 1
11-t-Loc kwasher KVQ 01008 4
12-I-Screw, Socket Hd. Cap KVQ 01007 4
13-I-Tee, Run #8 JIC-#8 JIC 00303* 1
14 Dlate Mounting KVQ 01006 1
15--Seal Set· ** 8
16-- Spool KVQ 01003 1
17--Connector, STR #4 JIC-#4 O-Ring 02525 3
18-I-Connector, STR #12 JIC-#12 O-Ring 00266 2
19-I-Connector, STR #6 JIC-#4 Pipe 02795 1
20-I-Connector, STR #4 JIC-#4 Pipe 01160 1
21-f-Bushing, O-Ring #4 Pipe-#12 O-Ring 21569 2
**Seal Kit (contains eight of Item 7 and one

of Item 2) 92079
<.
11/85
FIGURE 10 TURRET ASSEMBLY (St.arting with Ser. No. 5395)
39
38 44
42 45
43 I
I
.....:
"
I
••
21
22
1
12 t 0
1
25-----
26
27 4
28
FIGURE 10 TURRET ASSEMBLY (Starting with Sere No. 5395)

2 Power Module Assembly Ref. Figure lOA 1
3 Screw, Hex Hd. Cap 1/211-13UNC x 2 1/2" Lg. BOW30110 4
4 Rotary Coupling Ref. Fi gure 9 1
5 Fuel Tank Assembly Ref. Fi gure lA 1
6 Cylinder, Topping Ref. Figure 27 1
7 Pin, Topping Cylinder to Turret 35013 1
8 Valve, Proportional Control - 4-Bank 32560 1
10 Switch, limit 40207 1
12 Filter, Return line 32522 1
13 Console, Ground Control Ref. Figure 16 1
14 Harness, Engine 35068 1
16
17
18 Harness, Valve Wiring 35609 1
19 Pin, Master Leveling Cylinder to Turret 35014 1
20 Pad, Boom Rest 2~Section Boom 35831 2
- --
.. 3-Section Boom 30324 2
21 Screw, Hex Hd. Cap 3/4 11 -10UNC x 411 Lg. BOW30160-450 4
22 Flat Washer, 3/4 11 BOW31418 4
23 Nut, lock 3/4 11 -10UNC BOW46986 4
24 Screw, Flat Hd. 3/8 11 -16UNC x 3/411 Lg. BOW34415-750 10
25 Screw, Hex Hd. Cap 5/16 11 -18UNC x 2-1/211 Lg. BOW46035 4
26 Flat Washer, 5/16 11 BOW36751 4
27 Lockwasher, 5/16 11 BOW36726 4
2e Nut, Hex 5/16 11 -18UNC BOW31202 4
29 Screw, Hex Hd. Cap 1/4 11 -20UNC x 1/211 Lg. BOW30000 2
31 Flat Washer, 1/411 BOW31411 10
32 Screw, Hex Hd. Cap 1/4"-20UNC x 3/4 11 Lg. BOW30002 8
33 Screw, Hex Hd. Cap 1/4 11 -20UNC x 211 Lg. BOW30008 2
34 Screw, Hex Hd. Cap 3/8 11 -16UNC x 3/4 11 Lg. BOW30052 6
36 Flat Washer, 3/8 11 BOW31413 14
38 Screw, Round Head #1O-32UNF x 1/2" Lg. BOW31144 2
40 Plate, 'Boom Pin 32148 2
43 Nut, Flanged BOW46986 4
44 Counterweight 35795 1
45 Pin, Pivot Half - Main Boom 35012 2
0
47 Flat Washer, 1/211 BOW31415
"
5/86
FIGURE lOA POWER MODULE ASSEMBLY - WISCONSIN GAS ENG[NE
/ '
9
20
19
18
13
14
11/85
FIGURE lOA POWER MODUlE ASSEMBLY - WISCONSIN GAS ENGINE
Power Module Assembly 35350

1- Plate, Mounting'- Power Module 35699 1
2- rEngine and Pump Assembly 35330 1
3-rTank Assembly, Hydraulic 35360 1
4- rMufflerInstallation Reference Figure18A 1
5- ~Air Cleaner Installation Reference Figure 19 1
6- rBattery, 12 VDC 32614 1
7- rBracket, Tie Down - Battery 3506.9 2
8- ~Deflector, Heat - RH 35595 1
9- rElectric Motor/Pump Assembly Reference Figure 20 1
10- rCable, Battery - Ground 67296-022 1
11-rCable, Battery - Starter 67296-025 1
12-rCable, Battery - Emergency Pump/Motor 67296-002 1
13-rScrew, Hex Hd. Cap 5/8"-11UNC x 2-1/4" Lg. BOW30Hl5-225 4
14- ~Fl at Washer, 5/8" BOW31416 4
15-rScrew, Hex Hd. Cap 1/2"-13UNC x 111 Lg. BOW30104 4
16-,-Lockwasher, 1/2" BOW31329 4
17--Flat Washer, 1/2" BOW31415 4
18--Flat Washer, 3/8" BOW31413 4
19--Lockwasher, 3/8" BOW31327 4
20- -Screw, Hex Hd. Cap 3/8"-16UNC x 3/4" Lg. BOW30052 2
21- -Screw, Hex Hd. Cap 3/8"-16UNC x 1-3/4" Lg. BOW30057 2
22- -Hose Assembly, Fuel Line 1/4" x 30" Lg. 1
23- -Hose Clamp, 1/4" BOW24108 2
24- -Deflector, Heat - LH 35594 1
25..- Flat Washer, 1/4" BOW 36701 4
26- -Lockwasher, 1/4" BOW31325 4
27- -Decal, Battery - DANGER Reference Figure 2A 1
-r~rofk ~/el/O,J t{O aO~
11/85
FIGURE lOB POWER MODULE ASSEMBLY - DEUTZ DIESEL ENGINE
12
3
9
20
19
18
5
14
11/85
FIGURE lOB POWER MODULE ASSEMBLY - DEUTZ DIESEL ENGINE
Power Module Assembly 35566 1

1 Plate, Mounting 0- Power Module 35699 1
2 Engine & Pump Assembly 35026 1
3 Tank Assembly, Hydraulic 35360 1
4 Muffler Installation Ref. Figure 18B 1
5 Hose Assembly, Fuel Line 1/411 x 36 11 Lg. 1
6 Ba ttery, 12 VDC 32614 1
7 Bracket, Tie Down - Battery 35069 2
8 Ground Strap 32783 1
9 Electric Motor/Pump Assembly Ref. Figure 20 1
10 Cable, Battery - Ground 67296-022 1
11 Cable, Battery - Starter 67296-025 1
12 Cable, Battery - Emerg. Pump/Motor 67296-002 1
13 Screw, Hex Hd. Cap 3/8 11 -16UNCx 1-3/411 Lg. -BOW30057 2
14 Hose Clamp, 1/411 BOW24108 2
15 Screw, Hex Hd. Cap 1/2 11 -13UNC x P Lg. BOW30104 8
16 .. ockwasher, 1/211 BOW31329 8
17 Flat Washer, 1/211 BOW31415 8
18 Flat Washer, 3/8 11 BOW31413 4
20 Screw,Hex Hd. Cap 3/8"-16UNC x 3/4" Lg. BOW30052 2
21 Decal, Battery - DANGER Ref. Figure 2A 1
11/85
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FIGURE 12 PUMP/DRIVE ASSEMBLY (WISCONSIN GAS ENGINE)
Engine &Pump Assembly 35330

1 --Engine, 37 HP (Gas) 40017 1
2 - ~Bracket, Alternator Mounting 40166 1
3 -I-Strap, Belt Tension Adjuster 40162 1
4 - rCover, Alternator Pulley 40170 1
5 - ~V-Belt, 3/8" x 18" 32573 1
6 - f-Solenoid, 12 V qa'M R Thm1tk So/f>I/,d 32111 2
7 - r--Throttle Wire 21607 1
8 - I-Be 11 Hous i ng 40171 1
9 - I-COUP 1i ng 68221 1
10- ~Pump, Hydraulic 32524 1
11--Screw, Hex Hd. Cap 5/8"-IIUNC x 2 1/4" Lg. BOW30145-225 2
12--Wire,> Choke 351¥4 1
13--Alternator 322 8 1
14--Clevis - 1/4" x 2" BOW2023 2
15--Valve, Check 21368 1
16--Circuit Breaker 80044 2
17--Relay 80045 2
18-I-Relay, Anti-Restart 67280 1
19-t-Pin, Clevis BOW2120 2
20-t-Pi n, Cotter 1/16" x 111 Lg. BOW 38210 2
21- Nut, Hex - Keps #6-32 BOW31231 4
22- I-Lock Nut 1/4 11 -20UNC BOW 34272 4
23- t-Screw, Hex Hd. Cap 1/411 -20UNC x 1/2" Lg. BOW 30000 2
24- I-Lockwasher, 1/4" BOW31325 2
25- i-Flat Washer, 1/4" BOW31401 2
26- -Screw, Rd. Hd. #6-32 x 5/8" Lg. BOW31125 4
27- -Nipple, 1/2" x 3" Lg. Pipe BOW13449 1
28- -Coupling, 1/2" Pipe BOW13312 1
29- -Bushing, Reducer 1/2" to 3/8 11 Pipe 02653 1
30- -Elbow, goo - #8 JIC to #6 Pipe 04200 1
31--Cap, #8 JIC 02503 1
32--Screw, Hex Hd. Cap 5/16 11 -18UNC x 3/4" Lg. >BOW30027 1
33--Lockwasher, 5/16" BOW31374 6
34-- Fl at Was her, 5/16" BOW31432 6
35-t-Screw, Hex Hd. Cap 5/16"-18UNC x 1" Lg. BOW30029 5
36-I-Screw, Hex Hd. Cap 1/2"-13UNC x 2-1/2" Lg. BOW30110 1
37--Lock Nut 1/2"-13UNC BOW34276 1
38--Spider 40233 1
39--Key Stock 3/8 11 >x 3/8 11 X 2-1/4" Lg. BOW33978-001 1
40- -Set Screw, Allen Hd. 5/16 11 -18UNC x 3/8" Lg. BOW40531 4
41- -Screw, Hex Hd. Cap 5/8 11 -HUNC x 1-3/4" Lg. BOW30145-175 2
42- -Lockwasher, 5/8" BOW31331 4
43-I-Screw, Hex Hd. Cap 1/2"-13UNC x 1-1/2" Lg. BOW 30106 2
44-I- Lockwasher, 1/2" BOW31329 2
45-I-Flat Washer, 1/2" BOW31415 2
46-I-Connector, Straight #20 O-Ring to #20 Pipe 00370 1
47-I-Connector, Straight #20 O-Ring to #20 JIC 02582 1
48-I-Bushing, Reducer #20 Pipe to #12 Pipe 00386 1
49- -Connector, Straight #12 Pipe to #12 Pipe 04176 1
50- -Elbow, 90° #6 JIC to #4 Pipe 00128 1
51- -Elbow, goo #8 O-Ring to #6 JIC 02671 1
52- -Elbow, 90° #4 O-Ring to #4 JIc 02236 1
53- -Elbow, goo Modified #12 JIC to #12 Pipe 35664 1
54- -Spring 67461 1
55- -Nut, Jam 1/4"-28UNF> BOW32281 2
56- -Bracket, Solenoid Mounting 58216 1
10/86
60
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FIGURE 12A PUMP/DRIVE ASSEMBLY (DEUTZ DIESEL ENGINE)
Engine & Pump Assembly 35026 1

1 Engine, Diesel (37 HP) 21340 1
2 Pump, Hydraulic 32524 1
3 Bell Housing - Pump Adapter 35035 1
4 Adapter, Pump - Motor 32261 1
5 Bracket, Engine Mount - Front 35828 1
6 Bracket, Engine Mount - Rear 35824 1
7 Hood, Cooling Air 35037 1
8 Screw, Hex Hd. Cap 14mm x 40mm 19. BOW42137 2
9 lockwasher, 14mm BOW42457 2
10 Flat Washer, 14mm BOW42467 2
11 Screw, Hex Hd. Cap - 10mm x 30mm BOW42082 8
12 lockwasher, IOmm BOW43964 8
13 Flat Washer, IOmm BOW42465 8
14 Screw, Hex Hd. Cap -8mm x 25mm 19. BOW42056 6
18 Screw, Hex Hd. Cap 1/2"-20UNF x 1-1/2" 19. BOW30281 2
20 Adapter, Banjo Fitting 67157-001 1
21 Bolt, Banjo 67157-002 1
22 Washer, Banjo Fitting 67157-004 2
23 Switch, Pressure 67282 1
24 ~lbow, 45° Street 1/8" NPT BOW13280 1
25 Coupling, 1/8" NPT BOW13309 1
26 Nipple, 1/8" Pipe x 6" 19. BOW13416 1
27 Connector, Straight #20 O-Ring to #20 Pipe 00370 1
28 Connector, Straight #20 O-Ring to #20 JIC 02582 1
29 Bushing, Reducer #20 Pipe to #12 Pipe 00386 1
30 Connector, Straight #12 Pipe to #12 Pipe 04176 1
31 Elbow, 90° #6 JIC to #4 Pipe 1
32 Va 1ve, Check 21368 1
33 Elbow, 90° #8 O-Ring to #6 JIC 02671 1
34 Elbow, 90° #4 O-Ring to #4 JIC 02236 1
35 Elbow, 90° Modified #12 JIC to #12 Pipe 35664 1
36 Spring 67461 1
37 Bracket, Solenoid Mtg. &Speed Adjustment 40902 1
38 Plate, Solenoid Mounting 40806 1
39 Solenoid, 12 VDC 40808 1
40 Bracket, Spring Attaching 40764 1
41 Bracket, Shut-Off 40761 1
42 Spring BOW21659 1
43 Screw, Hex Hd. Cap 1/4"-20UNC x 3/4" 19. BOW30002 2
45 locknut, Hex 1/4"-20UNC BOW36780 5
46 Pin, Clevis 1/4" Dia. x 3/4" 19. BOW2120 1
47 Pin, Cotter 1/16" Dia. x 3/4" 19. BOW38209 1
48 Clevis BOW2023 1
49 Jam Nut, Hex 1/4"-28UNF BOW32281 1
51 Pin, Cotter 3/32" Dia. x 3/4" 19. BOW38216 1
52 Plate, Mounting - Electrical Relays 35047 1
11/85
FIGURE 12A PUMP/DRIVE ASSEMBLY (DEUTZ DIESEL ENGINE)
53 Screw, Hex Hd. Cap 1/4 -28UNC x 1/2/1 Lg.

11
BOW30000 3
54 Relay 80045 2
55 Relay, Anti-Restart 67280 1
56 Ci rcui t Breaker 80044 1
57 Screw, Round Hd. #6-32UNf x 1/2" Lg. BOW31124 2
58 Screw, Hex Hd. Cap - 12mm x 25mm Lg. BOW42101 4
60 Flange; Exhaust 35224 1
61 Elbow, 90° STR 1 1/2" NPT BOW13527 1
62 Union, 1 1/2" NPT BOW13394-1 1
63 Nipple, Pipe 1 1/2" NPT x 3" Lg. BOW13487 1
11/85
FIGURE 14 FUEL TANK ASSEMBLY
Fuel Tank Assembly 35386 1

1 Tank Weldment 35380 1
2 Cap 35382 1
3 Gauge EKI.,02627 1
4 Elbow, goo #4 JIC to #4 Pipe 00315 1
5 Cap! #4 04003 1
6 Coupling, goo Bulkhead #4 to #4 02317 1
7 Clamp, Hose BOW24108 2
8 Hose Assembly, 1/411 ID x 5-3/811 Lg. 35384 1
9 Valve, Gas 50545 1
10 Elbow, goP #4 JIC to #4 Pipe 00314 1
11 Screw, Hex Hd. Cap 3/8 11 x 16UNC X 111 Lg. BOW30054 3
12 Flat Washer, 3/8 11 BOW31413 3
13 Lockwasher, 3/8 11 BOW36727 3
14 Wobbulator 80188 1
16
15
14
If
10
1
2
1TT"--3
11/85
FIGURE 15 HYDRAULIC TANK ASSEMBLY
13
11/85
FIGURE 15 HYDRAULIC TANK ASSEMBLY
Hydraulic Tank Assembly 35360 1

1 Tank Weldment 35358 1
2 Elbow, 90° #12 JIC to #16 Pipe 02676 1
3 Elbow, 90° # 6 JIC to # 6 Pipe 00498 2
4 Nipple, Close Pipe 1/211 x 311 Lg. BOW13449 1
5 Quick Disconnect 67051 1
6 Elbow, 90° Street 1/211 Dia. BOW13273 1
7 Cap, Breather 35352 1
8 El bow, 45° Swivel #12 JIC 02328 1
9 Elbow, 90° Street 1-1/411 NPT BOW13276 1
10 Nipple, Close Pipe - 1-1/411 NPT BOWI3403 1
11 Valve, Ball "- 1-1/411 NPT 67714 1
12 Elbow, 90° - #20 JIC to #20 Pipe 02679 1
13 Gauge 35370 1
11/85
FIGURE 16 GROUND CONTROL CONSOLE
..
-
&I'l
FIGURE 16 GROlflD CONTROL GONSOLE

-
Control Console Assembly 35051 1

1 Switch, Toggle· 40874 4
2 Circuit Breaker, 20 Amp 80025 3
3 Hour Meter 80027 1
4 Switch, Toggle 50075 2
5 Ammeter, ±~O Amp 67240 1
6 Lock Switch, Ignition 80043 1
7 Screw, Sheet Metal - iffi x 3/8" Lg. BOW31711 7
8 Switch, Toggle 80026 1
9 Potentiometer 67203 1
10 Knob 67204 1
11 Re 1ay, Latchi ng 80023 2
12 Relay 67275 1
13 Relay 80377 1
14 Cap Screw, Hex Hd. 1/4"-20UNC x 4" Lg. BOW30016 4
15 Spacer 1/2" 00 x 3-1/4" Lg. ClLOO199-004 4
16 Rivot, Pop 1/8" Di a. BOW34172 7
17 Cover 35070 1
18 Flat Washer, 1/4" ID BOW31401 4
19 Slope Sensor 32002 1
20 Holden, Operation &Safety Manual 21383 1
21 Screw, Rd. H. #10-32UNF x 1 1/2 Lg. BOW31147 2
23 Nut, Hex #10-32 BOW31255 2
24 Flat Washer, #10 BOW31430 2
25 Decal - OPERATION AND SAFETY MANUAL Ref. Fi g. 2,2A 1
IS- Po,y- 7ef'tt1 ~1ijp RrNf)'B~3
4/86
FIGURE 17 TURRET ROTATION SPEED REDUCER (Starting with Ser. No. P282-005397)
1
11
10
7/86
FIGURE 17 TURRET ROTATION SPEED REDUCER (Starting with Ser. No. P282-005397)

-
1 Motor, Hydraulic 32762 1

2 Valve, Crossover Relief 32763 1
3 Speed Reducer 35971 1
4 Turret Weldment Ref. Fig. 10 1
5 Screw, Hex Hd. Socket 1/2"-13UNCxl 1/2" BOW33664 2
6 Lockwasher, 1/2"-High Collar BOW36745-l/2 2
7 Union, STR O-Ring #4-#4 Pipe 02525 1
8 Tube Assembly, 1/4" 1
9 Nut, Hex 5/8"-11UNC BOW31207 2
10 Bolt, Square Hd. 5/8"-llUNCx3 11 Lg. BOW63188 2
11 Washer, Square 35447 4
13 Screw, He~ Hd. Cap 1/2"-13UNCxl 3/4" Lg.Gr.8 BOW36107 4
14 Elbow, 90 Swivel #4-#4 02219 3
15 Shuttle Valve 35096 1
16 Screw, Hex Hd. Cap 5/16"-18UNCx2 1/2" Lg. BOW30035 4
18- Tube Assembly, 1/4" 2
19 Reducer, #6-#4 00425 2
20 Washer, Flat 5/16" BOW36726 4
21 Tee, O-Ring #6-#6 0 02576 2
22 Hose Assembly, #6-#6/90 22" Lg. BOW40180-172 2
23 Key, Woodruff - 1/4"x7/8" BOW31958 1
7/86
FIGURE 18 MUFFLER INSTALLATION (GAS)
REF DESCRIPTION PART ~UMBER QTY
1--+-Muffler--------------+---35529 ----1--1
2 U-Bolt Assembly 35574 2
3 Nut, Hex 1/2"-13UNC BOW31205 4
"4 Lockwasher, 1/2" BOW31329 4
5 Flex Tubing, Exhaust 30344 1
6 Union, 1-1/2" NPT . BOW13394-1 1
7 NiPfle, Close 1-1/2" NPT BOW13404 1
8 ue Tank Ref. Figure 15 1
7 _____~~)
6
3
11/85
FIGURE 18A MUFFLER INSTALLATION (DIESEL)
I.--+- Muffler - - - - - - - - - - - - - - - 1 - - - - 35529 - - - - 1 - - 1

2 U-Bolt Assembly 35574 2
3 Nut, Hex 1/2 11 -13UNC BOW31205 4
'4 Lockwasher, 1/2" BOW31329 4
5 Flex Tubing, Exhaust 40097 1
6 Union, 1-1/2" NPT BOW13394-1 1
7 Nipple, Close 1-1/2" X 3" Pip BOW13487 1
8 Elbow, 90° Street - 1-1/2" Pi pe BOW13277 1
9 Fuel Tank Ref. Figure 15 1
\
,
11/85
FIGURE 19 AIR CLEANER INSTALLATION
1 Bracket (Modification) 35608 1

2 Flexib le Hose 35610 1
3 Clamp BOW24118 4
4 Elbow, goo (Rubber) 35605 1
5 Tube, Connector 35612 1
6 Air Cleaner Modification 35657 1
9 Nut, Hex 1/4"-20UNC BOW31201 4
11/85
FIGURE 16 ELECTRIC MOTOR/PUMP ASSEMBLY FOR EMERGENCY SYSTEM
4-86
Motor/Pump Assembly 35659

1 Pump 35245 1
2 Motor 35244 1
3 Solenoid AZPOIOO5 1
Motor/Pump Assembly 35388

1
1--+-Pump---------------+---35389----+--1
2 Motor 35390 1
3 So lenoid AZPOlO05 1
11/85
FIGURE 21 BOOM ASSEMBLY (2-SECTION BOOM)
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FIGURE 21 BOOM ASSEMBLY (2-SECTION)
Boom Assembly (2-Section) 35400 1

1 Outer Boom Weldment 35420 1
2 Inner Boom Weldment 35430 1
3 Plate, Wear Pad Retaining 32718 5
4 Set Screw, 1/2"-20UNF x 3/4" Lg. BOW40561 10
5 Jam Nut, Hex 1/2"-20UNF BOW32285 10
6 Screw, Hex Hd. Cap 3/8"-16UNC x 5/8" Lg .. BOW30051 20
8 Wear Pad, Top 32717 1
9 Nut, Tee - 4-Prong 68276 2
10 Wear Pad, Sides 21812 4
11 Wear Pad, Bottom 32648 1
12 Mount, Wear Pad - Front 32647 1
13 Screw, Hex Hd. Cap 3/8"-16UNC x 3-1/4" Lg. BOW30063 2
14 Cylinder Assembly, Slave Leveling 30596 1
15 Screw, HexHd. Cap 1/4"-28UNF x 3/4" Lg. BOW30177 10
17 Plate,Cover 68223 1
18 Pin, Boom Eccentric 35409 2
19 Set Screw, Allen Hd. 3/8"-16UNC x 1/2" Lg. BOW41143 3
20 Bushing, Boom Pivot Pin 35417 2
21 Pin, Main Boom - Extension Cylinder 35788 1
22 Screw, 82° Flat Hd. Socket 3/8"-16UNC x
3/4 11 Lg. BOW36833 6
23 Nut, Lock 3/8"-16UNC BOW34274 4
24 Wear Pad 35194 1
25 Plastitrak, 59 Links 33082-013 1
26 Spacer, Extension Cylinder 35046 2
27 Wear Pad 32628 2
28 Nut, Hex 1/4"-20UNC BOW31201 2
29 Cable, Electric 30616-008 1
1.C.~~;' -~q Q., ~ QQ~4a SS9
30 Hose Assembly 2
31 Pi n, Cylinder 32024 2
33 Jam Nut, Hex 1/2 11 -13UNC BOW32275 1
34 Set Screw, Socket-Full Dog Pt. 1/2 11 -13UNC x
1-1/4" Lg. BOW40557-125 1
36 Pin, Master Leveling Cylinder to Boom 35015 1
37 Cylinder, Boom Extension Assembly Ref. Figure 26 1
38 Bearing 30389 2
39 Plate, Cover - Inner Boom ... 36398 1
40 Cylinder, Master Leveling ef. Fi~ure 25 1
41 Bracket, Track Mounting (Male) 6866 1 pro
42 Bracket, Track Mounting (Female) 68670 1 pro
43 Lock Nut, Hex 1/4 11 -20UNC BOW34272 4
44 Screw, Hex Hd. Cap 1/4"-20UNC x 5/8" 19. BOW30001 6
45 Star Nut, #10-24 BOW31234 2
47 Screw, Round Hd. #10-24UNC x 1/2" Lg. -. BPW30624 2
48 Screw, Hex Hd. Cap 1/4"-20UNC x 1/2" Lg. BO~!30000 4
49 Clamp, Cable - 1" BOW32585-1 2
50 Ring, Tie Down 32536 1
51 80143-011 2
Hose Assembly
52 .Wear Pad .35431 1
53 Wear Pad 35187 1
10/86
"
FIGURE 21A BOOM ASSEMBLY (3-SECTION BOOM)
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87 . 56 m
92 57
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FIGURE 21A BOOM ASSEMBLY (3-SECTION)
1 Outer Boom Weldment 35512 1

2 Intermediate Boom Weldment 35511 1
3 Inner Boom Weldment 35510 1
4 Cylinder, Extension Assembly Ref. Figure 26A 1
5 Evener Bracket, Trunnion Weldment 30428 1
6 Sheave 30204 4
7 Pin, Sheave 30398 4
8 Plastitrak, 83 Links 33082-012 1
9 Wire Rope, Extension Assembly 35517 2
10 Wire Rope, Retraction Assembly 35518 2
11 Guide Bracket Assembly . . 35709 1
12 Pin, Master Leve li n9 Cyl i nder 35015 1
13' Pin, Eccentric 35490 2
14 Pin, Extension Cylinder 35489 1
15 Pin, Extension Cylinder Trunnion 30246 2
16 Plate, Cover 68223 1
17 Wear Pad Mounting Bracket 30395 2
18 Wear Pad, Top and Side 30396 3
19 Wear Pad, Top Rear 68182 1
20 Plate, Back-Up 68036 1
21 Wear Pad, Top Front 30387 1
22 Capscrew, Hex Hd. 1/4"-20UNC x I" Lg. Gr. 5 BOW30004 8
23 Bracket, Track Mounting - Male 68669 1 pre
24 Bracket, Track Mounting - Female 68670 1 pre
25 Wear Pad, Guide Bracket - Side 35707 2
26 Pin, Leveling Cylinder 68192 1
27 Cylinder, Slave Leveling Ref. Figure 23 1
28 Wear Pad, Outer Boom 30225 6
29 Spacer 68183 6
30 Spacer, Wear Pad Bracket 30211 6
, 31 Holder, Wear Pad 68186 6
32 Hydraulic Hose Assembly 80143-009 4
33 Electrical Cable Assembly 30616-008 1
34 Wear Pad, Top Rear' 30230 1
35 Ring, Tie;.JDown 32536 1
36 Wear Pad Mounting Bracket. 33019 . 1
37 Pin, Main Pivot (Evener) 30423 1
38 Spacer, Evener 30262 2
39 rlead-End Bracket, RH 30458 1
40 Lockwasner, 3/8" BOW31327 10
41 ~am Nut, 1/2u -20UNF BOW32285 8
42 Screw,Hex Hd. Cap 1J4"-28UNF x 3/4" Lg. Gr.8 BOW 46300 6
43 Plate, Cover 30479 2
44 Bushing, Pivot Pin 35417 2
45 Wear Pad, Bottom Front 35777- 1
46 Dead-.f:nd Bracket, LH 30224 1
47 Bracket, Cable - Wear Pad Support 35775 1
48 Wear Pad, Rear Bottom 68180 2
49 Pin, Cable End 30216 4
50 Spacer 30394 1
51 Wear Pad, Side 30231 4
52 Wear Pad 30227 1
53 Nut, Tee 68276 6
54 Set Screw, Socket Hd. Cup Pt. 3/8"-16UNC x
1/2" Lg. BOW41139 5
6/86
FIGURE 21A BOOM ASSEMBLY (3-SECTION)
55 Star Nut, #10-24UNC BOW31234 2

57 Screw, #1O-24UNC x 1/211 Lg. BOW30624 2
58 Set Screw, Socket Hd. Cup Pt. 3/8 11 -16UNC x
3/411 19. BOW41140 '2
59 Wear Pad, Rear Bottom _""" 35778 2
60 Cover, Boom 30481 1
61 Screw, Hex Hd. Cap 3/8 11 -16UNC x P 19. BOW30054 2
62 Screw, Flat Hd. Socket Cap 1/4 11 -20UNC x
1/211 19. BOW36812 4
63 Spacer, EVener Rotation Pin 35642 1
64 Nut, Hex 5/8 11 -11UNC BOW36657 8
65 Flat Washer, 3/8 11 BOW36703 4
66 Screw, Hex Hd. Cap 1/4 11 -20UNC x 1/211 Lg.Gr8 BOW46000 16
68 Ring, Retaining BOW35300 1
69 Cylinder, Master leveling Ref. Fi gure 25 1
71 Locknut, 1/4"-20UNC BOW36780 8
72 Screw, "Flat Hd. Socket Cap 1/411 -20UNCx1 19II BOW41502 8
73 Grease Fitting, STR (Zerk) 1/4 11 -28UNF BOW7589 4
74 Screw, Flat Hd. Socket Cap 5/16 11 18UNC x
1-1/411 19. Gr.8 BOW41513 12
75 Set Screw, Socket Hd. Cup Pt. 5/8"-11UNC x
1-1/211 19. BOW41085 4
76 Jam Nut, 5/8"-llUNC BOW32277 4
77 Screw, Fl at Hd. Socket Cap 3/8"-16UNC x
1-1/211 19. BOW36836 12
78 lock Nut, 3/8"-16UNC BOW34274 33
"79 Screw, Flat Hd. Socket Cap 3/8 11 -16UNC x
1-1/411 19. BOW36835 6
80 Screw, Flat Hd. Socket Cap 3/8"-16UNC x
3/4" 19. BOW36833-750 8
81 Flat Washer, SAE 3/8" BOW36703 8
83 Screw,Hex Hd. Cap 1/2 11 -13UNC x 1-1/211 19.
Gr.8 BOW36106 4
84 Screw, Flat Hd. Socket Cap 3/8 11 -16UNC x
111 19. BOW36834 6
85 E-Clip, 7/16" Diameter BOW35239 4
86 Wear Pad, Guide Bracket - Top 35711 1
87 Screw, Flat Hd. Socket Cap 1/4"-20UNC x
1/211 19. BOW3681i1! 6
88 Screw,Hex Hd. Cap 3/8 11 -16UNC x 111 19. Gr.t:: BOW36054 16
89 Set Screw, Socket Hd. Cup Pt. 1/211-20UNF x
111 19. BOW40562 8
90 Plate, Cover - Inner Boom 36398 1
91 ~uide Bracket We'idment 68422 1
92 Screw, Hex Hd Cap 1/4 11 -20UNC x 3/4" 19.Gr.B BOW46002 11
93 .Jam Nut, 1/4 11 -20UNC BOW32271 8
94 Cable Clamp, P Diameter BOW32606 2
95 Screw, Hex Hd. Cap 3/8"-16UNC x 1-1/411 19.
Gr.E BOW36055 6
6/86
FIGURE 23 SLAVE LEVELING CYLINDER ASSEMBLY
Slave Leveling Cylinder Assembly 35402

1-+--S1ave Leveling Cylinder with Valve----f----30596 - - - - - + - - 1
2 Cylinder . 35074 2
3 Valve, Holding 30322 1
4 Tube Assembly 35404 2
5 Straight Connector, #4 JIC to #4 Pipe 00394 2
6 Screw, Hex Hd. Cap' 1/4 11 -20UNC x 1-1/211 Lg. BOW 36006 3
8 Flat Washer, J/411 BOW31431 3
9 Strap BOW5924 1
10 E1 bow, goo #4 JIC to #2 Pipe 00312 1
8
7
4 6
10
1
,..---...
/
j
/
/
FIGURE 25 MASTER LEVELING CYLINDER
12
12
Mcster Level ing Cylinder 35075 1

1 Locknut - Self-Locking 92027 1
2 Piston Secl - U-Cup * 2
3 Piston 92032 1
4 Rod Stctic Secl * 1
5 Bcrrel Assembly 92033 1
6 Rod Assem b Iy 92034 1
7 Glcnd Stctic Secl * 1
8 Glcnd 92023 1
9 Rod Secl * 1
10 Rod Wiper * 1
11* Secl Kit (Contcins Items 2,4p7,9,1O) 40684 1
12 Elbow, 90° #4 JIC to #2 ipe 00312 2
11/85
FIGURE 26 BOOM EXTENSION CYLINDER ASSEMBLY (2-SECTION BOOM)
Boom Extension Cylinder Assembly 35446

1---4-Cylinder 35072-----+---1
2 Holding Valve Assembly 40817 1
3 Wear Pad 32623 2
4 Screw, Hex Hd. Socket Cap 1/4"-20UNCx1/2" Lg.--BOW36812 8
5 Screw, Hex Hd. Cap 3/8/1-16UNCx3-1/2/1 Lg. BOW30064 4
Extension Cylinder with Holding Valve -35684
t
t
~
I
A
11/85
FIGURE 26A BOOM EXTENSION CYLINDER (3-SECTION BOOM)
Cylinder Assembly, Boom Extension 35554

1 Cyl inder 35071 1
2 Wear Pad 30386 1
3 Screw, Hex Hd. Cap Socket' 3/8"-16UNCxl Lg. ll BOW33634 6
4 Wear Pad 68191 1
5 Valve, Holding 40817 1
6 Screw, Hex Hd. Cap 3/8 -16UNCx3-1/2 Lg.
11 11 BOW30064 4
Cylinder with Holding Valve 35685 :i1.
7
6
5
I
, 3
~
11/85
FIGURE 27 TOPPING CYLINDER
Cyl tnderwtth YqJ v~ 30564 1

Cylinder only' . 3B073 1
I Piston 93018 I
2 Glond 93019 I
3 Barrel Assembly 93020 I
4 Rod .6ssembly 93021 I
5 Manifold Assembly 93022 I
6 Spacer 93023 I
I
7 Collar 93024
8 Bushing, Bronze 92001 4
9 Bolt, Valve Assembly 92009 2
10-I- Set Screw wi Nylon Insert 92012 I
II Nut, Hex Head 93025 I
12-I-Gland Static Seal I
13-I-Rod Seal
* I
* 2
14- -Piston Seal
*
15- -Rod Wiper I
*
16- -Rod Static Seal * I
17- - Counterbalance Valve Assembly 67455 I
18- I-lo ckwasher 92011 2
19-I- Plain Washer 92010 2
20-I - Cartridge 32585 1
21- I--Elbow, 90° #4 J Ie to #2 Pipe 00312 1
* Sea 1 Jit. o~ BS(?'1! 1
17
9
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18
19
20 6
~ ~
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12 13
21
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~ ~\'~ ////
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u 1
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11/82
FIGURE 28 PLATFORM ROTATION CYLINDER
1 Cylinder 35469 1
2 Lube Fitting, Drive-Type - 3/16 11 BOW7596 2
Seal Kit 35701 1
1
2
I I
n 11
I
I I
I
/
-
I@I
I' II - 0
,I I
I
11/85
FIGURE 30 PLATFORM ASSEMBLY
1 Platform Weldment 35458 1

60" x 30" X 43-1/211 High
FIGURE 31 PLATFORM CONTROL CONSOLE ASSEMBLY
Platform Control Console Assembly 35202

I Switch 50077 2
2 Switch 40877 I
3 Switch 40874 3
4 Switch 40876 I
5 Controller Assembly 40865 4
6 Switch 40872 2
7 Switch 40874 I
8 Panel 40867 I
9 Exterior Panel Housing 40870 I
10 Decal label 40869 I
/I Switch 50075 I
12 Indicator lamp 40879 I
13 Switch Guard 40880 10
13
FIGURE 32 PLATFORM SKIRT
1 Skirt Weldment 35470 1

2
FIGURE 33 PLATFORM FORK
1 Fork We 1dment 35440 1

FIGURE 35 ROTATION
180 0 PLATFORM~ _ _ ASSEMBLY
_ __
M
.-
-
N
..-
N
I
I
L\r--,,\\
0) /
~--1li-
1\ --0-
~I
M
.-
lI)
N
FIGURE 35 180 0 PLATFORM ROTATION ASSEMBLY
180 0 Platform Rotation Assembly 35225 1

1 Fork Weldment Ref. Figure 33 1
2 Link 35492 1
3 Bushing 35493 4
4 Bushing 35425 2
5 Bellcrank Weldment 35478 1
6 Screw, Hex Hd. Cap 1/4"-20UNC x 1/2" Lg. BOW 30000 13
8 Valve, -Holding 30322 1
9 Screw, Hex Hd. Cap 1/4"-28UNF x 13/4"-Lg: BOW36307 -3
10 Valve, Needle - 21479 1
11 Cover 35586 1
12- Cylinder, Rotation 35165 1
13 Skirt Weldment Ref. Figure 32 1
14 Rod End Weldment 35466 1
15 Pin, Cylinder to Skirt 35481 1
16 Bushing 35463 2
17 Pin, Bellcrank to Skirt 35475 1
18 Pin, Link to Bellcrank 35476 2
21 Pin, Fork to Skirt 35482 1
22 Pin, Fork to Link 35480 1
23 Snap Ring, 1-1/4" Diameter BOW35296 1
24 Snap Ring, 3/4" Diameter BOW35290 4
25 Screw, Hex Hd. Cap 1/2"-13UNC x 3" Lg. BOW30112 4
27 Lube Fitting (Zerk) BOW7596 4
28 Pin 35017 2
29 --
30 Nut, Hex 1/2"-13UNC BOW31205 1
31 Screw, Hex Hd. Cap 1/2"-13UNC x 1-3/4" Lg. BOW30107 1
32 Cl amp, 1" Di ameter BOW32606 1
33 Snap Ring, 1" Diameter BOW35293 1
34 Grommet 35661 2
35 Platform Assembly Ref. Figure 30 1
FIGURE 35A PLATFORM NON-ROTATION ASSEMB___
LY
~~\
LJ '"
I
I
L\~
00
,...
FIGURE 35A PLATFORM NON-ROTATION ASSEMBLY
Platform Non-Rotation Assembly 35230 1

1 Fork Weldment Ref. Figure 33 1
2 Skirt Weldment Ref. Figure 32 1
3 Link, Non-Rotation 35628 1
4 Pin, Fork to Link 35480 1
5 Pi n, Fork to Skirt 35482 1
6 Pin, Bellcrank to Skirt 35475 "
1
7 Pin, Boom to Skirt 35017 1
8 Pin, Slave Leveling to Skirt 35018 1
9 Bushing 30389 2
10 Snap Ring, 3/4 11 Diameter BOW35290 1
11 Snap Ring, 1-1/411 Diameter BOW35296 1
12 Snap Ri ng, 111 Di ameter BOW35293 1
13 Clamp, 111 Diameter BOW32606 1
14 LockWasher, 1/411 BOW31325 9
15 Screw,Hex Hd. Cap 1/4 11 -20UNC x 1/211 Lg. BOW 30000 9
16 Fl at Washer, 1/211 BOW31415 12
18 Screw,Hex Hd. Cap 1/2 11 -13UNC x 311 Lg. BOW30112 4
19 Platform Assembly Ref. Figure 30 1
20 Cover 35586 1
FIGURE 39 FOUR -WHEE!:..L~DR~IV~E~..:..:.:.:.
(OPTION_ 35543)
__
M
M
11/85
FIGURE 39 FOUR-WHEEL DRIVE (OPTION 35543)
1 Valve, Check 40795 2

2 - rE1bow, goo LL #8-#8 02514 1
3 - !-Flow Divider 21457 1
4 - -Coupling, STR M. Pipe #8-#8 02658 -2
5 - -Tee, Run - Male #8-#8 02697 2
6 - - Reducer, #8-#4 00564 3
7 - -Elbow, 90° Street #8-#8 00562 2
8 - -Valve, Flow Control - 6 GPM 40595 2
9 - -Valve, Selector 40594 1
10- -Elbow, goo O-Ring #4-#4 02236 3
11--Bushing, O-Ring ~12~#8 04039 3
12--Coupling, STR O-Ring #8-#12 00303 1
13--E1 bow, 90° - #4J IC #4 Pipe 00314 1
14--Va 1ve, Shuttle 35096
- .
-
1
15--Coupling, STR Male #4-#4 04174 2
16--Valve, Pressure Reducing 40597 1
17--Coupling, STR - ~4 JIC-#4 Pipe 01160 1
18·--Tee, Run #4-#4 02692 -1
19--Cap, #4 04003 i
20- - P.l ug ,O-R i ng 00417 1
21- -£1 bow, goo O-Ring #8-#12 02664 3
22- ~Tee, Service #4-#4 00344 3
23- -Rotary Coupling 32554 1
24- -Elbow, 90° Swivel #8-#8 02338 1
25-f-Tee, Service 90° Swivel #8-#8 00326 5
26- r- Tube Assembly 35118 1
27-rElbow, goo . #4JIC-#4JI~ 02424 1
28-I-CO llectorB lock 40577 1
29- f-Elbow, goo Swivel #4-#4 02219 1
30- r-E1bow, goo #8-#8 02475 1
31- rCoup1ing, Swivel #6M-#6FM Swivel 04215 2
32- I-Elbow, goo - Male #4-#6 02444 4
33- r- Coupli ng, STR - #4 J IC-#6 Pi pe 02793 3
34- f-Hose Assembly, 1911 Long 40180-239 2
35- I-COUp 1 i rig, STR O-Ri ng 00414 1
36- f-Coupling, STR #4-JIC-E4 Pipe 01160 1
37- f-Coupling, STR #4 Pipe-#4 Pipe 04174 1
38-,- I-Coupl ing ,STR #12 Pipe-#12 Pipe' 04176 1
39- I-Tube Assembly -- 35117 2
11/85
DaHl 4!'c. . r,-I-ll-U-S-TRA-T-EO-PA-R-T-S-B-REA-KD-OW-N-SE-C-T-ION----.
HAROlINES BRACKET 8
Ref. (PIN 35304)
3
4
9
FIGURE 15 HYDRAULIC TOOL CIRCUIT INSTALLATION
9200 Sorensen, Santa Fe Springs, CA 90670-2645

(213)946-6561 • Telex69-8378 • Fax213-946-2265
46Q8- 80-15 - 01
FROM SERIAL NO. 6154 ISSUED AUG. '89
B9NJIH'.··· ILLUSTRATED PARTS BREAKDOWN SECTION
OASH(-) ITEM NOT ILLUSTRATED
ITEM CALAVAR
NUMBER PART NUMBER DESCRIPTION QUANTITY
1 234 5
-1 46Q8-80-15 Installation, Hydraulic Tool Circuit Ref

(See 46Q8-80-01 for NHA)
2 34826 • Assembly, Tool Circuit 1
(See 46Q8-80-16 for OET)
3 67441 • Valve, Relief 1
4 EBROI004 • • Cartridge, Pressure Reducing 1
5 40595-003 • Valve, Adjustable Flow Valve 1
6 67169-005 • U-Bo1t (attaching parts) 1
7 27656 • Valve, Solenoid 1
8 36611 • Assembly, TEMP Troller 1
Electric Oil Cooler
9 36448 Assembly, Oil Cooler 1
(See 46Q8-80-17 for OET)
10 BOW23927 • Tie-Down AIR
-11 BOW26921 • Tie-Down AIR
FIGURE 15 HYDRAULIC TOOL CIRCUIT INSTALLATION
9200 Sorensen. Santa Fe SQrin9S. CA 9Oe1o-2645

(213)946-6561 • re'.ll69-8318 • Fax 213-~22es
46Q8 ~ 80- 15 -02
BaNI 48 B1e 8
• • Ir-I-LL-U-ST-RA-TE-O-PA-R-T-S-B-REA-m-OWN--SE-C-T-IO-N-
19
FIGURE 16 TOOL CIRCUIT ASSEMBLY

46Q8 - 80-16i' - 01
(213) 946-6561 • Telex 69-8378 • Fax 213-946-2265 FROM SERIAL NO. 6154 ISSUED AUG. '89
B9NJlN' • . . . ILLUSTRATED PARTS BREAKDOWN SECTION
DASH(-) ITEM HOT ILLUSTRATED
ITEM CALAVAR
12 3 45
-1 34826 Assembly, Tool Circuit Ref
2 • Assembly, Tube 2
3 • Assembly, Hose 2
5 AQTOI004 • Disconnect, Quick 1
6 AQTOI005 • Disconnect, Quick 1

7 34400 • Bracket, Cover 3
8 BOW30008 • Bolt, Hex (attaching parts) 3

9 BOW34272 • Nut, Hex Lock (attaching parts) 3
10 34820 • We1dment, Cover 1

12 BOW31326 • Washer, SPL Lock (attaching parts) 8
13 BOW31432 • Washer, Flat (attaching parts) 8
14 34373 • Plate, Track 1
15 34392 • Plate; Track 1
17 BOW31412 • Washer, Flat (attaching part 4
19 34825 • Channel, Track 1

20 BOW34283 • Nut, Lock (attaching parts) 2

22 34282 • Track, Close Cable 39
9200
CORPORATION
Santa Fe Springs. CA 90610-2645

(213) 946-6561 • Telex 69-8318 • Fax 213·9*2285
46Q8 - 80 - 116' - 02
ILLUSTRATED PARTS BREAKDOWN SECTION
OASH(-) ITEM NOT ILLUSTRATED
ITEM CALAVAR
1 2 3 4 5
23 34192 • Bracket, Cable (pair) 1

24 34191 • Bracket, Cable (pair 1
26 BOW31412 • Washer, Flat (attaching parts) 8
27 BOW34283 • Nut, Lock (attaching parts) 8

~vnR
CORPORATION
SivAn_n Santa Fe Springs. CA 90670-2645

(213) 946-6561 • Telex 69-8378 • Fax 213-946-2265
46Q8-80-16-03
fJOM SERIAL NO. 6154 ISSUED AUG. '89
saNl 48 rne••• Ir--I-ll-U-S-TRA-TE-O-PA-R-T-S-B-REA-KD-OW-N-SE-C-T-IO-N--'
TO
2 HYORAULIC
TANK
10
FIGURE 17 OIL COOLER ASSEMBLY

R.vnn
CORPORATION
9200 Sorensen. Santa Fe Springs, CA 90670-2645

46Q8- 80-171- 01
(213)946-6561 • Telex 69-8378 • Fax 213-946-2265 FROM SERIAL NO. 6154 ISSUED AUG. '89
ILLUSTRATED PARTS BREAKDOWN SECTION
DASH(-) ITEM NOT ILLUSTRATED
ITEM CALAVAR
1 2 345
-1 36448 Assembly, Oil Cooler Ref.
4 02440 • Connector, STR 2
5 35304 • Bracket, Hard1ines Mounting 1

8 02808 • Connector, STR 2
9 21463 • Cooler, Oil 1
10 GXC01526 • Clamp, Oil Cooler 6

14 BOW31201 • Nut, Hex (attaching parts) 6
-15 BOW23927 • Tie - Down AIR
FIGURE 17 OIL COOLER ASSEMBLY
9200 Sorensen. s.nta Fe SOling.. CA 90670-2645

(2131946-6561 • Te'ex 69·8378 • Fax 213·946-2215
46Q8- 80- 17-02
·oatu ~4 r&~. me-all> ,r--------.
. ILLUSTRATED PARTS BREAKDOWN SECTION]
13
14
10
~7
J,----8 11
® 12
FIGURE 28 DIESEL ENGINE SPECIAL OPTION INSTALLATION

CORPORATION
46 Q 8 - 8 0 - 2 8 - 0 1
(213)946-6561 • Telex 69-8378 • Fax 213-946-2265 FROM SERIAL NO. 6154 ISSUED AUG •• 89
B9NJIR' 4~-·· ILLUSTRATED PARTS BREAKDOWN SECTION
DASH(-) ITEM NOT ILLUSTRATED
ITEM CALAVAR
1 2 345
-1 46Q8-80-28 Installation, Diesel En9ine SpeCial Option Ref
2 58342 • Assembly, Air Cleaner 1
3 CNM00206 • • Cap, Air Inlet 1
4 • • Vacuator 1
5 • • Weldment, Cover 1
6 CNM00208 • • Element, Air Cleaner 1
7 • • Washer, Gasket 1
8 • • Bolt 1
9 CNM00202 • • Mount, Horizontal 2
10 • • Baffle 1
11 • • Pan, E1 ement 1
12 CNM00205 • • Band, Mounting 1
13 36600 • Separator, Fuel and Water 1
14 67808 • Panel, Diesel Engine Safety 1
FIGURE 28 DIESEL ENGINE SPECIAL OPTION INSTALLATION
SOrensen Santa Fe Springs. CA 90670-2645

(213,946-6561 • Tetex 69-8378 • Fax 213-946-2265
46Q8" SO - 2S- 02
~ROM SERIAL NO_ 6154 ISSUED AUG_ '89
BOOM exTENSION CY'llt'OER ASSV.
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HYDRAULIC TANK
,J J2800
DRIVE BlOCK
CAPACITY = 26,7 GALLONS_

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WHEEL MOTORS
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505047 .. 8 10 INUlAJiIIGI
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55 474e 5761 10 tMtA'1GJ
OPERATION AND SAFETY MANUAL
TELESCOPIC SELF-PROPELLED
AERIAL WORK PLATFORM
MODE LS 46Q-S AND 66Q-S
For Your Own Safety and Protection

• Read This Manual
Completely Before
Operating the Condor.
• Retain This Manual
en Lft.VnR on the Condor at all times.
CORPORATION
9200 S. SORENSEN AVE.• SANTA FE SPRINGS. CALIFORNIA 90670 Part No. 92246
SPECIFICATIONS
Model 46Q8 Model 66Q8
Maximum Platform Height 40 ft. 60 ft.
Maximum Working Height 46 ft. 66 ft.
P1 atform 5i ze 60"x30"x43.5" 60"x30"x43.5"
Rated Platform Capacity (Unrestricted) 500 lbs. 500 lbs.
Overa 11 length 26 ft. 31 ft.
Overall Height 7 ft. - 10 in. 7 ft. - 11 in.
Overall Width 7 ft. - 10 in. 7 ft. - 10 in.
Wheelbase 8 ft. S ft.
Travel Speed - Stowed 3.0 mph 2.5 mph
Travel Speed - Raised 1. 5 mph 1. 25 mph
Turning Diameter - Inside 14 ft. 19 ft.
Gross Weight - Approximate 13000 1bs. 28000 lbs.
Gradeability 18° (32%) 14° (25%)
Tires - Pneumatic 12x16.5 load Range D 15x19.5 load Range F
Turret Tail Swing Zero Zero
Hydraulic Tank Capacity 27 Gal. 52 Gal.
Fuel Tank Capacity 27 Gal. 40 Gal.
OPERATIONAL FUUCTION TIMES
lift - Up 45 Sec. 45 Sec.
lift - Down 40 Sec. 40 Sec.
Telescope - Extend 60 Sec. 65 Sec.
Telescope - Retract 55 Sec. 65 Sec.
Rotate 112 Sec. 125 Sec.
DRIVE SYSTEM TIMES - 50 ft. on firm level ground
High Speed - Forward 18 Sec. 13 Sec.
High Speed - Revers~ 18 Sec. 13 Sec.
low Speed - Forward 33 Sec. 26 Sec.
low Speed - Reverse 33 Sec. 26 Sec.
The Condor Models are designed and built to conform to Ca1avar ' s understanding
and interpretation of all applicable OSHA rules and regulations as well as ANSI
standards:
• OSHA TITLE 29, PARAGRAPH 1910.67 -
Vehicle Mounted
Elevating and Rotating
Work Platforms - Labor
• OSHA TITLE 29, PARAGRAPH 1926.556 - Aerial lifts
Construction
• ANSI STANDARD A92.5 - 1980 - Self-Propelled Elevating
Work Platforms
I CAUTION'
It is imperative that all owners and operators of the Condor read, understand,
and conform to these regulations.
Ultimate compliance to prevailing OSHA regulations is the RESPONSIBILITY of the
employer utilizing the equipment.
-1-
DIMENSIONAL DATA
CONDOR 66QB
TIP MOUNTED PLATFORM (Standard) TOP MOUNTED PLATFORM (Optional)
70' 70'
65' t-t--t--+--ib-;--+-+-+~_ _+--+----il 6S'
60' 60'
5S' 55'
50' SO'
4S' 45'
40' 40'
J: :c
3S' .9.'
'I> 35' ~
J:
::::
30'
g 30' E
(5
25'
iCL 25' ~
Q.
20' 20'
15' 15'
10' 10'
5' 5'
0' 0'
t--t-+-t-t--t-+-+-~::p;:::::;!::"d!rL-1l---1i-5'
!
L-...L...L-'--J_"--..l--I--..I..--1_'---'---'---I-10' ~...L--L.---L_'--...L--L.--L_'--.l..-...J...-'-......JL-.J_1 0'
-S' 0' S' 10' 1S' 20' 25' 30' 35' 40' .S' SO' 55' SO' -5' 0' S' 10' 15' 20' 25' 30' 35' 40' 45' 50' 55' 60'
Platform Reach (from centerline of turret rotation) Platform Reach (from centerline 01 turret rotationl
CONDOR 46Q8
TIP MOUNTED PLATFORM (Standard) TOP MOUNTED PLATFORM (Optional)
55' 55'
SO' SO'
45' .5'
d3. 40' 1"8 40'
/I ./ ",
J: J:
I!
~7
.--
'\.
35' .2'
30'
41
J:
E l;to- 1/
~ r--....
" '" \ 35'
30'
.2'
41
J:
E
t '"
(5
- \ 25' ~
0
25' -=.!!
~ '"
.- 1\ \ a:: CL
20' - 20'
--i
I[ \ 15' r-
f\ \ 15'
10' \ 10'
~r ~ ~ ~
5' ~ ~ .... ~ 5'
10 ~
::-,
~L--3
- h -.J
0'
-5'
-• 0'
-5'
-10' 10'
-5' 0' 5' 10' 15' 20' 25' 30' 35' 40' 45' -5' 0' 5' 10' 15' 20' 25' 30' 35' 40' 45'
Platform Reach ('rom centerline o'turret rotation) Platform Reach ('rom centerline 01 turret rotationl
-2-
INTRODUCTION
This manual is printed to assist the operator to better understand and operate
the Self-Propelled Condor TELESCOPIC Aerial Work Platform in a safe and profi-
cient manner.
For the operator's safety and protection, THIS MANUAL MUST BE RETAINED ON THE
CONDOR WORK PLATFORM AT ALL TIMES.
DESCRIPTION OF CONDOR
The Condor is a telescopic aerial work platform and is rugged, maneuverable, and
safe. It is designed for work on firm level surfaces with normal operation
controlled by an operator using a control box in the platform. All operational
modes can be accomplished from the platform including drive and steer. The
Condor provides industrial, construction and maintenance workers the ability to
safely elevate and perform installation maintenance and replacement tasks.
The Condor Model 46Q8 is powered by a Wisconsin Model VG4D air-cooled gasoline
engine rated, at 37 horsepower at 2400 R.P.M. As an option, a Deutz Diesel
engine Model F2L912 is utilized having a nominal horsepower rating of 30.
The Condor Model 66Q8 is powered by a Ford Model LSG-423 water-cooled gasoline
engine rated, at 63 horsepower at 2800 R.P.M. As an option an Isuzu t40del QD-60
water-cooled diesel engine is utilized with a horsepower rating of 60 at 3000
R.P.~1.
OPERATORS QUALIFICATION
Each Condor TELESCOPIC UNIT has undergone a thorough Quality Control inspection
at the factory. The design incorporates built-in safety features. A person of
average skill can readily become proficient and safe in the operation of the
CONDOR. It is a personnel lifting device and can be potentially dangerous in
the hands of UNTRAINED or CARELESS OPERATORS.
Knowing the characteristics of the machine and function of the controls is
important to SAFE, PROPER OPERATION AND USE. Becoming familiar with the
controls and practices will result in smooth accurate positioning.
It is the responsibility of all users to read and comply with the following
rules and information designed to promote SAFETY and UNDERSTANDING of the
Condor.
• A thorough understanding of the operating characteristics and
limitations of the CONDOR machine is always the first requirement for
any user, regardless of his prior experience with similar types of
equipment.
• Only QUALIFIED/TRAINED and AUTHORIZED personnel must be ALLDWED.to
operate the Condor. A QUALIFIED/TRAINED operator is one who has READ
and UNDERSTOOD the instructions in this manual, and is thoroughly
familiar with the operating characteristics and limitations of the
machine.
-3-
• REPAIR and ADJUSTMENTS should be made only by QUALIFIED/TRAINED
personnel.
• No MODIFICATION is to be made to the machine without prior written

consent of the Calavar Engineering Department.
• UNDERSTAND and OBEY all Federal, State and Local statutes and regula-
tions applying to safe operation and use of aerial work platform.
YOUR SAFETY IS OUR UTMOST CONCERN

AND YOUR RESPONSIBILITY
DANGER, CAUTION AND WARNING DECALS are designed for your protection. Know and·
adhere to the information they provide.
ELECTROCUTION .HAZARD
YOU MUST NOT OPERATE THIS MACHINE
KEEP CLEAR UNlESS YOU AR£ QUAlIFI£o 8Y TRAINING AND EXPERIENCE
OIATII 01 SEIIOtS ".Ut, (All IISUlT flOM IN THE SAn OP£RATION OF THIS MACHINE.
{ONTAO WIT" THIS EQUlPMEIiT 01 V£HKlE TRAINING INCLUO£S COMPlETE KNOWLEDGE OF
If IT SMOUlt I( W<TRKAUY (llAlQD. "11,·, YOUR EMPlOYER·S WORK RUlES. All GOVERNMENTAL
REGULATIONS. AND MANUUCTURER·S OPERATOR
AND SAFETY MANUALS R£LATIVE TO THIS
MACHINE·S SAfE USE.
AN UNTRAINED OPERATOR SUBIECTS HIMSElF ANO OTHERS TO
DEATH OR SERIOUS INJURY
ELECTROCUTION HAZARD & CAUTION

...ITAII WE aU"len fUM UfCTlICAllllES
All . "..Am ' " MUST w... FOt _ SMAY. 1. DO NOT OPERATE THIS MACHINE UNlESS YOU ARE QUAUFIED BY
_ . II sac ... EIlCTlICAl OlE ... l ••• lRAlNING It EXPERIENCE IN ITS SAFE OPERA11ON.
SWAn",
TIIII .IIAl .... PUTfII. HEI lIT ......E
2. RAISE PlAWORM ONLY 'MiEN MACHINE IN ON A FIRM. LE\£L SURFACE.
PllTlCTIII fUM C"'ACT .,TI "'IIMI"
lUcmcW.' C_EI alltlCTIl
II II •• l. DO NOT DRI'tt: ON SLOPE UNLESS PlAWORM IS FULLY LOWERED.
4. If' SLOPE ALARM SOUNDS. CARRIAGE IS OUT OF LE\£L. RElRACT BOOM
'III IIIST OIT"I A cn...UE If aT nAST II
flU tmI£ll AI, .AIT If TIE .... tUff.....
AND LOWER ARt.ts. THEN REPOSI11ON MACHINE ON A FIRM.
lUI ... AI, UfCIIICAl UIE .1 m.""I
_ I I ' ., II 5.111 IOUS. alE FGeT .aDlTIO••l
LE\£L SURFACE.
CllA..ICl IS 1£",lIfI FOI Etfn ••DlTtOtAl
5. THIS MACHINE IS NOT INSULATED. DO NOT OPERAlE WITHIN 10 FEET
lUll lOllS III IlSS OF ELECTRICAL POWER UNE5.
••" III SUIIUS IIIJIII' .'ll usun fl . . 8. IN CASE OF EMERGENCY. PUSH POWER -OfF" BUTTON ON THE PLA WORM
CIITACT II .IAluu.n ClU ...C[
CONTROL CONSOLE.
-4-
LOADING-TRANSPORTING-UNLOADING
The Condor -TELESCOPIC UNIT- although somewhat small in stature compared to larg-
er type construction equipment still requires the same care and attention in
LOADING, TRANSPORTING, and UNLOADING as does the larger heavier type equipment.
At no time should sight of this be OVERLOOKED.
LOADING AND UNLOADING

Before loading/unloading the Condor, inspect for any physical damage or defects.
DO NOT OPERATE A DEFECTIVE OR MALFUNCTIONING UNIT •
. 1 CAUTION _
The Condor Model 46Q8 weighs approximately 13000 lbs. and the Model 66Q8 weighs
approximately 28000 lbs. Whatever means is used to load/unload the unit, it
should be of sufficient strength to withstand the weight of the Condor.
DO NOT ATTEMPT TO OPERATE THE UNIT UNTIL YOU READ AND THOROUGHLY UNDERSTAND ALL
INFORMATION PROVIDED ON THE OPERATION OF THE UNIT. FAMILIARIZE YOURSELF WITH THE
CONTROLS, THEIR FUNCTION AND OPERATION.
IWARNING'
REMOVE TURRET LOCK-PIN BEFORE ROTATING TURRET, IF SO EQUIPPED
A. RAMP METHOD
1. Ensure that ramp being used is sufficiently strong to handle the weight
of the unit.
2. Ramp should be· set at an angle no steeper than 18° (32%) 39 11 rise in
10ft. for Model 46Q8 and 14° (25%) 30 11 rise in 10 ft. for Model 66Q8.
3. The normal driving position of the Condor is with the turret
counterweight over the steering/drive wheels. The controller movement
is based on this configuration. When the counterweight is positioned
over the non-steering wheels, the drive and steering controls will be
reversed. Try each control momentarily to orient yourself with the
direction of operation.
4. Before driving the unit on the ramp, test all the controls and the
brake system. Make sure that the operating levers return smoothly to
the neutral, center position. Then move the Condor slowly back and
forth and ensure brakes automatically apply each time the drive control
lever goes back to the neutral position.
-5-
5. Move the unit on the truck or trailer, up or down the ramp approximate-
ly a foot at a time allowing the steering corrections to be made. Keep
unit in alignment with the carrier and ramp during loading or unloading
procedure.
6. It may be necessary to elevate the boom slightly to clear the ground or
ramp as you load or unload. The unit is equipped with a slope sensor
which senses 5° out of level condition. When unit encounters a slope
of 5° or more the boom functions are automatically de-energized.
B. TRANSPORTING
The Condor can be easily and safely transported from job site to job site if
a few simple rules and procedures are followed:
1. Block all wheels to prevent forward and reverse motion.
2. Tie down the Condor with chains or cables running them through the tie
down brackets.
3. Place wooden pallets under platform then tie down platform as indicat-
ed.
PALLETS
-6-
\
PRE-OPERATION INSPECTION
The CONDITION of the unit prior to .start up is a very IMPORTANT factor as it di-
rectly affects the operator's SAFETY. It should be a common practice that the
operator perform a general inspection before each day's operation of the work
platform.
The purpose of the operator's inspection is to keep the CONDOR in PROPER working
condition and to DETECT any sign of malfunction during normal operations between
scheduled maintenance checks.
DOWNTIME is COSTLY and can be prevented by taking a few minutes prior to startup.
A thorough walk around inspection must be performed each day before the Condor is
operated. Report damage or faulty operation immediately. Attach a sign at the
ground control area stating DO NOT OPERATE. Repair any discrepancies before use.
Some of the major items to check are:
1. OVERALL MACHINE CONDITION
A. Ground controls/platform controls - Controls return to neutral
(center) when actuated.
B. Hydraul i c leaks.
C. Electrical system for frayed or broken wires or loose connections.
D. Missing, broken, or damaged parts, pin retainers, bolts and nuts.
E. External structural damage, or cracked welds.
F. Condition of tires - pits, tears, cracks or cuts.
G. Steering connections, tie rod, cylinder.
H. Wheel lug nuts - misSing or loose.
I. Decals, placards, warning signs.
J. Proper tire pressure.
K. Boom - pivot, pin areas, wearpads, cylinder.
L. Check bolts securing ring gear to chassis and turret for tightness and
that all lock tabs are in place.
M. Inspect boom cables for fraying or damage and tightness and proper
installation on sheave (3-section boom units).
2. PLATFORM
A. Pivot points, connections.
B. Structural condition - damaged railings, flooring.
C. Control box - electrical wiring for frayed or broken wires, damaged
components; hoses, loose connections.
D. Access openings, slide bar freely moves.
-7-
3. BATIERIES
A. Electrolyte level - all caps present.
B. Cables and connections - ground connection.
C. Battery holddown.
4. ENGINE
A. Fuel level.
B. Oil level.
C. Mounting.
D. Check for fuel, oil leaks.
5. HYDRAULIC SYSTEM
A. Hydraulic leaks.
B. Loose or damaged hoses, tubing.
C. Fluid level, hydraulic tank breather cap. Refill only with Automatic
Transmission Fluid - Dextran II.
D. Hydraulic valves and control levers.
E. Cleanliness of hydraulic fluid - non-milky, bright in color.
6. MULTI-AXIS 5° SLOPE SENSOR
A. General condition.
• B• Loose or damaged wires.
C. Push to test. Moveable on mounting.
O. Warning light/alarm in platform is operable.
KNOW THE UNIT AND ITS CAPABILITIES. Report any unusual operation, erratic sway
or motion of boom or platform while being operated, excessive, unusual noise,
abnormally slow or fast operation.
CAUTION'
Defective components, structural damage, missing parts or equipment malfunctions

jeopardize the SAFETY of the operator and other personnel and can cause extensive
damage to the Condor. A POORLY MAINTAINED machine could become the greatest OP-
ERATIONAL HAZARD you may encounter.
-8-
CONDOR 46Q8 COMPONENT IDENTIFICATION
MOTOR/PUMP HYDRAULIC TURRET

ASSEMBL Y ---.. TANK
BATTERY -----.
WARNING HORN
ENGINE ----.
FUEL TANK
SPEED REDUCER -----
ROTARY COUPLING
GROUND CONTROL BOX
FILTER PROPORTIONAL_----' 5" SLOPE SENSOR

CONTROL VALVE
OUTER BOOM -----.. TURRET
PLATFORM
INTERMEDIATE CARRIAGE
BOOM (3-SECTION ONLY)
FOOT _---J
SWITCH
INNER BOOM
L------------------------9-----------------------~
CONDOR 66Q8 COMPONENT IDENTIFICATION
50 SLOPE SENSOR - - - - " - 7
GROUND
CONTROL ---,.
BOX
WARNING HORN --""""'\
SPEED
REDUCER
PROPORTI ONAL
CONTROL VALVE
ROTARY COUPLING
OUTER
BOOM ------ TURRET
HYDRAULIC
TANK ---,.
FUEL _ _,
TANK
RETU
FILTER
AERIAL INTERMEDIATE
CONTROL--"""'\ BOOM ---.
BOX
PLATFORM HIGH PRESSURE

'-----'-...;;.. FI LTE R
DRIVE VALVE---'
FOOT SWITCH PROPORTIONAL DRIVE
VALVE
~--------------------------------10--------------------------------~
CONTROL FAMILIARIZATION AND LIMITATIONS
It is important from a SAFE operational standpoint that you, the operator, know
the function of each control, its limitations, as well as that of the unit. A
good understanding of the controls, limitations and capabilities will enhance op-
eration and assure maximum operating efficiency and SAFETY.
A. PLATFORM CAPACITY
The platform capacity of the Condor TELESCOPIC BOOM UNIT is unrestricted and
is applicable within the operational envelope/positions when operated on
firm surfaces and slopes not exceeding 5°. The capacity includes the re-
quired OSHA and ANSI safety margins. DO NOT lessen the SAFETY MARGIN by
overloading the platform beyond RATED CAPACITY.
Model 46Q8 -------------------- 500 lbs. (TIP MOUNTED 5 FT. PLATFORM)
Model 46Q8 -------------------- 750 lbs. (TOP MOUNTED 5 FT. PLATFORM)
Model 66Q8 -------------------- 500 lbs. (TIP MOUNTED 5 FT. PLATFORM)
Model 66Q8 -------------------- 650 lbs. (TOP MOUNTED 5 FT. PLATFORM)
The platform capacity noted above is the combined weight of all personnel, their
tools and any other equipment or materials carried by the platform. Larger
platforms require de-rating capacity.
I
WARNING I
Proper stability of the CONDOR is based and tested on the standard unit and all
of its components as supplied by the factory. Any modifications of the unit ei-
ther by the addition or removal of parts and/or weight can greatly affect the
unit's STABILITY and SAFETY.
B. TRAVEL
Travel can be accomplished from both the stowed position or with platform
elevated. Although the gradeability of the unit is 18° (32%) for Model
46Q8; 14° (25%) for Model 66Q8, this should only be negotiated with the
platform in stowed position. The CONDOR is designed to travel with platform
elevated on firm level surfaces only.
The brake of the unit is automatically applied when drive control is re-
turned to neutral. It is automatically released when drive control is acti-
vated. RELEASE of drive lever will APPLY the brake. AVOID RELEASING of
drive lever at full speed as drive function will CEASE ABRUPTLY causing a
sudden movement of the platform.
Maximum travel speed is 3.0 m.p.h. for Model 46Q8; 2.5 m.p.h. for Model
66Q8. This;s high speed travel and is only available with boom below
horizontal.
Low speed mode is available by moving HIGH/LOW SPEED toggle switch to LOW.
Low speed is automatically shifted when boom is elevated above horizontal.
-11-
C. GROUND CONTROLS
The ground controls are located on the turret. No means is provided to
DRIVE or STEER the unit from the GROUND CONTROLS.
Only the aerial functions can be accomplished. The boom can be raised or
lowered, extended, or retracted and the turret can be rotated.
• KEY SWITCH
The ground panel has a POWER KEY SWITCH. The key straight up center
position is "OFF" and disconnects all power. With switch in "ON" posi-
tion the electrical circuit is energized. Switch must be "ON" to
energize ground or platform controls.
• ENGINE START/STOP - SWITCH
Toggle switch for start-stop of engine. Switch is momentary meaning it
returns to center position when released. Actuate switch UP to START
engine; DOWN to STOP engine.
• CHOKE SWITCH
Toggle switch to activate engine choke. May be used in conjunction·
with engine START toggle switch. Purpose to assist starting of engine
first time in morning or after long periods of non-use. Actuate CHOKE
switch "UP" for operation.
• AERIAL/GROUND SWITCH
Two-posit-ion toggle switch for selection of operation from ground con-
trol or platform controls. The "GROUND" position directs the power to
the ground control panel. The "AERIAL" position directs the power to
the aerial control console energizing it for operation of the platform
controls. NOTE: When in AERIAL position the control can be moved to
"GROUND" at anytime making aerial controls inoperable.
• 800M RAISE/LOWER
Momentary, return to center, toggle switch to raise or lower boom. Ac-
tuate switch to "UP" position RAISES boom; "DOWN" position LOWERS boom ..
• TURRET - ROTATE
Momentary, return to center, toggle switch to rotate turret. Actuate
switch to "RIGHT" rotates turret CLOCKWISE; to "LEFT" rotates turret
COUNTERCLOCKWISE.
• 800M - EXTEND/RETRACT
Momentary return to center toggle switch to extend or retract boom.
Actuate switch to "UP" position to EXTEND boom; -DOWN- position to RE-
TRACT boom.
-12-
• SPEED CONTROL
Since a toggle switch control does not offer feathering of function the
speed of the function can be controlled by use of the SPEED CONTROL.
With knob set at TURTLE speed the function is MINIMUM/SLOW. Turning
knob toward RABBIT/FAST increases speed.
• EMERGENCY CONTROL
The momentary toggle switch positioned in the triangle border is used
to activate the emergency pump and motor. Actuate and hold EMERGENCY
switch in conjunction with desired aerial function; boom up-down; tur-
ret rotate or boom extend-retract.
• CIRCUIT BREAKERS
Circuit breakers are used to protect the electrical system. These are
of the fuse type. Should one burn out it is due to overload or
short-circuit and cause should be investigated before further opera-
tion.
• HOURMETER AND AMMETER
Hourmeter is used to record number of hours machine is used. Note the
key switch energizes the hourmeter which records even if engine is not
running.
Ammeter is used to indicate the battery draw and charge.
D. PLATFORM CONTROLS
The platform controls are only ENERGIZED when the key switch at ground panel
is NONN and the SELECTOR switch is in AERIAL position.
The platform control console provides for complete operation of the unit.
The controls are energized only when the FOOTSWITCH is depressed and held.
• POWER ON/OFF SWITCH
Pull to turn on, START engine ------ push to turn off, STOP engine.
NOTE - This is also the emergency switch. PUSH TO STOP ALL FUNCTIONS.
INOTE'
The controls for drive and the aerial functions of the boom and turret
are a proportional control. This type control enables the operator to
obtain a higher degree of controllability by feathering the controller.
The controller contains a safety lock feature which is released by
pulling UP on the KNOB. The lever is also spring return to neutral.
-13-
• DRIVE FORWARD/REVERSE
Forward motion is determined with STEERING/DRIVE wheels leading the
way. REVERSE motion is determined with NON-STEERING wheels leading the
way. Actuate lever AWAY from the operator for FORWARD motion; TOWARD
the operator for REVERSE motion.
INOTE I
The recommended travel position is with TURRET COUNTERWEIGHT over the
STEERING/DRIVE wheels.
• HIGH/LOW SPEED
Two (2) position toggle switch for selection of travel speed. Actuate
switch AWAY from operator for HIGH speed; TOWARD operator for LOW
speed.
NOTE - High speed can only be obtained with boom below HORIZONTAL.
Speed will be AUTOMATICALLY switched to LOW if boom is RAISED above
HORIZONTAL. This will occur even if HIGH-LOW switch is in HIGH
position.
• STEER .- LEFT/RIGHT
Toggle switch for control of steering wheels. Switch is momentary
meaning it returns to center position when released. Actuate switch to
LEFT to turn wheels for LEFT turn; RIGHT for RIGHT turn.
• BOOM - RAI SE/LOWER
Proportional control for raising or lowering boom. Move lever AWAY
from operator to RAISE boom; TOWARD operator to LOWER boom.
• BOOM - EXTEND/RETRACT
Proportional control for extending or retracting telescopic section of
boom. Move lever TOWARD operator to EXTEND boom; AWAY from operator to
RETRACT boom.
• TURRET - ROTATE
Proportional control for rotation of turret. Move lever TOWARD op-
erator to rotate turret CLOCKWISE; AWAY from operator to rotate
COUNTERCLOCKWISE.
• PLATFORM TILT
Toggle switch for control of changing the attitude of the platform in
the relation to the ground. It is a powered means of adjusting the
levelness of the platform. To TILT platform UP, actuate toggle switch
away from operator; TOWARD operator tilt platform DOWN.
-14-
• PLATFORM ROTATION
Toggle switch for control of platform rotation 90° either sided of cen-
ter. Actuate switch to RIGHT, pl atform wi 11 rotate to operator's
RIGHT; Actuate switch to LEFT to rotate to LEFT.
• SLOPE - WARNING LIGHT
This light is used to indicate that unit is being operated on slope in
excess of 5°. When light is -ON- the aerial functions are INOPERABLE.
When this occurs unit must be repositioned.
• EMERGENCY CONTROL
The momentary toggle switch positioned in the triangle border is used
to activated the emergency pump and motor. Actuate and hold EMERGENCY
switch then actuate desired aerial function toggle switch; boom down;
turret rotate; boom retract.
COIITROl [DEllI FI CATIOII
EXTEND
TURRET BOOM--...., REVERSE
ROTATION RETRACT DRIVE
FORWARD
UP
800M--_ START
DOWN ENGINE
STOP
5' SLOPE
ALARM
PLATFORM
ROTATION----------
UP
PLATFORM -----+--'~~~_"r.\
DOWN
LEFT _ EMERGENCY
STEER -::, ,:3, TURRET
RIGHT ROTATION
GAS/ LP~EMERGENCY BOOM RET.
EMERGENCY
CHOKE SYSTEM
ACTIVATION
UP
TURRET _ _---..
ROTATION
DOWN
EXTEND
BOOM
BOOM---....... RETRACT
EMERGENCY
FAST/SLOW - -....... SYSTEM
ACTIVATION
AERIAL
CONTROL BOX----.,.
GROUND HOUR METER
SiART
___--ENGINE
CHOKE---, STOP
AMP METER
KEY SWITCH
-15-
SYMBOL CONVERSION
~
£
UP ON
EMERGENCY ",.
BOOM SYSTEM LIGHTS
DOWN ACTIVATION
® OFF
(OPTION)
~
TURRET
ROTATION EMERGENCY
BOOM
RETRACTION ® START
AUX. ENGINE
®
STOP
t
RETRACTION
BOOM
EMERGENCY
EXTENSION BOOM
ROTATION
REVERSE
@ START
ENGINE
t <i STOP
DRIVE EMERGENCY
FORWARD
BOOM
LOWER
";'" KEY SWITCH

it'
FAST
~
Y STEER TRAVEL SPEED

R/L SLOW
HOUR METER
~\
UP HORN AMP METER
PLATFORM CJ~
DOWN
~
IS] CHOKE AERIAL CONTROL
BOX ACTIVATED
..,¥, PLATFORM
ROTATION
GASOLINE
~
GROUND CONTROL
BOX ACTIVATED
e~
PUll TO START
ENGINE DUAL FUEL
!: ! PUSH TO STOP Gt> ( OPTION)
16
OPERATIONAL PROCEDURE
Prior to operation of the Condor, for your OWN SAFETY, it is your
RESPONSIBILITY to insure that the unit is in proper working condition and
the PRE-OPERATION INSPECTION has been performed.
I CAUTION I
Located on the inside cover of this manual are a few DO NOT'S relative to proper
operation and maintenance. ACQUAINT yourself with these simple RULES and be
ALERT to their signs.
I WARNING I
OBSERVE ALL SAFETY PRECAUTIONS WHILE OPERATING THE MACHINE. Before starting en-
gine check fuel level and for any leaks in the fuel system.
A. OPERATION FROM GROUND CONTROLS

• Turn KEY SWITCH to RON R position.
• Move START-STOP toggle switch to START position. Note: It may be nec-
essary to choke engine. Actuate CHOKE switch holding into position
while actuating START switch.
• Place AERIAL-GROUND selection switch to GROUND position.
I
WARNING I
Check for overhead obstructions directly over machine as well as over platform.
Also if unit is to be rotated check for obstructions on either side of the ma-
chine.
• Raise platform by actuating boom RAISE-LOWER toggle switch to RAISE po-
sition.
• Extend boom by actuating boom EXTEND-RETRACT toggle switch to EXTEND
position.
I
WARNING I
REMOVE TURRET LOCK PIN BEfORE ROTATING TURRET IF SO EQUIPPED.
• Rotate turret by actuating ROTATION toggle switch to desired position.
RIGHT for CLOCKWISE rotation; LEFT for COUNTERCLOCKWISE rotation.
-17-
NOTE'
Ground panel is equipped with a SPEED CONTROL for the aerial functions. Rotating
knob toward TURTLE slows function; toward RABBIT increases speed.
CAUTION I
Exercise extreme care in operating these controls. AVOID JERKY MOVEMENTS. Al-
ways LOOK in the direction of platform and turret movement. Make SURE there is
no OBSTRUCTION and that SUFFICIENT CLEARANCE exists for the platform.
• To lower platform activate appropriate functions' toggle switch for
LOWER, RETRACT or ROTATION modes.
• At the end of the operation STOP engine and turn KEY SWITCH to OFF po-
sition.
B. OPERATION FROM PLATFORM CONTROLS

• At ground control console turn KEY SWITCH to RON R. Move AERIAL-GROUND
selector switch to AERIAL position.
• Enter the platform of the CONDOR with the access provided. Ensure that
the platform entrance SLIDE BAR is in the DOWN position.
• At the control console pull the POWER switch to RON" position. This
will start the engine.
• Depress the FOOT SWITCH and HOLD. This will energize the control cir-
cuit as long as the foot switch is depressed.
• DRIVE
To operate drive, lift up on knob and gradually move lever in desired
direction of travel. Make SURE area around the machine is ClEAR before
traveling.
I WARNING I
FORWARD/REVERSE and LEFT/RIGHT steering movement directions indicated on the
control panel refer to control with the platform and boom over the steering/drive
wheels.
• The speed of operation is dependent on the position of the control le-
ver, full position will give full speed. The brakes are automatically
released when drive control is activated and automatically applied when
control is returned to neutral/center position.
-18-
• Start and stop the operation GRADUALLY. The SMOOTHER you move the con-
trol lever the SMOOTHER the unit will respond. AVOID releasing the le-
ver COMPLETELY.
• STEERING
Is controlled by activation of the toggle switch. Move switch in de-
sired direction and HOLD until the turn is complete. Switch will re-
turn to center position however steering wheels will remain in last ac-
tivated position. To center wheels move switch in appropriate direc-
tion until travel is straight.
• BOOM - RAISE/LOWER
To raise boom, depress footswitch and move lever on control console
AWAY from operator. To LOWER boom move lever TOWARD operator.
• BOOM - EXTEND/RETRACT
Depress footswitch and move lever TOWARD operator to EXTEND; AWAY from
the operator to RETRACT.
• TURRET ROTATION - CLOCKWISE/COUNTERCLOCKWISE

To rotate turret depress footswitch and move lever in desired direction
for desired movement; TOWARD operator for CLOCKWISE rotation; AWAY from
operator for COUNTERCLOCKWISE rotation.
• TILT - UP/DOWN
To make adjustment for leveling of platform or tilting to facilitate
loading of materials, depress footswitch and actuate toggle switch to-
ward operator to LOWER; AWAY from operator to RAISE.
• PLATFORM ROTATION
To rotate platform depress footswitch and actuate toggle switch to
RIGHT to rotate platform RIGHT; to LEFT to rotate platform LEFT.
IWARNING'
When operating control levers in UP or EXTEND mode, remember you are head and
shoulders above the platform railings. BE SURE sufficient OVERHEAD clearance
exists before you activate control.
Also when activating control to LOWER or RETRACT mode ensure that the path below
platform is CLEAR.
Only ROTATE turret after you are SURE no OBSTRUCTIONS exi.st to side of intended
movement.
-19-
C. SHUT DOWN
• Push POWER switch "IN- on the platform control console. This will STOP
engine as well as DEACTIVATE control circuit.
• At ground panel turn KEY SWITCH to OFF position.
D. EMERGENCY OPERATION
The emergency controls at the ground console and platform console are
operated in the same manner.
• Actuate and HOLD toggle switch located inside triangle and actuate ap-
propriate toggle switch for boom raise/lower; boom extend/retract or
turret rotate.
A CAREFUL, TRAINED AND OBSERVANT OPERATOR

IS THE GREATEST SAFETY DEVICE AVAILABLE
-20-
PREVENTATIVE MAINTENANCE
In conjunction with the PRE-OPERATION INSPECTION a good preventative maintenance

program will enhance a properly operating machine and the SAFETY of those operat-
ing and using the equipment.
AN OUNCE OF PREVENTION IS A POUND OF CURE
I NOT E I
This section of the manual is directed to those items of maintenance which the
operator should be aware of and which can be accomplished by or for him prior to
operation of the equipment. Refer to SERVICE MANUAL for a more detailed
breakdown and recommended time interval of PREVENTATIVE MAINTENANCE.
LUBRICATION
Refer to the Condor lubrication diagram for the location of items requiring lu-
brication. Recommended lubricating intervals are based on normal use in normal
environmental conditions. User is cautioned to adjust the lubricating interval,_
accordingly, to meet each individual condition and usage.
Specific lubricants recommended, are generally the best choice. Should these lu-
bricants be unavailable in your area, consult your local supplier for an equiva-
1ent. - / ; " . - .
-21-
LUBRICATION
1. PRESSURE GUN LUBE POINTS
• Lubricant ------------------- Chassis 9rease (Shell Darna AX70330

or equal).
• Time Interval --------------- Once a week or every 50 hours of

operation.
• Procedure ------------------- Service all fittings as indicated on

chart. Clean lube fittings and
apply with pressure gun. Wipe away
all excess lubricant from exposed
surfaces. Excess lubrication can
collect dirt and foreign matter both
of which act as abrasives.
2. STEERING CYLINDER
• Lubricant ------------------- S.A.E. 30 weight engine oil.
• Time Interval --------------- Once a week or every 50 hours of

operation.
• Procedure ------------------- Apply with oil can to both sides

pivot.
~f
3. WHEEL BEARINGS
• Lubricant ------------------- Wheel bearing grease.
• Time Int~rva1 --------------- 500 hours or yearly whichever comes

first or upon reassembly.
• Procedure ------------------- Remove hub cap, clean out old lubri-

cant and repack.
I CAUTION'
Do not perform any maintenance or repair on the Condor unless a means is used to
hold arms in elevated position.
4. ROTATION GEAR TEETH AND PINION
• Lubricant ------------------- Crown 7045 heavy duty open gear oil

or equal.
• Time Interval --------------- 500 hours of operation or yearly

• Procedure ------------------- Wipe gear teeth clean on rotation

ring and pinion. Spray on
lubricant.
-22-
LUBRICATION
5. ROTATION GEAR BOX . .'
• lubricant ------------------- S.A.E. 90 weight EP oil.
• Time Interval --------------- Check every 50 hours. Change every

500 hours of operation or yearly,
• Procedure ------------------- Remove drain plug. Refill until
level reaches about 1 inch from top
of fill hole.
6. DRIVE TORQUE HUBS
• lubricant ------------------- S.A.E. 90 weight EP oil.
• Time Interval --------------- Check periodically and fill, as

required. Change every 500 hours
or yearly whichever comes first.
• Procedure ------------------- To check level, rotate wheel so

that level plug is horizontal.
Remove plug. If steady flow of oil
pours forth, unit is sufficiently
full.
7. HYDRAULIC SYSTEM - KEEP SYSTEM CLEAN
• Fluid level ----------------- Check level daily. Maintain fluid

'evel at full mark on dipstick with
the unit in fully retracted
position.
• Hydraulic Oil Filters ------- Change return line filter located

in hydraulic tank after the first
30 days or 50 hours of operation.
Thereafter change the filter every
3 months or 300 hours of operation.
• Tank Breather --------------- Clean every 50 hours of operation.

Remove from tank and clean with
solvent. Air blow dry.
• Hydraulic Tank -------------- Drain oil tank every 500 hours

or yearly whichever comes first and
replace filter element. Add oil to
tank to required level.
INOTEI
Use only ATF DEXTRON II or equal. DO NOT MIX hyraulic oil.
It may be necessary to lubricate or service the hydraulic system more frequently
when operating in abnormal environments such as dusty conditions.
-23-
INTERVAL SYMBOL MODEL 46Q8 HYD. TANK FILTER SHEAVE PIN
FLUID - ATF 2 PLCS.
~ 50 HOURS OR SEMI-MONTHLY DEXTRON II
r==J 100 HOURS OR MONTHLY
CENTRAL lUBE BRACKET
<==> 500 HOURS OR ANNUALLY FOR PINS - 5 PlCS.
TYPE OF LUBRICANT STEERING CYl. - 2 PlCS,

CRANKCASE, TIEROO - 2 PlCS
CG - CHASSIS GREASE KING PINS - Each
SHELL DARNA AX70330 OR EQUAL AIR CLEANER
SL - SPRAY LUBE
CROWN 7045 OPEN GEAR AND
WIRE ROPE lUBE OR EQUAL
i
EO - ENGINE OIL (REFER TO ENGINE MANUAL)
8
:;Ia
GO - GEAR OIL SAE 90 WEIGHT EP

WB - WHEEL BEARING GREASE §
E
ell'
SHEAVES ....
:;Ia
N 2 PLCS.
~
E
....
i
~
.g
....
=
z
....
V)
TORQUE HUB
RING GEAR - 2 PlCS.
SPEED REDUCER
PLATFORM FORK - CHANGE OIL
PIVOT PIN ROTATION CYl - 2 PlCS. WHEEL
LINKS BOOM PIN ROTATION GEAR BEARINGS
-5 PLACES lEVELING CYl - 2 PlCS. TEETH & PINION
INTERVAL SYMBOL MODEL 66QB
c::> 50 HOURS OR SEMI-MONTHLY
SHEAVE PIN
2 PLCS.
~ 100 HOURS OR MONTHLY
o 500 HOURS OR ANNUALLY
LIFT CYL
2 PLCS.
FOR PINS - 5 PLCS.
TYPE OF LUBRICANT
CG - CHASSIS GREASE
SHELL DARNA AX70330 OR EQUAL
SL - SPRAY LUBE
CROWN 7045 OPEN GEAR AND
HYD. TANK FILTER
FLUID - ATF
DEXTRON II
ig
WIRE ROPE LUBE OR EQUAL
EO - ENGINE OIL (REFER TO ENGINE MANUAL) "
01
GO - GEAR OIL SAE 90 WEIGHT EP
WB - WHEEL BEARING GREASE SHEAVES
§
2 PLCS. E;
=
N
U'I
"
1-4
E
1-4
i
~
.g
1-4
~
~
:z
~
(I)
STEERING
CYL - 2 PLCS. WHEEL
TIE RODS - 2 PLCS BEARINGS
RING GEAR - 2 PLCS.
PLATFORM FORK CRANKCASE FILL
PIVOT PIN ROTATION CYL - 2 PLCS, SPEED REDUCER
LINKS BOOM PIN CHANGE OIL
5 PLACES LEVELING CYL - 2 PLCS.
TORQUE HUB
ROTATION GEAR
TEETH & PINION
.,
fo ...... .0
rt r-- - ~
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CAPACII ( = 28,7 GALLONS
21~68
WHHI MOIOHS
I L._ - ~ .
_.
WHEN PROPERLY MAINTAINED AND OPERATED
SELF-PROPELLED CONDOR MACHINES ARE
SAFE AERIAL WORK PLATFORMS
Everyday application of product knowledge and common sense will help make your
Condor the safest tool you operate.
1. DO NOT operate the Condor machine unless you are qualified by training
and experience in its safe operation.
2. DO NOT overload the platform; know the rated capacity.
3. DO NOT operate the Condor on soft or uneven surfaces. Do not elevate
the Condor platform when machine is on a slope. (The Condor is
designed to be used on firm and level surfaces only.)
4. DO NOT elevate the Condor platform unless the guardrails access
opening (entrance) is closed with the slide bar provided.
5. DO NOT operate the Condor when the wind velocity exceeds 25 mph.
6. DO NOT tow the Condor unless equipped with option for in-plant towing
(5 mph max.)
7. DO NOT jerk controls. Operate smoothly and deliberately into and out
of movements.
8. DO NOT force the platform or its railing against any adjacent struc-
ture to brace the Condor unit.
9. DO NOT sit or climb on platform railing. Keep both feet on the plat-
form floor at all times.
10. DO NOT-allow overhanging loads on the work platform.
11. DO NOT use ladders, planks, or other devices on the aerial platform
for achieving additional height or reach.
12. DO NOT operate a machine that is malfunctioning.
13. DO NOT perform maintenance with platform in an elevated position,
without the safety bar in place.
14. DO NOT make any modifications to the Condor without prior written
consent of the Calavar Corporation Engineering Department. Do not
alter or disable any interlocks or other safety devices on the Condor.
15. DO NOT operate near energized electrical conductors. This is a
non-insulated aerial work platfonn. You must maintain a clearance of
at least 10 feet between any part of the machine or its load and any
electrical power line.
16. DO NOT use the Condor for any other purpose than to position personnel
and their tools or equipment. The Condor is not designed for use as a
crane.
17. DO NOT recharge batteries near sparks or open flame. Batteries that
are being charged emit highly explosive hydrogen gas.
-28~
For Your Own
Safety and Protection
• Read This Manual
Completely Before
Operating the Condor.
• Retain This Manual
on the Condor at all times.
Distributed by
Copies of this manual (Part No. 92246) can be obtained from:
CORPORATION
9200 Sorensen. Santa Fe Springs. CA 90670

(213) 946-6561
CALAVAR CORPORATION
CORPORATION SAFETY INSPECTION FOR SelF-PROPELLED CONDOR
Addre§ ______________________________________________
Customer Name
Madel Serial No. ______________

Date
The purpose of this form is to provide the customer with an itemized list of safety related items that shall b~ inspected at intervals
of 30, 90 and 180 days. These forms should be filled out completely and returned to Calavar Corporation at the recommended
intervals. Proper use of these Safety Inspection Forms will point out any portentially unsafe conditions which will enable )IOu to
take corrective action, thereby aSsuring a safe operating unit. It is recommended to the end user that this system be continued on
a schedule of at least every 90 days.
l item .
No. Description I ..
COheKck if II~.:::::C:o:rr:e:c:t:iv:e:A:c:t:io:n::Ta:k:e:n::::::::::::~
I BASE
A Decals for clarity

B Visual inspection of all welds
C SteerinQ knuckle
1 Cracks
2 Bushinos
3 Wheel bearings
D Tie Rods
1 Cracks
2 Security
3 Toe-in alignment
4 Steerina stoos
E nre Air Pressure Note Decal on B,!se
.... F Tire candition
G Brakes
H Two-speed shift
I Ring Gear bolts
J Lug nuts
II BASE SERVICE
A Toraue hub oil level

B RiM Qear lubrication
C Wheel bearina lubrication
D Steering lubrication
1\1 TURRET

B Visual insoection of all welds
C CounterweiQht for security and/or damaae
D Front counter weiQht (Model 6066)
E Pin Retainer Plates
1 Damaoe
2 Security
F Turret rotation oear box for security
G Fuel leaks
H Prooer exhaust
I Drive line condition
J Damaaed hydraulic lines
K Damaged electrical lin~
I
Item
No. Description
Check if
O.K. II Corrective Action Taken
III TURRET (Continued)
l Moving warning horn

M Descent horn (option)
N Slope sensor
0 Stop and start circuit
p Engine operation
Q Hydraulic leaks
R Ring gear bolts
S Motor mount (Diesel!
T Motor mount bolts
IV TURRET SERVICE
A Ring gear lubrication

B Engine service
C Hydraulic Oil filter (return)
0 Hydral.llic oil filter (control)
E Check oil cooler
1 Damage
2 aean
F lube drive lines
G lube all pins
H Check oil level rotation gear box
I Condition of hydraulic oil
J Check hydraulic pressure (see spec. sheet for your model)
V BOOM
8 Mechanical cables for torque
C Check mechanical cables for damage
0 Check tension on electrical cables
E Check tension on hydraulic hoses
F Visual inspection of all welds
G Check for damage to rotation fork assembly
H Rotation pillow block
1 Security
2 Damage
I Pin retainer for skirt to boom assembly
J Topping cylinder pivot pin retainer
1 Damage
2 Security
K 800m pivot pin retainer
1 Damage
2 Security
l Master leveling cylinder pin
1 Damage
2 Security
M Slave leveling cylinder pin
1 Damage
2 Security
N Boom extension cylinder pin
1 Security
2 Alignment
0 Topping Cylinder for leaks
p Boom extension cylinder
Q Master leveling for leak
R Slave leveling cylinder for leaks
S Bleed down valve
T Bleed down valve
Item
No. Description
Check if
O.K. II Corrective Action Taken
V BOOM (Continued)
U Horizontal limit swi~ch
1 Security
2 Operation
V Extension limit switch
1 Security
2 Operation
W Check atl hydraulic lines
VI BOOM SERVICE
A Lube all pins
B Lube points in boom (refer to lube chart for location)
VII PLATFORM CONTROL STATION

A "0" Rings
B Platform bolts and nut
C Foot-operated Deadman
D Controllers self-centered and lock
E Decals for clarity
F Start Stop
G Slope sensor indicator light
H Guard rail and chains
I Toggle switches
J Basket condition
~fety Inspection performed by _ _ _ _ _ _ _ _ _ _-:-:-:----:-_ _ _ _ _ _ _ _ __

(Name) (Title) (Date)
Return f6rm to CALAVAR CORPORATION, Santa Fe Springs, California
#242

Condor Operator'S Maintenance AND Parts Manual

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Condor Operator'S Maintenance AND Parts Manual

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SIN 5259

PREVENTATIVE MAINTENANCE INSPECTION

Overall Condition Inspect platform, boom, turret and carriage to

Battery Cable Connections Inspect for looseness and corrosion of

Hydraulic Fluid Leaks Inspect to ensure that there is no evidence of

Main Electrical Connections Inspect harness connections at rear of ground

B. FLUID CHECK LEVEL

Engine Coolant Level Add as required (water-cooled engine only).

Fuel Tank Level Check level.

Hydraulic Tank Level If I'ow, add Shell Te"~s T32 as required.

Battery Electrolyte Level Add as required.

A. Electrolyte level - all caps present.

B. Cables and connections - ground connection.

D. Check for fuel, oil leaks.

B. Loose or damaged hoses, tubing.

D. Hydraulic valves and control levers.

E. Cleanliness of hydraulic fluid - non-milky, bright in color.

6. MULTI-AXIS 5° SLOPE SENSOR

B. Loose or damaged wires.

C. Push to test. Moveable on mounting.

D. Warning light/alarm in platform is operable.

Defective components, structural damage, missing parts or equipment malfunctions

5. ROTATION GEAR BOX

• Lubricant. ...................... . S.A. E. 90 weight EP oil.

.Procedure ....................... . Remove drain plug. Refill until level reaches

6. DRIVE TORQUE HUBS

• Lubricant. ..................... . S.A. E. 90 weight EP oil.

• Time Interval.. ................ . Check periodically and fill, as required. Change

.Procedure...................... . To check level, rotate wheel so that level plug is

7. HYDRAULIC SYSTEM - KEEP SYSTEM CLEAN

.Tank Breather.................. . Clean every 50 hours of operation. Remove

w :d- O- \.r-~ c;:O (J'-

REF DESCRIPTION PART NUMBER QTY

1 Decal - WARNING 32200 1

o SOO HOURS or ANNUALLY

PLA TFORM LEVELING CYLIN DER

o 100 HOURS or MONTHLY AIR CLEANER

~ ENGINE OIL DIPSTICK

TOPPING CYLIN DER

REF DESCRIPTION PART NUMBER QTY

Turret Assembly 35050

REF DESCRIPTION PART NUMBER QTY

1 Fork Weldment 35650 1

o 50 HOURS or SEMI-MONTHLY CHECK SPEED REDUCER SHEAVE PIN

o 500 HOURS Of ANNUAllY

ROTATION CYLI NDER

o 500 HOURS or ANNUAllY AIR CLEANER

3-Sect i on Boom LUBRICATION, CHART FOR QUBIC- 8 MODEL 46 Sheet 2 of 2

REF DESCRIPTION PART NUMBER QTY

1 Tie-Down Ring 32536 1

REF DESCRIPTION PART NUMBER QTY

1 Decal - WARNING 32200 1

REF DESCRIPTION PART NUMBER QTY

Turret Assembly 35050

Item Part No. lli Description

Item Part No. Qty Description

REF DESCRIPTION PART NUMBER QTY

~ Engine & Pump Assembly 35330

: .:.,,;" --:.: :~~..,:.:::~:~"..', .;...:...~, ".~ ~~:::. '!".:. ".

BOOM EXlENSlON C'tUNOER ASSY. _!<r~~4)1;~_ti0'gtt;!-i.;t!a

PUVP AT MAX. STROKE (2.3 .C~ IN./REV.)

(,S) l>€"S'4"N~ S/~ H:JJ>/2().l..INS LTR. D.R.N. NO D<JJ: 35784 A

1--Cover, Engine 32676 1