CONDA S&P Manual 13

Service and Parts manual

SUMI CONDA Straddle Stackers

PART NUMBER 942015
ISSUED MARCH 8th 2007

This manual covers the SUMI model CONDA Straddle stackers manufactured in Australia by
OSKO Forklifts Pty Ltd.

Thankyou for purchasing this AUSTRALIAN MADE LIFT TRUCK.

This unit is designed and built to provide many years of trouble free service. To ensure that
you obtain the performance and reliability that is designed into all SUMI lift trucks we ask that
you observe the following:

Make certain that all Service Technicians are fully conversant with the operation and
maintenance requirements of the lift truck. We strongly recommend that all technicians read
both PART A and PART B of this manual.

Ensure that this machine receives regular service as described in PART B of this manual.
NOTE: It is always a good policy to quote the model and serial number when ordering
replacement parts, or requesting service personnel to call.

Use only genuine SUMI spare parts. The reliability of your machine could be affected by
using non-genuine components that are similar in appearance but have not been subjected
to the rigid quality control scrutiny of genuine SUMI spares.

OSKO FORKLIFTS PTY. LTD. Your local SUMI dealer is:

5 CORD STREET
DUDLEY PARK
SOUTH AUSTRALIA 5008
TELEPHONE: (08) 8269 6777
FAX: (08) 8344 4120
Email: [email protected]
Website: www.sumi.com.au

CONDA Service and Parts manual

Tel: +61 8 8269 6777 Fax: +61 8 8344 4120
[email protected] www.sumi.com.au

Intro 2
 TABLE OF CONTENTS

PART A – OPERATION

PARAGRAPH TITLE PAGE No

SECTION 1 - OPERATION
1.1 General 1
1.2 Operating Precautions 2
1.3 Safety features 3
1.4 Driving and Stopping Procedures 4
1.5 Belly-button Safety Guard 5
1.6 Dead-man Brake 5
1.7 Operating Raise / Lower controls 5
1.8 Operating Side Shift 6
1.9 Loading and Unloading 7
1.10 Parking 7
1.11 Optional Features 7

SECTION 2 - MAINTENANCE
2.1 General 8
2.2 Operator Daily Checks- Visual 8
2.3 Multi – Function Spy-Glass Gauge 9
2.4 Operator Daily Checks – Operational 10
2.5 Scheduled Maintenance 11
2.6 Lubrication 12
2.7 Battery Care 14
2.7.1 Battery Charging & Maintenance 14
2.7.2 Safety Rules for Batteries 14
2.7.3 Cleaning 15
2.7.4 Checking Electrolyte Level 15
2.7.5 Checking Specific Gravity 15
2.7.6 Temperature Correction 16
2.7.7 Charging Battery 16
2.7.8 Removing Battery From Charger 17
2.7.9 Battery Removal 17

PART IDENTIFICATION ILLUSTRATIONS

FIGURE TITLE PAGE No
1.1 Handle Controls 3
1.2 Electric Brake 4
1.3 Raise / Lower & Side Shift Control Levers 6
2.1 Layout of Dash Panel 9

TABLE TITLE PAGE No

2.1 Daily Check List – Visual Checks 8
2.2 Daily Check List – Operational Checks 10
2.3 Monthly, Quarterly and Yearly Inspection and Service Chart 11
2.4 Recommended Lubricants 12
2.5 Lubrication Schedule 13
2.6 Charging Times 17

Intro 3
PART B – SERVICE AND PARTS

PARAGRAPH TITLE PAGE No

SECTION 3 – CONTROL HANDLE, STEERING ARM AND PIVOT ARM
3.1 Control Handle 18
3.1.1 Removal of Control Assembly from Handle Base 18
3.1.2 Re-Assembly of Control Assembly to Handle Base 18
3.1.3 Removal of Control Handle Base from Steering Arm 19
3.1.4 Re-Assembly of Control handle Base to the Steering Arm 19
3.1.5 Replacement of Left Side Lower Switch 22
3.1.6 Replacement of Left Side Lift Switch 22
3.1.7 Replacement of Right Side Lower Switch 22
3.1.8 Replacement of Right Side Lift Switch 24
3.1.9 Replacement of Right Side Proportional Lower Switch 24
3.1.10 Replacement of Right Side Proportional Lift Switch 24
3.1.11 Replacement of MUX PC Board Assembly 26
3.1.12 Replacement of Horn Cover or Springs 27
3.1.13 Replacement of Slow Speed Select Cover or Springs 28
3.1.14 Replacement of Safety Reverse Cover or Springs 28
3.2 Steering Arm and Pivot Arm 29
3.2.1 Removal of Pivot Covers and Pivot Arm Cover 29
3.2.2 Re-Assembly of Pivot Arm Cover and Pivot Covers 29
3.2.3 Removal of Steering Arm Cover 29
3.2.4 Replacement of Steering Arm Cover 29
3.2.5 Adjustment of Handle Return Spring Tension 32
3.2.6 Replacement of Handle Return Spring 32
3.2.7 Removal of Pivot Arm From Pivot Tube 34
3.2.8 Replacement of Pivot Arm on Pivot Tube 34
3.2.9 Removal of Harness Assy – Control Handle to Pivot Arm 34
3.2.10 Replacement of Harness Assy – Control handle to Pivot Arm 35
3.2.11 Removal of Dash Panel 35
3.2.12 Replacement of Dash Panel 35
3.2.13 Removal of Pivot Tube 37
3.2.14 Replacement of Pivot Tube 37

SECTION 4 – TRANSMISSION, DRIVE MOTOR, ELECTRIC BRAKE

4.1 Electric Brake 38
4.1.1 Brake Pad Adjustment 38
4.1.2 Brake Pad Replacement 41
4.1.3 Replacement of Brake Assembly 42
4.2 Drive Motor 43
4.2.1 Removal of the Drive Motor 43
4.2.2 Replacement of the Drive Motor 45
4.3 Transmission 46
4.3.1 Removal of the Transmission Assembly 46
4.3.2 Replacement of the Transmission Assembly 47
4.3.3 Removal of the Transmission, Drive Motor, Brake Assembly 47
4.3.4 Replacement of the Transmission, Drive Motor, Brake Assembly 49
4.3.5 Repair of Transmission 50
4.4 Replacement of Drive Wheel 50

Intro 4
PART B – SERVICE AND PARTS

PARAGRAPH TITLE PAGE No

SECTION 5 – ELECTRICAL SYSTEM
5.1 Transistor Controller 51
5.2 Multi Function Spy-Glass Gauge 51
5.3 Electrical Panel Assembly 54
5.4 Emergency Power Disconnect & Key Switch 56
5.5 Main Contactor 57
5.6 Charger 58
5.7 Explanation of Electrical Diagrams 59
5.8 Main Cables – Identification & Location 60
5.9 Drive Motor 63
5.9.1 Drive Motor Servicing 63
5.9.2 Inspection and Replacement Drive Motor Brushes 63
5.10 Pump Motor 65
5.10.1 Pump Motor Servicing 65
5.10.2 Inspection and Replacement Pump Motor Brushes 65
5.11 Batteries 67
5.11.1 Battery Replacement 67
5.11.2 Battery Cable Replacement 67
5.12 Horn Testing and Replacement 69

SECTION 6 – REAR BODY, ADD-ON BODY AND MAST

6.1 Lift Cylinder Removal / Replacement 70
6.2 Chain Sheave Removal / Replacement 70
6.3 Lift Chain Tension Adjustment 70
6.4 Mast Lubrication 73
6.5 Rear Body Covers 72
6.6 Rear Body & Mast 74
6.7 Load Wheel Removal / Replacement 75

SECTION 7 – HYDRAULICS
7.1 Hydraulic Cylinder 76
7.1.1 Repair of Hydraulic Cylinder 5215XXT 77
7.1.2 Repair of Hydraulic Cylinder 5317XXT 78
7.2 Lift Cylinder 79
7.3 Hydraulic Pump & Motor Assembly 80
7.4 Proportional Lower Solenoid Valve Manual Over Ride 81
7.5 Emergency Lower of the Carriage 81
7.6 Two Spool Hydraulic Control Valve 84
7.7 Optional Side Shift 85

Intro 5
PART B – SERVICE AND PARTS

PART IDENTIFICATION ILLUSTRATIONS

FIGURE TITLE PAGE No

3.1 Control Handle 20
3.2 Location of Cables for Switch Assys–Handle with On-off switches 23
3.3 Location of Cables for Switch Assys–Handle with Prop’n’l switches 25
3.4 Replacement of Cover or Springs-Horn or Low Speed Select Sw 27
3.5 Steering Arm and Pivot Arm 31
3.6 Routing of Harness Assy – Control Handle to Pivot Arm 33
3.7 Dash Panel – Removal / Replacement 36

4.1 Electric Brake Assembly 38

4.2 Brake Pad Adjustment 39
4.3 Electric Brake Pad Replacement 40
4.4 Brake Replacement 42
4.5 Drive Motor and Transmission 44
4.6 Transmission, Drive Motor, Brake Assembly 48

5.1 Multi–Function Spy- Glass Gauge 51

5.2 Schematic Wiring Diagram Curtis Controller 53
5.3 Electrical Hardware Assembly 54
5.4 Electrical Hardware - Dash Panel 55
5.5 Emergency Power Disconnect & Key Switch 56
5.6 Main Contactor 57
5.7 Battery Charger 59
5.8 Main Cables – Identification & Location 60
5.9 Electrical Diagram Standard CONDA 61
5.10 Electrical Diagram CONDA with extra Hydraulics 62
5.11 Drive Motor Assembly 64
5.12 Pump Motor Assembly Complete 66
5.13 Battery & Cable Assembly 68
5.14 Horn Assembly 69

6.1 Adjustable Forks, Mast & Carriage Assembly 71

6.2 Rigid Forks, Mast & Carriage Assembly 72
6.3 Rear Body Covers 73
6.4 Rear Body & Mast 74
6.5 Load Wheel Assembly 75

7.1 Hydraulic Cylinder 5215XXT 77

7.2 Hydraulic Cylinder 5317XXT 79
7.3 Hydraulic Pump & Motor Assembly 80
7.4 Hydraulic Lay-Out 82
7.5 Two Spool Hydraulic Control Valve 84
7.6 Optional Side Shift Hydraulic System 85

TABLE TITLE PAGE No

5.1 List of Error Codes 52
7.1 List of 2 Stage Cylinders 76

Intro 6
PART A – OPERATION AND MAINTENANCE
SECTION 1 - OPERATION
1.1 - GENERAL
This section gives detailed operating instructions for your SUMI lift truck.
Routine precautions are included to ensure safe operation.

Warning
Please read this manual before operating the
SUMI CONDA Straddle Stacker

Only trained and authorised personnel are

permitted to operate this truck

Operators must be trained in accordance with

local statutory requirements

Operators must not lift loads exceeding the

capacity of this truck (refer to data plate)

CONDA S&P Manual 1

PART A – OPERATION AND MAINTENANCE
SECTION 1 - OPERATION
1.2 - OPERATING PRECAUTIONS

WARNING:

Improper operation of the lift truck may result in operator injury, or load and/or lift truck
damage. Observe the following precautions when operating the SUMI lift truck.

¾ Do not operate this truck unless you have been trained and authorised to do so. Read all
warnings and instructions in this manual and on the lift truck.
¾ Do not operate this truck until you have performed the daily visual and operational
checks.
¾ Do not operate in unauthorised areas and always give way to pedestrians.
¾ Operate the lift truck only from the designated operating position.
¾ Do not carry passengers.
¾ Do not exceed the rated capacity (see information data plate). Check load weight and
load centre information.
¾ Observe applicable traffic regulations, yield right of way to pedestrians. Slow down and
sound horn at cross aisles and wherever vision is obstructed.
¾ Start, stop, travel, steer and brake smoothly. Slow down for turns and on un-even or
slippery surfaces that could cause truck to slide or slippery surfaces that could cause
truck to slide or overturn. Use special care when travelling without load as the risk of
overturn may be greater
¾ For safety and ease of operation, you should lead the unit when travelling, i.e. walk with
the unit behind you.
¾ Always look in direction of travel. Keep a clear view, and when load interferes with
visibility, travel with load or lifting mechanism trailing.
¾ Use special care when operating on ramps; travel slowly and do not angle or turn. Go up
ramps in forward direction and down ramps in reverse.
¾ Always use the safety equipment provided and wear appropriate footwear.
¾ Centre and carry the load as far back as possible toward the back rest.
¾ Do not handle unstable or loosely stacked loads and use special care when handling
long, high, or wide loads. The wider the load, the lower the stability of the lift truck.
¾ Pick up loads on both forks. Using only one fork reduces the capacity.
¾ Always lower the load when travelling. Do not pick up loads on the tips of the forks.
¾ When stacking pallets take care when turning with the load elevated; travel slowly and
brake smoothly.
¾ Check for overhead obstructions when raising or lowering the lift carriage.
¾ Apply the brake gently, except in cases of emergency.
¾ Follow correct battery charging procedures.
¾ Check bridge plates, ramps and boards are stable before use.
¾ Do not allow anyone to stand or pass under the load or lifting mechanism.
¾ Park your lift truck in authorised areas only with forks fully lowered to the floor.
¾ Notify your dealer of any faults, do not operate until faults are corrected.
¾ Do not operate the truck when under the influence of drugs or alcohol. If in doubt contact
your supervisor.

CONDA S&P Manual 2

PART A – OPERATION AND MAINTENANCE
SECTION 1 - OPERATION
1.3 - SAFETY FEATURES

Your SUMI lift truck is designed and engineered to provide maximum safety for the operator
and payload. Some of the safety features incorporated into the design are:
• Dead-man switch to apply the brake and cut off drive power when the handle is
released.
• Belly-button safety guard and switch to prevent the operator from being accidentally
pinned against a wall or obstruction when the truck is being driven forward.
• All controls automatically return to “OFF” when released.
• High speed limit switch to restrict speed when the lift carriage is raised above the pre-
set limit.
• Emergency power disconnect push button on console.
• Separately fused control circuits and power circuits.
• Two independent braking systems, electronic and electric.
• Load back rest to protect against load spills.
• Overload by-pass valve

FIGURE 1.1 - HANDLE CONTROLS

CONDA S&P Manual 3

PART A – OPERATION AND MAINTENANCE
SECTION 1 - OPERATION

FIGURE 1.2 - ELECTRIC BRAKE

1.4 - DRIVING AND STOPPING PROCEDURES (Refer to Figures 1.1 and 1.2)

The following procedure describes driving and stopping your SUMI lift truck.

• Ensure that the battery connector is plugged in the truck (under top cover).

• Turn the keyswitch to the “ON” position. Pull out the red Emergency Stop Button.

• Grasp the grips of the handle so that the speed controls can be comfortably operated by
either thumb.

• Lower the handle to a comfortable position above horizontal to disengage the brake and
to energise the electrical circuits.

• To move forward (with load trailing), slowly press the lower portion of the speed control.
Press the forward speed control further to increase speed.

• To stop, release the speed control and lower the handle to the horizontal position. At this
position, the brake will be applied.

• The brake can also be applied by raising the handle to the upright position.

CONDA S&P Manual 4

PART A – OPERATION AND MAINTENANCE
SECTION 1 - OPERATION
1.4 - DRIVING AND STOPPING PROCEDURES (Continued) (Refer to Figs.1.1 & 1.2)

• To travel in reverse, lower the handle to a comfortable position and slowly press the
upper portion of the speed control. Press the reverse speed control further to increase
speed.

NOTE: (1) Acceleration in reverse is the same as in the forward direction.

NOTE: (2) Plug Braking - SUMI CONDA models are equipped with transistor speed control
which provides electronic braking without risk of damage to drive components.

• To Plug Brake - slowly reverse the speed control against your direction of travel and
release when unit stops.

1.5 - BELLY-BUTTON SAFETY GUARD

• The belly-button safety guard minimises the possibility that the driver might be pinned by
the handle if walking backwards while driving the lift truck in forward. The safety guard
activates a switch, which immediately changes the direction of the lift truck to reverse in
low speed.

• N.B. The belly button switch will not operate in the brake-on position.

1.6 - DEAD-MAN BRAKE

• The return spring automatically raises the handle to the upright position for parking/
dead-man brake. If the handle snaps up abruptly, or does not return fully, immediate
adjustment should be carried out.

1.7 - OPERATING RAISE/LOWER (Refer to Figures 1.1 and 1.2)

• Standard CONDA models are fitted with instantaneous raise/lower controls on the left
hand side of the control handle. On the right hand side of the handle are proportional
raise/lower controls, which allow more precise fork positioning when lifting or lowering.

• CONDA models equipped with side shift or extra hydraulic service options are fitted with
instantaneous raise/lower controls on both sides of the control handle and a console
mounted RAISE/LOWER control lever, which can be used to regulate the lifting and
lowering of the forks.

• It is recommended that the instantaneous raise/lower controls in the control handle

should only be used for non-critical fork positioning.

WARNING:
Check the space above the mast and the load to be sure that there is sufficient
room before raising the forks. Be careful to start and stop the lift/lower
movement gradually.

CONDA S&P Manual 5

PART A – OPERATION AND MAINTENANCE
SECTION 1 - OPERATION
• To lift the forks depress the RAISE control on the handle and hold it until the lift carriage
reaches the desired height.
Alternatively, slowly lift the RAISE/LOWER control lever towards UP position (upwards)
and hold it until the forks approach the desired height. Then slowly return the
RAISE/LOWER control lever to its neutral position.

• To lower the forks depress the LOWER control on the handle and hold it until the lift
carriage is at the desired height.
Alternatively, slowly push the RAISE/LOWER control lever towards DOWN position
(downwards) and hold it until the forks approach the desired height. Then slowly return
the RAISE/LOWER control lever to its neutral position.

SIDE SHIFT OPTION

FIGURE 1.3 - RAISE / LOWER AND SIDE SHIFT CONTROL LEVERS

1.8 - OPERATING SIDE SHIFT (Refer to Figure 3)

• The SIDE SHIFT control operates the fork side shifting mechanism.

• To shift the forks to the left, slowly push the SIDE SHIFT control lever toward UP
position (upwards) and hold it until the forks approach the desired position. Then
slowly return the SIDE SHIFT control to its NEUTRAL position.

• To shift the forks to the right, slowly pull the SIDE SHIFT control lever toward DOWN
position (downwards) and hold it until the forks approach the desired position. Then
slowly return the SIDE SHIFT control to its NEUTRAL position.

CONDA S&P Manual 6

PART A – OPERATION AND MAINTENANCE
SECTION 1 - OPERATION
1.9 - LOADING AND UNLOADING

• Check that weight and dimension of load is within unit capacity.

• Adjust the spread of the forks to the maximum practical width.

• Raise the forks to the desired height for easy load entry. Then move the lift truck so that
the forks are fully within the pallet or skid. The load must be centred over the forks and as
far back as possible.

• Lift the forks to lift the load.

• Reverse the lift truck; when the load is clear, lower the load until just clear of the floor for
transporting.

• Drive the loaded lift truck slowly and use extra care when turning.

• Move the lift truck to align the load with it's new position. Raise the forks to the desired
height.

• Drive the truck forward to position the load correctly.

• Lower the load until it rests squarely in place and the forks are free of the pallet or skid.

• Slowly move the truck backward, making sure the forks do not catch on the pallet or skid.
Lower the forks when they are clear.

1.10 - PARKING

• When finished with moving loads, drive the lift truck to its maintenance or storage area.
Turn key switch off and charge battery as described in Section 2.0, paragraphs 2.5.1 to
2.5.9.

1.11 - OPTIONAL FEATURES

Please discuss with your local SUMI dealer your specific requirements and we will be happy
to customize your SUMI CONDA lift truck.

Some options available are:

• Side Shift
• Extra Hydraulic Service
• Special Straddle Widths
• Special Straddle Dimensions
• Drop down Rider Platform
• Travel / Safety Beeper
• Larger Traction Battery
• Work light
• Special Epoxy paint
• Cold conditioning
• Flame proofing

CONDA S&P Manual 7

PART A – OPERATION AND MAINTENANCE
SECTION 2 - MAINTENANCE
2.1 - GENERAL

• Maintenance involves both the operator daily check procedures and scheduled
maintenance.
• Any service requirements found during the operator daily checks or the monthly, quarterly
and yearly scheduled maintenance procedures, MUST be performed by a qualified
technician.

2.2 - OPERATOR DAILY CHECKS - VISUAL

• To ensure the safety of the lift truck at all times and to prolong the life of the unit, the
operator MUST make the daily checks as detailed below. (See Table 2.1 below)

CAUTION: If the lift truck is in need of repair, or is in an unsafe condition,

report immediately.
Do not operate the unit until it has been restored to safe operating
condition.
Do not make unauthorised repairs or adjustments.

TABLE 2.1 DAILY CHECK LIST - VISUAL CHECKS

ITEM PROCEDURE

DAMAGE Check for bent, dented or broken parts.

LEAKS Check drive unit and hydraulic system.

TYRES AND WHEELS Check drive wheel and load wheels.

FORKS Check that forks are in place and properly secured.

CHAINS, CABLES AND HOSES Check that they are in place and are not loose.

BATTERY Check water level, vent caps in place, cleanliness.

BATTERY CONNECTOR Check for cracks and burns. Also for tight fitting
connection.

GUARDS Load back rest and Safety Screen.

CONDA S&P Manual 8

PART A – OPERATION AND MAINTENANCE
SECTION 2 – MAINTENANCE
2.3 - MULTI - FUNCTION SPY-GLASS GAUGE
All SUMI CONDA models are fitted with a multi-function Curtis Spy-Glass Gauge on the dash
panel. This meter has three LED indicators for operating hours, battery discharge and
diagnostic/ service. (refer to Figure 2.1 below)
The Spy-Glass Gauge displays the following when the battery is connected and the
keyswitch is in the “ON “ Position.
Keyswitch Operating Hours- When the handle is in the upright position and no functions
are operating.
Traction Motor Operating Hours- When the handle is in the upright position and forward or
reverse control is operated – Error Code 2.3 will display for a couple of seconds before the
traction hours are displayed.
Pump Operating Hours- When the handle is upright position and the lift switch is operated.
Battery Discharge % - When the handle is pulled down into the operating position, the % of
discharge of the battery is displayed. - e.g. 85%
Error Codes – if there is a fault in either the controller or with the inputs to the controller, an
error code will be displayed. – e.g. 3.1
If an error code displays, the truck needs to be checked by an authorised technician to
diagnose and repair the fault. Park the truck in a safe area, press the emergency disconnect
button to cut the power and remove the key. Call your local representative, advise the error
code ( to assist with fast track diagnosis ) and make arrangements for the unit to be checked
and repaired as soon as possible.
Service Intervals – A trained technician can program service intervals into the Curtis
controller. A “Spanner” LED will light up when the preset operating hours have transpired..
Intervals can be set for the Traction Motor, Pump Motor and Total hours.

These procedures must be performed by a qualified service technician

or your SUMI service representative.

FIGURE 2.1 – LAYOUT OF DASH PANEL

CONDA S&P Manual 9

PART A – OPERATION AND MAINTENANCE
SECTION 2 – MAINTENANCE
2.4 - OPERATOR DAILY CHECKS - OPERATIONAL
• To ensure the safety of the lift truck at all times and to prolong the life of the unit, the
operator MUST make the daily checks as detailed below. (See Table 2.2 below)

CAUTION: If the lift truck is in need of repair, or is in an unsafe condition, report

immediately.Do not operate the unit until it has been restored to
safe operating condition.
Do not make unauthorised repairs or adjustments.

TABLE 2.2 DAILY CHECK-LIST - OPERATIONAL CHECKS

ITEM PROCEDURE
HORN Check for correct operation.
STEERING Check for no binding, no excessive play.
TRAVEL CONTROLS Check all speed ranges, forward and reverse, for
unusual noises.
HYDRAULIC CONTROLS Check that the raise/lower controls in the handle operate
correctly and that the controls work correctly from
console mounted hydraulic valve (if equipped)
BRAKES Check that the operating brake stops the lift truck within
the required distance and works smoothly. Check
dead-man brake function and parking brake.
LIMIT SWITCHES Check Operation
ATTACHMENTS Check for proper functioning and no unusual noise.

CONDA S&P Manual 10

PART A – OPERATION AND MAINTENANCE
SECTION 2 - MAINTENANCE
2.5 - SCHEDULED MAINTENANCE

Table 2.3 is a MONTHLY, QUARTERLY AND YEARLY INSPECTION AND SERVICE

CHART based on normal usage of equipment, five days per week. If the lift truck is used in
excess of a single shift, or in very arduous conditions, the frequency of inspection should be
increased accordingly.

TABLE 2.3 MONTHLY, QUARTERLY AND YEARLY

INSPECTION AND SERVICE CHART

INTERVAL INSPECTION OR SERVICE

MONTHLY Check condition of drive motor commutator, brushes and

springs.

MONTHLY Check condition of pump motor commutator, brushes

and springs.

MONTHLY Check electric brake for proper operation.

MONTHLY Check load wheels and drive wheel for wear. Torque
drive wheel bolts to 100 Nm (76 ft.lb).

MONTHLY Inspect wiring for loose connections and damaged

insulation.

MONTHLY Inspect contactor tips for excessive pitting and wear.

MONTHLY Check dead-man brake switch for proper operation.

MONTHLY Check lift chain tension.

QUARTERLY Clean suction filter on pump quarterly if operating in an

extremely dusty environment. Otherwise, clean half
yearly.
Check lift cylinder for leakage.

QUARTERLY Check lift cylinder wiper ring and packing.

YEARLY Check transmission oil level – top up if required.

YEARLY Drain hydraulic tank oil and re-fill tank with new oil 25mm
below bottom of filler.

CONDA S&P Manual 11

 PART A – OPERATION AND MAINTENANCE
SECTION 2 - MAINTENANCE
2.6 - LUBRICATION

• To ensure the safety of the lift truck and to prolong it's life, all moving parts must be
lubricated as necessary.

• If the lift truck is used in excess of a single shift, or in very arduous conditions, the
frequency of lubrication should be increased accordingly.

• Units used in low temperature environments must use low temperature specified oils and
greases.

• Refer to Table 2.4 for the recommended types of oils and greases to be used.

• Castrol brand products are specified

• Refer to Table 2.5 to identify the items requiring lubrication.

TABLE 2.4 RECOMMENDED LUBRICANTS

REF NO. DESCRIPTION GRADE

GENERAL USE LOW TEMP

(down to 0 C ) (down to –26C)

No. 1 Gear Oil CASTROL - EPX90 EPX80W-90

No. 2 Grease CASTROL - EPL2 FN(EP)

No. 3 Engine oil CASTROL - SAE30 SAE15W-40

No. 4 Hydraulic oil CASTROL - AWS32 AWH32

No. 5 Chain lube CASTROL - Chain Oil Chain Oil

CONDA S&P Manual 12

PART A – OPERATION AND MAINTENANCE
SECTION 2 – MAINTENANCE
TABLE 2.5 LUBRICATION SCHEDULE

ITEM TYPE NOTES INTERVAL

Table 4

Pivot Tube Bearing No. 2 Grease. Quarterly

Hydraulic System No. 4 Lower carriage, fill to 25mm Monthly

below top of reservoir.

Handle elbow No. 3 1 or 2 drops each time truck Monthly

is serviced.

Transmission No. 1 Top up to plug level. Yearly

Masts No. 2 Full length of masts where Quarterly

rollers touch

Fork Bars No. 2 Contact surfaces. Quarterly

Lift Chains No. 5 Full length of lift chains. Quarterly

Chain Sheaves No. 2 Grease Yearly

(for standard models)

Dismantle & grease Yearly

(for side shift models)

CONDA S&P Manual 13

PART A – OPERATION AND MAINTENANCE
SECTION 2 – MAINTENANCE
2.7 - BATTERY CARE

2.7.1 - BATTERY CHARGING AND MAINTENANCE

CAUTION: Only qualified and experienced personnel should perform maintenance

on batteries.

CAUTION: Gases caused by a battery can be explosive. Do NOT smoke, use an

open flame, create an arc or sparks in the vicinity of the battery.
Ventilate area well when servicing and when charging.

• Batteries contain sulphuric acid, which may cause severe burns. Avoid contact with eyes,
skin, or clothing. In case of contact, flush immediately and thoroughly with large amounts
of clean water. Remove contaminated clothing. Obtain medical attention.

• In cases of spills, dilute spill cautiously with five to six volumes of water and gradually
neutralise with lime, soda ash or baking soda.

• For waste disposal, consult Federal, State or Local Regulations.

2.7.2 - SAFETY RULES

• Wear protective clothing, such as rubber apron, gloves, boots and goggles when
performing any maintenance on batteries. Do not allow electrolyte to come into contact
with eyes, skin, clothing or floor. If electrolyte comes into contact with eyes or skin,
flush thoroughly with large amounts of clean water, remove contaminated clothing and
obtain medical help immediately.

• Keep vent plugs firmly in place at all times except when adding water or taking
hydrometer readings.

• Do not bring any type of flame, spark, etc., near the battery. Gas formed while the battery
is charging is highly explosive. This gas remains in the cells long after charging has stopped.

• Do not lay metallic or conductive objects on battery. Arcing will result.

• Do not allow dirt, cleaning solution, or other foreign material to enter cells. Impurities
in electrolyte has a neutralising affect reducing available charge.

• Observe the battery safety decal.

• The care and maintenance of your battery is very important to obtain maximum efficiency
from the battery charge and obtain maximum battery life.

CAUTION: Wear protective clothing, such as rubber apron, gloves, boots and
goggles when performing any maintenance on batteries

CONDA S&P Manual 14

PART A – OPERATION AND MAINTENANCE
SECTION 2 – MAINTENANCE
2.7 BATTERY CARE (continued)

2.7.3 - CLEANING: (Follow Safety Rules at all times)

• Always keep vent plugs tightly in place when cleaning battery. When the water level and charge
are correct, the battery will remain clean and dry. All that is necessary is to brush or blow off any
dust or dirt which may accumulate on the battery.

• However, if electrolyte is spilled or overflows from the cell, dilute spill cautiously with five
to six volumes of water and gradually neutralise with lime, soda ash or baking soda. To do
this, remove the battery from the truck and clean with the solution of soda and water, brushing
the soda solution to get the solution between the connectors and removing grime from the covers.

• Then rinse the battery with cool water from a low pressure supply to remove the soda and
loosened dirt. If batteries stay wet consistently, they may be either overcharged or overfilled.
This condition should be investigated and corrected.

2.7.4 - CHECKING ELECTROLYTE LEVEL (Follow Safety Rules at all times)

• Battery electrolyte level should be checked before each charge of the battery. The level should
be maintained at 12mm above plates or just below the lower lip of the filler hole at all times.

• If low, add distilled water or approved local supply at end of charge cycle. - do not overfill

2.7.5 - CHECKING SPECIFIC GRAVITY (Follow Safety Rules at all times)

• For maximum battery life, specific gravity readings should be taken weekly on a pilot cell and
recorded. A different pilot cell should be selected on a monthly basis with readings taken on
all cells at semi-annual intervals.

• Do not take specific gravity readings immediately after adding water. Water and electrolyte
must be thoroughly mixed by charging before a reliable reading can be taken. Normal full
charge specific gravity should be taken. Normal full charge specific gravity should be between
1.265 and 1.285 corrected to 26.7 degrees Celsius.

• Do not assume a battery will not take a charge because you have been charging it for a while
and the hydrometer float will not rise.

• The battery may have been fully discharged and will require considerable charging before
reaching the minimum specific gravity of the hydrometer float. The lower the float sinks
into the electrolyte, the lower its specific gravity.

CONDA S&P Manual 15

PART A – OPERATION AND MAINTENANCE
SECTION 2 - MAINTENANCE
2.7 BATTERY CARE (continued)

2.7.6 - TEMPERATURE CORRECTION

• Hydrometer floats are calibrated to give a true reading at one fixed temperature only. A correction
factor must be applied for any specific gravity reading made when the electrolyte temperature is
different from the hydrometer float calibration.

• A correction factor of 4 "points of gravity" (0.004 specific gravity) is used for each 5.5 degrees Celsius
change in temperature. 4 "points of gravity" are added to the indicated reading for each 5.5 degrees
Celsius increment above hydrometer calibration. 4 "points of gravity" are subtracted for each 5.5
degrees Celsius increment below hydrometer calibration.

2.7.7 CHARGING BATTERY

CAUTION: Never smoke or bring flames near the battery. Gas formed during charging is
highly explosive and can cause serious injury.

Charging requirements will vary depending on use of truck. A battery with a specific gravity reading of
1.160 should be recharged.

Follow safety rules when placing a battery on charge. Proceed as follows:

• Park truck at a charging station with forks lowered and emergency stop button off. Make sure area is
well ventilated and not near any open flame or anything that could cause a spark.

• Check the condition of the 240 volt supply lead. If there are any cuts in the cable, any exposed wires,
or loose plugs, DO NOT attempt to charge the battery. Contact a supervisor or appropriate personnel
for repair.

• Put on appropriate protective clothing: rubber apron, gloves, boots and goggles. Check battery fluid
acid level by removing vent caps.

• Connect the AC cord to the AC power source. The fully automatic charger (no timer) will disconnect
power to the truck control circuit and will commence charging the battery automatically (charges the
battery, depending on amount of charge needed).
• Refer to Table 2.6 below for charging time:

CAUTION: Only add water if plates are exposed. If plates are exposed, only
add enough water to cover the plates. Adding more water may cause
battery to boil over during charging. The appropriate time to fill a battery is
after it is charged. Never add acid to a battery.

CONDA S&P Manual 16

PART A – OPERATION AND MAINTENANCE
SECTION 2 - MAINTENANCE

2.7 - BATTERY CARE (continued)

TABLE 2.6 CHARGING TIMES

Specific Gravity Charger Time (hours)

1250 2

1240 4

1220 5

1200 8

1180 10

1160 12

1140 14

NOTE: The smart charger will automatically reduce the charging rate to a trickle charge
when the batteries are fully charged. However, it is not recommended that the charger be
left connected for long periods unattended, for safety reasons.

2.7.8 - REMOVING BATTERY FROM CHARGER

• Turn the charger off at the AC power source.
• Disconnect AC plug from the AC power source, wind up the cord and place in a safe place ready for
use at the next charge.
• Put on protective clothing such as rubber apron, gloves, boots and goggles. Remove vent caps and
add water as needed.

2.7.9 - BATTERY REMOVAL (Follow Safety Rules at all times)

CAUTION:
Extreme care must be used when removing a battery from a lift truck. Contact
between battery terminals and metal components of the truck or removal
equipment can cause a short circuit resulting in a battery explosion.
CAUTION:
Obtain assistance or use appropriate lifting gear to lift the batteries out of the truck.

CAUTION:
If the Batteries have to be replaced make certain the same batteries or batteries of
equal weight are installed in the truck for truck stability.
See nameplate for minimum battery weight.

CONDA S&P Manual 17

PART B – SERVICE AND PARTS
SECTION 3 – CONTROL HANDLE, STEERING ARM AND PIVOT ARM
The new SUMI CONDA models are fitted with the DURA ergonomically designed control handle,
featuring butterfly type forward / reverse speed control for safe and easy operation.
The standard models are fitted with instantaneous lift and lower switches on the left hand side of the
handle for fast positioning and proportional lift and lower switches on the right hand side. The
proportional switches allow the operator to vary lift and lower speed to enable accurate positioning of the
forks.
Other handle functions available to the operator are horn, safety reversing and slow speed select.
All CONDA models come standard with Curtis Sepex traction and hydraulic system controllers, for
optimum operating power and performance.

Detailed service instructions and parts listings for the DURA handle are provided in this section.

3.1 - CONTROL HANDLE

3.1.1 – REMOVAL OF CONTROL ASSEMBLY FROM HANDLE BASE (refer to Fig 3.1)

1. Press the emergency disconnect button & remove the key to cut power.

2. Check the 240V power lead to the Charger is turned Off & Disconnected

3. Remove the top cover and disconnect the battery. Replace top cover.

4. Remove the 3 screws (26) from underside of the handle. Rotate the speed control butterfly in
“reverse” direction. At the same time, pull the Control Assembly (1) of the handle upward and
away from the steering arm to release it from the Control Handle Base (22).

5. Disconnect the Upper Harness (P/N 944204) from the plug on the PC Board (AJ2) to avoid
damaging the cable or PC Board.

CAUTION: Do NOT attempt to service the control handle unless the power to the truck
is disconnected. The truck could travel without warning and cause injury.

3.1.2 – RE-ASSEMBLY OF CONTROL ASSEMBLY TO HANDLE BASE (refer to Fig 3.1)

1. Re-connect the Upper Harness (P/N 944204) to the plug on the PC Board (AJ2)

2. Ensure that the inner edge of the PC Board is located in the groove in the Control Assembly body.

NOTE: If the PC Board is not located in the groove when assembling the Control Assembly to
the Handle Base, the maximum speed in one direction may be slower than the other.

3. Rotate the speed control butterfly in “reverse” direction. At the same time, move the Control
Assembly (1) of the handle towards the steering arm and down onto the handle base (22).

CONDA S&P Manual 18

PART B – SERVICE AND PARTS
SECTION 3 – CONTROL HANDLE, STEERING ARM AND PIVOT ARM
3.1 CONTROL HANDLE (continued)

3.1.2 – RE-ASSEMBLY OF CONTROL ASSEMBLY TO HANDLE BASE (continued)

4. Insert the 3 screws (26) through the underside of the handle and tighten to secure the Control
Assembly to the Handle Base.

5. Remove the top cover and re-connect the battery. Replace top cover.

6. Insert the key and turn on, then pull out the emergency disconnect button to connect the power to
the truck.

7. Test the handle for correct operation.

CAUTION:
When testing the handle, ensure that the drive wheel is clear of the floor to
avoid unexpected travel and possible injury.

3.1.3 – REMOVAL OF CONTROL HANDLE BASE FROM STEERING ARM

(Refer to Figure 3.1)

1. Remove the Control Assembly (1) as per 3.1.1 above.

2. Unscrew the two Screws (27) and remove the Control Handle Base (22) from the Steering Arm.

3.1.4 – RE-ASSEMBLY OF THE CONTROL HANDLE BASE TO THE STEERING ARM

(Refer to Figure 3.1)

1. Assemble the Control Handle Base (22) to the Steering Arm and secure with the two Screws (27).

2. Reassemble the Control Assembly (1) as per 3.1.2 above.

CONDA S&P Manual 19

PART B – SERVICE AND PARTS
SECTION 3 – CONTROL HANDLE, STEERING ARM AND PIVOT ARM

3.1 - CONTROL HANDLE (continued)

FIGURE 3.1 – CONTROL HANDLE

CONDA S&P Manual 20

PART B – SERVICE AND PARTS
SECTION 3 – CONTROL HANDLE, STEERING ARM AND PIVOT ARM
3.1 - CONTROL HANDLE (continued)

REF PART NO DESCRIPTION QTY

--- 943200 Control Handle with On-off lift/ lower switches 1
or 943200P † Control Handle with Proportional lift/ lower switches 1
1 943201 * Control Assembly with On-off lift/ lower switches 1
or 943201P † Control Assembly with Proportional lift/ lower switches 1
2 943202 † * Raise On/ Off Micro-switch with cable and connector 1 or 2
3 943203 † * Lower On/ Off Micro-switch with cable and connector 1 or 2
4 943204 † * On-off switch Micro-switch only with cable & connector 2 or 4
5 943205 † Raise Proportional Micro-switch with cable & connector 0 or 1
6 943206 † Lower Proportional Micro-switch with cable & connector 0 or 1
7 943207 † Adaptor Cable-Proportional Switches to PC Board 0 or 1
8 943208 Lower switch symbol (yellow) 2
9 943209 Raise switch symbol (yellow) 2
10 943210 Return Spring – Speed Control 1
11 943211 Socket Head Cap Screw 2
12 943212 Right Hand Butterfly Control 1
13 943213 Left Hand Butterfly Control 1
14 943214 Cam Shaft – Speed Control 1
15 943215 * PC Board assembly – all On-off lift/ lower switching 1
or 943216 † PC Board assembly – proportional lift/ lower switching 1
16 943217 Cover - Belly Button Switch 1
17 943218 Spring - Belly Button Switch 2
18 943219 Spring – Horn Switch 2
19 943220 Cover - Horn Switch 1
20 943221 Bush – Speed Control 2
21 943222 Control Assembly Body 1
22 943228 Control Handle Base 1
23 943229 Cover – Slow Speed Switch 1
24 943218 Spring – Slow Speed Switch 2
25 944204 Upper Harness – Handle PCB to Pivot Cap Connector 1
26 943210 Socket Head Cap Screw 3
27 943229 Socket Head Cap Screw 2

† These parts are used on Handle with Proportional Raise and Lower switches
• These parts are used on Handle with On-Off Raise and Lower switches

PARTS LIST FOR - FIGURE 3.1 CONTROL HANDLE

CONDA S&P Manual 21

PART B – SERVICE AND PARTS
SECTION 3 – CONTROL HANDLE, STEERING ARM AND PIVOT ARM
3.1 - CONTROL HANDLE (continued)

3.1.5 – REPLACEMENT OF LEFT SIDE LOWER SWITCH (on-off)

(Refer to Figures 3.2 and 3.3)

1. Remove the Control Assembly (1) as per 3.1.1 above.

2. Unplug the connector from “LOWER-2” Plug on PC Board.

3. Push in the retainer clips on the switch and push the switch out of the hole in the control assembly
body. Feed the cable and connector out through the hole.

4. Fit the new cable and connector through the hole in the control assembly body and clip the new
lower switch into position using the two retaining clips on the switch.

5. Plug the connector into the “LOWER-2” Plug on the PC Board.

6. Re-assemble the Control Assembly (1) as per 3.1.2 above.

3.1.6 – REPLACEMENT OF LEFT SIDE LIFT SWITCH (on-off)

(Refer to Figures 3.2 and 3.3)

1. Remove the Control Assembly (1) as per 3.1.1 above.

2. Unplug the connector from “LIFT-2” Plug on PC Board.

3. Push in the retainer clips on the switch and push the switch out of the hole in the control assembly
body. Feed the cable and connector out through the hole.

4. Fit the new cable and connector through the hole in the control assembly body and clip the new
lower switch into position using the two retaining clips on the switch.

5. Plug the connector into the “LIFT-2” Plug on the PC Board.

6. Re-assemble the Control Assembly (1) as per 3.1.2 above

3.1.7 – REPLACEMENT OF RIGHT SIDE LOWER SWITCH (on-off)

(Refer to Figure 3.2)

1. Remove the Control Assembly (1) as per 3.1.1 above.

2. Unplug the connector from “LOWER-1” Plug on PC Board.

3. Push in the retainer clips on the switch and push the switch out of the hole in the control assembly
body. Feed the cable and connector out through the hole. Fit the new cable and connector
through the hole in the control assembly body and clip the new lower switch into position using the
two retaining clips on the switch.

4. Plug the connector into the “LOWER-1” Plug on the PC Board.

CONDA S&P Manual 22

PART B – SERVICE AND PARTS
SECTION 3 – CONTROL HANDLE, STEERING ARM AND PIVOT ARM
3.1 - CONTROL HANDLE (continued)

3.1.7 – REPLACEMENT OF RIGHT SIDE LOWER SWITCH (on-off) (continued)

(Refer to Figure 3.2)

5. Re-assemble the Control Assembly (1) as per 3.1.2 above

FIGURE 3.2 – LOCATION OF CABLES FOR SWITCH ASSEMBLIES

HANDLE FITTED WITH ON-OFF LIFT AND LOWER SWITCHES ONLY

CONDA S&P Manual 23

PART B – SERVICE AND PARTS
SECTION 3 – CONTROL HANDLE, STEERING ARM AND PIVOT ARM
3.1 - CONTROL HANDLE (continued)

3.1.8 – REPLACEMENT OF RIGHT SIDE LIFT SWITCH (on-off)

(Refer to Figure 3.2)

1. Remove the Control Assembly (1) as per 3.1.1 above.

2. Unplug the connector from “LIFT-1” Plug on PC Board.

3. Push in the retainer clips on the switch and push the switch out of the hole in the control assembly
body. Feed the cable and connector out through the hole.

4. Fit the new cable and connector through the hole in the control assembly body and clip the new
lift switch into position using the two retaining clips on the switch.

5. Plug the connector into the “LIFT-1” Plug on the PC Board.

6. Re-assemble the Control Assembly (1) as per 3.1.2 above.

3.1.9 – REPLACEMENT OF RIGHT SIDE PROPORTIONAL LOWER SWITCH

(Refer to Figure 3.3)

1. Remove the Control Assembly (1) as per 3.1.1 above.

2. Unplug the connector on the switch cable from “PLUG A”.

3. Push in the retainer clips on the switch and push the switch out of the hole in the control assembly
body. Feed the cable and connector out through the hole.

4. Fit the new cable and connector through the hole in the control assembly body and clip the new
lower switch into position using the two retaining clips on the switch.

5. Plug the connector on the switch cable into the “PLUG A”.

6. Re-assemble the Control Assembly (1) as per 3.1.2 above

3.1.10 – REPLACEMENT OF RIGHT SIDE PROPORTIONAL LIFT SWITCH

(Refer to Figure 3.3)

1. Remove the Control Assembly (1) as per 3.1.1 above.

2. Unplug the connector on the switch cable from “PLUG B”.

3. Push in the retainer clips on the switch and push the switch out of the hole in the control assembly
body. Feed the cable and connector out through the hole.

4. Fit the new cable and connector through the hole in the control assembly body and clip the new
lift switch into position using the two retaining clips on the switch.

5. Plug the connector on the switch cable into the “PLUG B”.

CONDA S&P Manual 24

PART B – SERVICE AND PARTS
SECTION 3 – CONTROL HANDLE, STEERING ARM AND PIVOT ARM
3.1 - CONTROL HANDLE (continued)

3.1.10 – REPLACEMENT OF RIGHT SIDE PROPORTIONAL LIFT SWITCH (continued)

(Refer to Figure 3.3)

5. Re-assemble the Control Assembly (1) as per 3.1.2 above.

FIGURE 3.3 – LOCATION OF CABLES FOR SWITCH ASSEMBLIES

HANDLE FITTED WITH PROPORTIONAL LIFT AND LOWER SWITCHES

CONDA S&P Manual 25

PART B – SERVICE AND PARTS
SECTION 3 – CONTROL HANDLE, STEERING ARM AND PIVOT ARM
3.1 - CONTROL HANDLE (continued)

3.1.11 – REPLACEMENT OF MUX PC BOARD ASSEMBLY (Refer to Figure 3.1)

1. Remove the Control Assembly (1) as per 3.1.1 above.

2. Unscrew the screw (11) securing the Left Hand Butterfly Control (13).

3. Pull the Left Hand Butterfly Control (13) off the Cam Shaft (14).

NOTE: The Butterfly Controls are marked LEFT or RIGHT on the inside face adjacent to the
control assembly body. When re-assembling the butterfly controls, make sure they
are positioned correctly as shown in Figure 3.1.

4. Remove the Right Hand Butterfly Control (12) and Cam Shaft (14) from the Control Assembly
Body (21). Take care to capture the Return Spring (10) and keep for re-assembly.

5. The MUX PC Board Assembly (15) can then be removed from the Control Assembly.

6. Note positions of all cable connectors to the PC Board. Progressively transfer each connector
from the defective PC Board to the new PC Board to ensure correct assembly of wiring.
Refer to Figures 3.2 or 3.3 as applicable for locations of connectors from switches to the MUX
PC Board.

7. Reinstall the new MUX PC Board assembly into the Control Assembly Body (21), making sure
the horn and belly button switches are aligned centrally.

8. Fit the Return Spring (10) in position.

9. Insert the Cam Shaft (14) into the Control Assembly Body (21), then through the access hole
in the MUX PC Board assembly (15) and through the other side of the Control Assembly
Body.

10. Fit the Left Hand Butterfly Control (13) to the Cam Shaft (14) and secure to the Cam Shaft
(14) with Screw (11).

11. Ensure that the MUX PC Board is located in the slot moulded in the Control Assembly Body
(21)

12. Reassemble the Control Assembly (1) to the Handle Base (22) as per 3.1.2.

CONDA S&P Manual 26

PART B – SERVICE AND PARTS
SECTION 3 – CONTROL HANDLE, STEERING ARM AND PIVOT ARM
3.1 - CONTROL HANDLE (continued)

3.1.12 – REPLACEMENT OF HORN COVER OR SPRINGS (Refer to Figures 3.1 and 3.4)

1. Remove the Control Assembly (1) as per 3.1.1 above.

2. Remove the MUX PC Board assembly as per 3.1.11 above.

3. Using a pair of long nose pliers, carefully squeeze inwards the lugs A on the Horn Cover (19 and
3). The cover will then be released from the two pivots on the Control Assembly Body (21 and 1)
and will drop out of the access opening.

NOTE: Take care to capture the two Springs (18 and 2) and retain ready for re-assembly.

4. Replace the Springs (18 and 2) if necessary.

5. Fit the Springs (18 and 2) in position on the locating bosses on Horn Cover (19 and 3). Assemble
the Horn Cover(19 and 3) to the Control Assembly Body(21 and 1) by inserting the lugs (B)
through the openings and then clipping in the two lugs(A) to secure the cover.

6. Reassemble the MUX PC Board assembly as per 3.1.11 above.

7. Reassemble the Control Assembly (1) as per 3.1.2 above.

FIGURE 3.4 – REPLACEMENT OF COVER OR SPRINGS

HORN AND SLOW SPEED SELECT SWITCHES

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PART B – SERVICE AND PARTS
SECTION 3 – CONTROL HANDLE, STEERING ARM AND PIVOT ARM
3.1 - CONTROL HANDLE (continued)

3.1.13 – REPLACEMENT OF SLOW SPEED SELECT COVER OR SPRINGS

(Refer to Figures 3.1 and 3.4)

1. Remove the Control Assembly (1) as per 3.1.1 above.

2. Remove the MUX PC Board assembly as per 3.1.11 above.

3. Using a pair of long nose pliers, carefully squeeze inwards the lugs A on the Slow Speed Select
Cover (23 and 3). The cover will then be released from the two pivots on the Control Handle Base
(22 and 1) and will drop out of the access opening.

NOTE: Take care to capture the two Springs (24 and 2) and retain ready for re-assembly.

4. Replace the Springs (24 and 2) if necessary.

5. Fit the Springs (24 and 2) in position on the locating bosses on Slow Speed Select Cover (23 and
3). Assemble the Slow Speed Select Cover (23 and 3) to the Control Handle Base (22 and 1) by
inserting the lugs (B) through the openings and then clipping in the two lugs(A) to secure the
cover.

6. Reassemble the MUX PC Board assembly as per 3.1.11 above.

7. Reassemble the Control Assembly (1) as per 3.1.1 above.

3.1.14 – REPLACEMENT OF SAFETY REVERSE COVER OR SPRINGS

(Refer to Figures 3.1 and 3.4 which can be used as a guide)

1. Remove the Control Assembly (1) as per 3.1.1 above.

2. Remove the MUX PC Board assembly as per 3.1.11 above.

3. Using a flat blade screwdriver, carefully wedge inwards each lug A on the Safety Reverse Cover
(16 and 3). The cover will then be released from the two pivots on the Control Assembly Body (21
and 1) and will drop out of the access opening.

NOTE: Take care to capture the two Springs(17 and 2) and retain ready for re-assembly.

4. Replace the Springs (17 and 2) if necessary.

5. Fit the Springs (17 and 2) in position on the locating bosses on Safety Reverse Cover (16 and 3).
Assemble the Safety Reverse Cover (16 and 3) to the Control Assembly Body (21 and 1) by
inserting the lugs (B) through the openings and then clipping in the two lugs (A) to secure the
cover.

6. Reassemble the MUX PC Board assembly as per 3.1.11 above.

7. Reassemble the Control Assembly (1) as per 3.1.1 above.

CONDA S&P Manual 28

PART B – SERVICE AND PARTS
SECTION 3 – CONTROL HANDLE, STEERING ARM AND PIVOT ARM
3.2 - STEERING ARM AND PIVOT ARM

3.2.1 - REMOVAL OF PIVOT COVERS AND PIVOT ARM COVER (Refer to Figure 3.5)

1. Press the emergency stop button & remove the key to disconnect power.

2. Check the 240V power lead to the Charger is turned Off & Disconnected

3. Remove the two Pivot Covers (2) from the Pivot Arm (4) by gently prying them free using a flat
edged screwdriver.

4. Unscrew the two Screws (6) which secure the Pivot Arm Cover (1) to the Pivot Arm (4).

5. Remove the Pivot Arm Cover (1) from the sides of the Pivot Arm (4) by gently prying them free
using a flat edged screwdriver.

NOTE: The Pivot Covers (2) and Pivot Arm Cover (1) are secured with contact adhesive.

3.2.2 - RE-ASSEMBLY OF PIVOT ARM COVER AND PIVOT COVERS

(Refer to Figure 3.5)

1. Fit the Pivot Arm Cover (1) around the Pivot Arm (4).

2. Align and fit the two Screws (6) through the bottom flange of the Pivot Cover (1) and tighten them
to secure the cover to the pivot arm.

3. Apply a small amount of contact adhesive to the inside faces of the sides of the Pivot Arm Cover
(1), allow to set, then fit the cover to Pivot Arm (4). Press inwards from each side to home the
Cover on the Pivot Arm.

4. Fit the two Pivot Covers (2) to the Pivot Arm (4) by pressing the edges over the retaining flange.
Apply contact adhesive before assembly to retain if required.

3.2.3 - REMOVAL OF STEERING ARM COVER (Refer to Figure 3.5)

1. Remove the Control Assembly (1) as per 3.1.1 above.

2. Remove the Handle Base (22) from the Steering Arm as per 3.1.3 above.

3. Remove the Pivot Arm Covers (1 and 2) as per 3.2.1 above.

4. Unscrew the six Screws (7) to release the Steering Arm Cover (3) from the Steering Arm (5).
Retain these for re-assembly.

NOTE: The steering arm will need to be pulled down slightly to ensure the cover is not forced
against the Rubber Stops (21) inside the Pivot Arm (4).

3.2.4 - REPLACEMENT OF STEERING ARM COVER (Refer to Figures 3.1 and 3.5)

1. Pull the steering arm downwards slightly and fit the front retaining flange of the Steering Arm
Cover (3) around the retaining bar located on the Steering Arm (5).

2. Fit the sides of the Steering Arm Cover (3) around the Steering Arm (5) so that the bottom flanges
of the cover are under the bottom face of the Steering Arm.

3. Secure the Steering Arm Cover (3) using the six Screws (7).

CONDA S&P Manual 29

PART B – SERVICE AND PARTS
SECTION 3 – CONTROL HANDLE, STEERING ARM AND PIVOT ARM
3.2 - STEERING ARM AND PIVOT ARM (continued)

3.2.4 - REPLACEMENT OF STEERING ARM COVER (continued) (Refer to Figure 3.5)

4. Re-assemble the Pivot Arm Covers (1 and 2) as per 3.2.2 above.

5. Reassemble the Control Handle Base (22) to the Steering Arm (5) as per 3.1.3 above.

6. Reassemble the Control Assembly (1) to the Control Handle Base (22) as per 3.1.2 above.

REF PART NO DESCRIPTION QTY

1 943130 Rubber Cover - Pivot Arm 1
2 943128 Rubber Cover - Pivot 2
3 943129 Rubber Cover - Steering Arm 1
4. 950035 Weldment - Pivot Arm 1
5 950030 Weldment - Steering Arm 1
6 943135 Screw 3
7 943135 Screw 6
8 065608 Socket Head Cap Screw 1
9 943126 Spring Tube Clamp 1
10 501371A Spring Tube 1
11 943124 Return Spring 1
12 943125 Pivot Arm Pin 1
13 061713S Circlip 2
14 943121 Shim – Steering Arm 1
15 944204 Harness Assy – Control Assembly to Pivot Arm 1
16 944200-01 Lower Harness – Electrical Panel to Pivot Arm 1
17 061006 Roll Pin ¼ in x 1-1/4 in. 1
18 061050 Roll Pin 3/8 in x 1-1/4 in. 1
19 940725 Flat Washer 8
20 940875 Cable Clip – Nylon 1
21 943109 Rubber Mushroom Buffer 2
22 077056 Flat Washer 2
23 052922 Flanged Bronze Bush 2
24 943122 Micro-switch 1
25 940854 Screw 2
26 077203 Lock Washer 2
27 940859 Hex Nut 2
28 950040 Weldment – Pivot Tube 1
29 941470 Hex Head Set Screw 6
30 943137 Lock Washer 6
31 944102ST Dash Panel Cover - standard 1
32 061002 Roll Pin ¼ in x ¾ in. 1
33 061051 Roll Pin 10mm x 20mm 1

PARTS LIST FOR FIGURE 3.5 – STEERING ARM AND PIVOT CAP

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PART B – SERVICE AND PARTS
SECTION 3 – CONTROL HANDLE, STEERING ARM AND PIVOT ARM
3.2 - STEERING ARM AND PIVOT ARM (continued)

FIGURE 3.5 – STEERING ARM AND PIVOT ARM

CONDA S&P Manual 31

PART B – SERVICE AND PARTS
SECTION 3 – CONTROL HANDLE, STEERING ARM AND PIVOT ARM
3.2 - STEERING ARM AND PIVOT ARM (continued)

3.2.5 - ADJUSTMENT OF HANDLE RETURN SPRING TENSION (Refer to Figure 3.5)

1. Press the emergency stop button & remove the key to disconnect power.

2. Check the 240V power lead to the Charger is turned Off & Disconnected

3. Remove the left side Pivot Cover (2) from the Pivot Arm (4) by gently prying it free using a flat
edged screwdriver.

4. Using the Sumi Tensioning Tool (P/N 501371AT), place the two pins in the two holes in the end of
the Spring Tube (10).

5. Supporting the control handle, loosen the Cap Screw (8) securing the Spring Tube Clamp (9) to
the Spring Tube (10).

6. Rotate the Tensioning Tool clockwise to increase spring tension, or anti-clockwise to reduce
spring tension.

7. Then tighten the Cap Screw (8) and test the adjustment. Re-adjust the tension up or down if
required.

8. Replace the left side Pivot Cover (2). (secure with contact adhesive if required.)

3.2.6 - REPLACEMENT OF HANDLE RETURN SPRING (Refer to Figure 3.5)

1. Ensure the emergency stop button is pressed to disconnect power.

2. Remove the left side Pivot Cover (2) from the Pivot Arm (4) by gently prying it free using a flat
edged screwdriver.

3. Using the Sumi Tensioning Tool (P/N 501371AT), place the two pins in the two holes in the end of
the spring tube (10).

4. Supporting the control handle, loosen the Cap Screw (8) securing the Spring Tube Clamp(9) to
the Spring Tube(10) and reduce the spring tension to zero.

5. With a piece of chalk or crayon, draw a straight line from the centre of the Spring Tube (10)
outward on to the Pivot Arm (4), marking the radial position of the tube to facilitate
re-assembly.

6. Remove Cap Screw (8) from the Spring Tube Clamp (9).

7. Whilst supporting the steering arm and handle, pull out the Spring Tube (10) from the Pivot Arm
(4).

NOTE: The Return Spring (11) may remain inside the Spring Tube (10).

8. Remove the Return Spring (11) from the Spring Tube (10). If the spring is severely jammed and
will not come loose, use a punch and drive the Roll Pin (18) into the tube. Capture the pin for re-
use. Remove the Spring. Tap the roll pin back into place.

9. Lubricate the ends and outer surface of the new Return Spring (11) with a lithium base general
purpose grease.

CONDA S&P Manual 32

PART B – SERVICE AND PARTS
SECTION 3 – CONTROL HANDLE, STEERING ARM AND PIVOT ARM
3.2 STEERING ARM AND PIVOT ARM (continued)

3.2.6 - REPLACEMENT OF HANDLE RETURN SPRING (continued) (Refer to Figure 3.5)

10. Insert the new Return Spring (11) into the Spring Tube (10) and press in, making sure that the
spring loop eye fits over the large Roll Pin (18) at the closed end of the spring tube.

11. Slide the Spring Tube (10) into the Pivot Arm (4) and Steering Arm (5), through the Spring Tube
Clamp (9) and through the loop of electrical cable. Slowly rotate the Spring Tube a few degrees
each way until the Return Spring snaps into place over Roll Pin (18).

NOTE: Ensure that the cable from the Control Handle to the Pivot Arm is looped from outside to inside as
shown in Figure 3.6 below.

FIGURE 3.6 ROUTING OF HARNESS ASSY – CONTROL HANDLE TO PIVOT ARM

12. Align the hole in the Spring Tube Clamp (9) with the hole in the Steering Arm(5) and insert Cap
Screw(8) through the steering arm into the spring tube clamp.

13. Then proceed to adjust the return spring tension as per paragraph 3.2.5 above.

CONDA S&P Manual 33

PART B – SERVICE AND PARTS
SECTION 3 – CONTROL HANDLE, STEERING ARM AND PIVOT ARM
3.2.7 - REMOVAL OF PIVOT ARM FROM PIVOT TUBE (Refer to Figure 3.5)

1. Ensure the emergency stop button is pressed & key removed to disconnect power.

2. Check the 240V power lead to the Charger is turned Off & Disconnected

3. Remove the Pivot Covers (2) and (1) from the Pivot Arm (4) as described in 3.2.1 above.

4. Disconnect the Harness Assembly (15) from Lower Harness (16) at the plug connector.

5. Remove the Circlip (13) from one end of Pivot Arm Pin (12). Then drive the Pivot Arm Pin (12)
out of the Pivot Arm and Pivot Tube (28) to release the Pivot Arm.

3.2.8 - REPLACEMENT OF PIVOT ARM ON PIVOT TUBE (Refer to Figure 3.5)

1. Ensure the emergency stop button is pressed & key removed to disconnect power.

2. Check the 240V power lead to the Charger is turned Off & Disconnected

3. Place Pivot Arm (4) over the Pivot Tube (28).

4. Fit Pivot Arm Pin (12) through the Pivot Arm (4) and Pivot Tube (28). Then secure the pin by
fitting Circlip (13) on the pivot arm pin.

5. Re-connect the Harness Assembly (15) from Lower Harness (16) at the plug connector.

6. Replace the Pivot Arm Covers (2) and (1) on Pivot Arm (4) as described in 3.2.2 above.

3.2.9 - REMOVAL OF HARNESS ASSY – CONTROL HANDLE TO PIVOT ARM

(Refer to Figures 3.2 and 3.5)

1. Ensure the emergency stop button is pressed to disconnect power.

2. Check the 240V power lead to the Charger is turned Off & Disconnected.

3. Disconnect the battery.

4. Remove the Pivot Covers (2) and (1) from the Pivot Arm (4) as described in 3.2.2 above.

5. Disconnect the Harness Assembly (15) from Lower Harness (16) at the plug connector.

6. Remove the Control Assembly from the Handle Base as described in 3.1.1.

7. Disconnect the Harness Assembly from connector AJ2 on the MUX PC Board Assembly. (refer to
Figure 3.2)

8. Pull the Harness Assembly (15) free of the Steering Arm (5).

CONDA S&P Manual 34

PART B – SERVICE AND PARTS
SECTION 3 – CONTROL HANDLE, STEERING ARM AND PIVOT ARM
3.2.10 - REPLACEMENT OF HARNESS ASSY – CONTROL HANDLE TO PIVOT ARM
(Refer to Figures 3.2 and 3.5)

1. Ensure the emergency stop button is pressed & key removed to disconnect power.

2. Check the 240V power lead to the Charger is turned Off & Disconnected

3. Disconnect the battery

4. Feed the new Harness Assembly (15) through the Steering Arm (5).

5. Re-connect the Harness Assembly from connector AJ2 on the MUX PC Board Assembly.
( Rrefer to Figure 3.2)

6. Assemble the Control Assembly from the Handle Base as described in 3.1.2.

7. Re-connect the Harness Assembly (15) from Lower Harness (16) at the plug connector.

8. Replace the Pivot Covers (2) and (1) from the Pivot Arm ( 4) as described in 3.2.2 above.

3.2.11 - REMOVAL OF DASH PANEL (Refer to Figure 3.7)

1. Remove Top Cover (1) and Rear Cover.

2. Unplug the Battery Disconnect Plug (17) to isolate the truck from the batteries.

3. Remove the Pivot Arm (4) from the Pivot Tube (28) as described in 3.2.7 above.
(Refer to figure 3.5).

4. Remove the Plug (2) from the back of the Curtis Diagnostic Gauge (3).

5. Unscrew Nut (4) and Lock Washer (5) and remove the Cable Clamp (6) securing the 240V lead
(7) to the Dash Panel (8).

6. Remove the Key (9) from the Emergency Disconnect Switch (12).

7. Remove the Circlip (10) to release the Emergency Disconnect Button (11) and pull the button off
the shaft of the switch.

8. Remove Screws (13) to free the Emergency Disconnect Switch (12) from the Dash Panel (8).
Capture the Packer (14) and retain for reassembly.

9. Remove the Valve Handles ( Side Shift Models Only)

10. Unscrew the three Nuts (15) and Lock Washers (16) to release the Dash Panel (8).

11. Lift the Dash Panel (8) up and clear of the Pivot Tube.

3.2.12 -REPLACEMENT OF DASH PANEL (Refer to Figure 3.7)

1. Install Dash Panel (8) in position with the three studs engaged in the holes on the body stiffener.

2. Fit the Lock Washers (16) and Nuts (15) and tighten to secure Dash Panel (8).

CONDA S&P Manual 35

PART B – SERVICE AND PARTS
SECTION 3 – CONTROL HANDLE, STEERING ARM AND PIVOT ARM

3.2.12 - REPLACEMENT OF DASH PANEL (Continued) (Refer to Figure 3.7)

3. Assemble the Valve Handles to the Valves ( Side Shift Models Only )

4. Fit the Emergency Disconnect Switch (12) with Packer (14) to the Dash Panel (8) and secure with
Screws (13).

5. Install Emergency Disconnect Button (11) on the Switch (12) and secure with Circlip (10).

6. Replace Key (9) in switch.

7. Secure Cable Clamp (6) to the Dash Panel (8) with Lock Washer (5) and Nut (4).

8. Re-assemble Plug (2) to the back of the Curtis Diagnostic Gauge (3).

9. Re-assemble the Pivot Arm (4) to the Pivot Tube (28) as described in 3.2.8 above.

10. Re-connect the Battery Plug (17) to connect the batteries to the truck.

11. Fit Top Cover (1) and Rear Cover.

FIGURE 3.7 – DASH PANEL – REMOVAL / REPLACEMENT

CONDA S&P Manual 36
PART B – SERVICE AND PARTS
SECTION 3 – CONTROL HANDLE, STEERING ARM AND PIVOT ARM

3.2.12 - REPLACEMENT OF DASH PANEL (Continued) (Refer to Figure 3.7)

REF PART NO DESCRIPTION QTY

1 950001 Top Cover 1
2 943155 8 Pin Molex Plug 1
3 943106 Curtis Diagnostic Gauge 1
4 940724 Hex Nut M4 1
5 940725 Washer M4 1
6 940875 Cable Clamp – Nylon 1/4 1
7 944201 Cable Assembly – Charger to IEC Plug to Relay 1
8 944102ST DashBoard Panel Cover – Standard Model 1
OR 944102 DashBoard Panel Cover – Side Shift Model 1
9 941602K Key - Battery Disconnect Switch 1
10 941602C Circlip 1
11 941602B Emergency Disconnect Button 1
12 941602 Emergency Disconnect Switch 1
13 943274 Screw – Pan Head M5 – 16mm 2
14 943123 Packer – Emergency Disconnect Switch 1
15 943118 Lock Washer M5 3
16 941079 Hex Nut M5 3
17 ---- Battery Disconnect Plug 1
18 941436 Valve Handles– Side Shift Model 1

PARTS LIST FOR FIGURE 3.7 – DASH PANEL – REMOVAL / REPLACEMENT

3.2.13 - REMOVAL OF PIVOT TUBE (Refer to Figure 3.5)

1. Remove the Dash Panel (8) as described in 3.2.11 above. (Refer to figure 3.7).

2. Remove the six Bolts (29) and Lock Washers (30) to release the Pivot Tube (28).
(Refer to Figure 3.5)

3. Lift the Pivot Tube (28) upwards, taking care not to damage the Lower Harness (16).

3.2.14 - REPLACEMENT OF PIVOT TUBE (Refer to Figure 3.5)

1. Feed the Lower Harness (16) up through the inside of the Pivot Tube (28) so that the multi pin
plug is exposed above the tube.

2. Assemble Pivot Tube (28) to the Motor Mount Bracket using six Bolts (29) and Lock Washers
(30). Torque bolts to 20 NM.

3. Re assemble Dash Panel (8) as described in 3.2.12 above. (Refer to Figure 3.7)

CONDA S&P Manual 37

PART B – SERVICE AND PARTS
SECTION 4 – TRANSMISSION, DRIVE MOTOR, ELECTRIC BRAKE
4.1 - ELECTRIC BRAKE
4.1.1 - BRAKE PAD ADJUSTMENT (Refer to Figures 4.1 and 4.2)

1. Ensure the emergency stop button is pressed to disconnect power.

2. Check the 240V power lead to the Charger is turned Off & Disconnected

3. Disconnect the battery

4. Chock the wheels to prevent truck moving.

5. Remove the Pivot Arm, Steering Arm and Handle Assembly, Dash Panel and Pivot
Tube as described in 3.2.13.

6. Locate the rubber seal on the brake assembly (1). Slide the rubber cover seal upwards onto the
armature to enable access to the adjustment points (2).

FIGURE 4.1 – ELECTRIC BRAKE ASSEMBLY

NOTE: From this point refer to Figure 4.2

7. Adjust the air gap between the armature plate (2) and the Stator (1) by loosening the three Fixing
Bolts (4) by half a turn to create an excessive air gap.

8. Screw the three Adjusting Bushes (3) anti-clockwise two turns.

9. To set the air gap, insert a Feeler Gauge (5) in the air gap adjacent to the Fixing Screw, turn each
of the three Fixing Screws (4) clockwise, moving the magnet body toward the Armature Plate (2)
until the required air gap is achieved. (Use standard feeler gauges to achieve the dimension
0.012” or 0.3mm at each adjusting bush, which sets the gap for the Armature Plate). When the
adjustment has been made at each adjusting bush, recheck the gap at the other two adjusting
bushes to verify the adjustment.

CONDA S&P Manual 38

PART B – SERVICE AND PARTS
SECTION 4 – TRANSMISSION, DRIVE MOTOR, ELECTRIC BRAKE

4.1 - ELECTRIC BRAKE (continued)

4.1.1 - BRAKE PAD ADJUSTMENT (continued) (Refer to Figures 4.1 and 4.2)

10. Then secure the setting by screwing the three Adjusting Bushes (3) clockwise, away from the
magnet body until contact is obtained.

11. Tighten the three Fixing Bolts (4).

12. Check the air gap once again and make minor adjustments as above if necessary.

13. Reinstall the Rubber Cover Seal (1, Figure 4.1). Make sure to seat the seal around the base of
the Armature plate and the lower groove in the Armature.

14. Replace the Pivot Tube, Dash Panel, Pivot Arm, Steering Arm and Handle Assembly as described
in 3.2.14.

15. Replace the Top Cover and Rear Cover.

16. Reconnect the battery and test the brake function.

17. Repeat the brake adjustment as needed to make sure that the machine stops properly

FIGURE 4.2 – BRAKE PAD ADJUSTMENT

CONDA S&P Manual 39

PART B – SERVICE AND PARTS
SECTION 4 – TRANSMISSION, DRIVE MOTOR, ELECTRIC BRAKE

4.1 - ELECTRIC BRAKE (continued)

REF PART NO DESCRIPTION QTY

1 901701 Complete Brake Assembly 1
2 901700 Socket Head Cap Screw 3
3 901702 Rotor 1
4 901703 Plate, Friction 1

FIGURE 4.3 – ELECTRIC BRAKE PAD REPLACEMENT

CONDA S&P Manual 40

PART B – SERVICE AND PARTS
SECTION 4 – TRANSMISSION, DRIVE MOTOR, ELECTRIC BRAKE

4.1 - ELECTRIC BRAKE (continued)

4.1.2 - BRAKE PAD REPLACEMENT (Refer to Figure 4.3)

1. Ensure the emergency stop button is pressed& remove key to disconnect power.

2. Check the 240V power lead to the Charger is turned Off & Disconnected

3. Disconnect the battery

4. Chock the wheels to prevent truck from moving.

5. Remove the Pivot Arm, Steering Arm and Handle Assembly, Dash Panel and Pivot tube as
described in 3.2.13.

6. Remove the three Brake Assembly Mounting Bolts (1).

7. Lift the Brake Assembly (2) off the Drive Motor Assembly.

NOTE: The splined hub on the Brake Hub Assembly must be positioned downwards, towards the
centre of the motor assembly. If the brake hub is not assembled in this fashion, damage to the
Splined Gear may result.

8. Slide the Rubber Cover Seal (5) upwards, loosening the Friction Plate (4) and Brake Hub (3)
Assembly.

9. Remove and replace the Friction Plate (4) and Brake Hub (3) Assemblies.

10. Align the Friction Plate Mounting Holes with the Mounting Bolt Holes.

NOTE: Make sure that the raised edge of the Friction Plate (4) is facing upwards towards the
Brake Hub Assembly.

11. Insert the three Mounting Bolts (1) through the Brake Assembly and reposition over the splined
shaft on the Drive Motor Assembly.

12. Secure the three Brake Assembly Mounting bolts (1). Torque the bolts to 23Nm.

13. Slide the rubber cover seal back into place.

14. Replace the Pivot Tube, Dash Panel, Pivot Arm, Steering Arm and Handle Assembly as described
in 3.2.8.

15. Remove blocking and lower truck.

16. Reconnect the battery and test the brake function.

17. Adjust the brake as described in 4.1.1 above.

18. Replace the Top Cover and Rear Cover.

CONDA S&P Manual 41

PART B – SERVICE AND PARTS
SECTION 4 – TRANSMISSION, DRIVE MOTOR, ELECTRIC BRAKE
4.1 - ELECTRIC BRAKE (continued)
4.1.3 - REPLACEMENT OF BRAKE ASSEMBLY (Refer to Figure 4.4)

1. Ensure the emergency stop button is pressed to disconnect power.

2. Chock wheels to prevent truck from moving.

3. Remove the Pivot Arm, Steering Arm and Handle Assembly, Dash Panel and Pivot tube as
described in 3.2.13.

4. Remove the three Brake Assembly Mounting Bolts (1).

5. Disconnect the wire harness at the in-line connectors.

NOTE: Note connections before removing wires.

6. Remove the old Brake Assembly (2).

7. Install new Brake Assembly and secure with the three Cap Screws (1).

8. Adjust the brake air gap. See section 4.1.1 Brake Pad Adjustment.

9. Slide the rubber cover seal into place.

10. Replace the Pivot Tube, Dash Panel, Pivot Arm, Steering Arm and Handle Assembly as described
in 3.2.8.

11. Remove blocking and lower truck.

12. Reconnect the battery and test the brake function. Adjust the brake as described in 4.1.1 above.

13. Replace the Top Cover and Rear Cover.

FIGURE 4.4 – BRAKE REPLACEMENT

CONDA S&P Manual 42

PART B – SERVICE AND PARTS
SECTION 4 – TRANSMISSION, DRIVE MOTOR, ELECTRIC BRAKE

4.2 - DRIVE MOTOR

4.2.1 - REMOVAL OF THE DRIVE MOTOR (Refer to Figure 4.5)

1. Ensure the emergency stop button is pressed & remove key to disconnect power.

2. Check the 240V power lead to the Charger is turned Off & Disconnected

3. Disconnect the battery.

4. Chock the wheels to prevent truck from moving.

5. Remove the Pivot Arm, Steering Arm and Handle Assembly, Dash Panel and Pivot tube as
described in 3.2.13.

6. Remove the Electric Brake as described in 4.1.3 above.

7. Label and disconnect the four Cables (1) to the Drive Motor (2).

CAUTION: The transmission is a precision assembly and severe damage will

occur if any foreign objects are allowed to fall into the sump.

8. Clean any debris from around the top surface of the Turntable Bearing (3) before attempting to
remove the Drive Motor (2).

CAUTION: When the bolts securing the drive motor are removed, the transmission can
drop down out of the turntable bearing.
Before proceeding to remove the drive motor, support the transmission
from underneath to prevent it falling if the truck is elevated above the
floor.

9. Remove the eight Socket Head Cap Screws (4) and Flat Washers (5) securing the Drive Motor
Mounting Plate to the Transmission (6).

10. Carefully lift the Drive Motor (2) upwards and clear of the transmission (6).

CAUTION: When the Drive Motor has been removed the transmission sump will be
exposed. Cover opening to prevent foreign objects from falling into the
transmission.

NOTE: The following work needs to be performed on a workbench in a clean environment.

11. Unscrew the Nyloc Nut (7) from the shaft of the Drive Motor (2).

12. Carefully remove the Motor Pinion (8) from the tapered shaft.

13. Remove the Woodruffe Key (9) from the Motor shaft.

14. Remove Circlips (12) to slide Brake Pinion (11) from motor shaft

15. Capture Key (13) for reassembly

16. Remove Pivot Tube Mount (14) from Drive Motor (2) by removing Screws (15)

NOTE: Repair of the Drive Motor is covered in Section 5.0.

CONDA S&P Manual 43

PART B – SERVICE AND PARTS
SECTION 4 – TRANSMISSION, DRIVE MOTOR, ELECTRIC BRAKE
4.2 - DRIVE MOTOR (continued)

FIGURE 4.5 – DRIVE MOTOR & TRANSMISSION

CONDA S&P Manual 44
PART B – SERVICE AND PARTS
SECTION 4 – TRANSMISSION, DRIVE MOTOR, ELECTRIC BRAKE

4.2 - DRIVE MOTOR (continued)

REF PART NO DESCRIPTION QTY

1 ------ Cables to Drive Motor 4
2 943181 24V Sepex Drive Motor 1
3 943182 Turntable Bearing 1
4 943183 Socket Head Cap Screw 8
5 943184 Flat Washer 8
6 943185 Transmission Assembly 1
7 943186 Nyloc Nut 1
8 943187 Motor Pinion 1
9 943188 Woodruffe Key 1
10 943189 O-ring 1
11 943190 Brake Pinion 1
12 943191 Circlip 2
13 943192 Key 1
14 943193 Mount – Pivot Tube to Motor 1
15 943194 Socket Head Cap Screw 3
16 943180 Drive Wheel – Polyurethane 1
17 901720 Lock Washer 5
18 901721 Hex Nut 5

PARTS LIST FOR FIGURE 4.5 – DRIVE MOTOR AND TRANSMISSION

4.2.2 - REPLACEMENT OF THE DRIVE MOTOR (Refer to Figure 4.5)

1. Clean the Drive Motor Shaft tapered section to remove any oil or grease.

2. Fit a new Woodruffe Key (9) to the Motor Shaft.

3. Slide the Motor Pinion (8) on to the shaft and align the keyway

4. Assemble Nyloc Nut (7) and tighten to secure Pinion (8). Torque to 30 NM.

5. Fit inner Circlip (12) on top end motor shaft. Assemble Key (13) in keyway of motor shaft.

6. Slide Brake Pinion (11) on to motor shaft until homed on inner Circlip (12). Fit outer Circlip (12) to
secure Brake Pinion on motor shaft.

NOTE: The centering-locating face for connection of the Drive Motor must be perfectly clean
and undamaged.

7. Wet the O Ring (10) with transmission oil and assemble it into the groove of the Motor Centering
Seat.

CONDA S&P Manual 45

PART B – SERVICE AND PARTS
SECTION 4 – TRANSMISSION, DRIVE MOTOR, ELECTRIC BRAKE

4.2 - DRIVE MOTOR (continued)

4.2.2 - REPLACEMENT OF THE DRIVE MOTOR (continued) (Refer to Figure 4.5)

CAUTION: The transmission is a precision assembly and severe damage will

occur if any foreign objects are allowed to fall into the sump.

CAUTION: With the drive motor removed, the transmission can drop down out of
the turntable bearing.

Before proceeding to install the drive motor, ensure that the transmission is securely supported
from underneath to prevent it falling.

8. Assemble the Drive Motor (2) cautiously into the transmission top section, taking care to engage
the teeth of the motor pinion in the mating gear.

9. Turn the motor to align the bolt holes of the motor and transmission top section adequately.

10. Fasten the Drive Motor (2) to Transmission (6) using the eight Socket Head Cap Screws (4) and
Flat Washers (5).

11. Torque the Screws (4) to 23 NM.

12. Connect the cables to the Drive Motor (2) ensuring they are positioned correctly and then tie as
necessary.

13. Replace the Electric Brake as described in 4.1.3 above.

14. Replace the Pivot Tube, Dash Panel, Pivot Arm, Steering Arm and Handle Assembly as described
in 3.2.8.

15. Remove blocking and lower truck.

16. Reconnect the battery and test the brake function.

17. Adjust the brake as described in 4.1.1 above.

18. Replace the Top Cover and Rear Cover.

4.3 - TRANSMISSION

4.3.1 - REMOVAL OF THE TRANSMISSION ASSEMBLY

1. Remove the Drive Motor as described in 4.2.1, steps 1 to 8 above.

2. The support block can then be removed and the transmission assembly lowered on to the floor or
a trolley.

3. Pull the transmission assembly out from under the truck.

CAUTION: The transmission is a precision assembly and severe damage will

occur if any foreign objects are allowed to fall into the sump.

CONDA S&P Manual 46

PART B – SERVICE AND PARTS
SECTION 4 – TRANSMISSION, DRIVE MOTOR, ELECTRIC BRAKE
4.3 - TRANSMISSION (continued)
4.3.2- REPLACEMENT OF THE TRANSMISSION ASSEMBLY

CAUTION: The transmission is a precision assembly and severe damage will

occur if any foreign objects are allowed to fall into the sump.

1. Position the Transmission Assembly under the truck.

2. Lift the Transmission Assembly up to engage in the Turntable Bearing until the assembly is
“homed”.

3. Place a support under the transmission to hold it in place.

4. Install the Drive Motor, electric brake, pivot tube, dash panel pivot arm, steering arm and handle
as described in section 4.2.2 above.

4.3.3 - REMOVAL OF THE TRANSMISSION, DRIVE MOTOR, BRAKE ASSEMBLY

(Refer to Figure 4.6)

The transmission, drive motor and electric brake can be removed as an assembly, allowing
disassembly to be undertaken in a clean and ergonomic environment.

To remove the transmission, drive motor, electric brake as an assembly, proceed as follows:

NOTE: Jack up the truck to provide clearance to remove the transmission. Block the truck to
prevent movement.

1. Remove the Handle and Pivot Arm Assembly from the Pivot Tube as described in 3.2.7.

2. Remove the Dash Panel as described in 3.2.11.

3. Remove the Pivot Tube as described in 3.2.13.

4. Label and disconnect the four cables to the Drive Motor.

5. Disconnect the cables from the electric brake at the in-line connectors.

6. Unscrew Stop Nut (1) from Hex Bolt (2) then remove Hex Bolt (2) & Lock Washer (3).

7. Support the Transmission Drive Motor Assembly (40 from underneath or from above, using an
overhead hoist.

8. Remove the five remaining Hex Bolts (5) and Lock Washers (6) and lower the Transmission and
Drive Motor Assembly (4) to the floor. Then move the Assembly out and clear of the truck.

9. Remove Stop (7) and Lock Washer (8). Also Bracket (8A) if equipped. Retain all for re-assembly.

10. Remove the Drive Wheel from the transmission as described in 4.4 below.

CONDA S&P Manual 47

PART B – SERVICE AND PARTS
SECTION 4 – TRANSMISSION, DRIVE MOTOR, ELECTRIC BRAKE
4.3 - TRANSMISSION (continued)

4.3.3 - REMOVAL OF THE TRANSMISSION, DRIVE MOTOR, BRAKE ASSEMBLY

FIGURE 4.6 – TRANSMISSION, DRIVE MOTOR, BRAKE ASSEMBLY

CONDA S&P Manual 48

PART B – SERVICE AND PARTS
SECTION 4 – TRANSMISSION, DRIVE MOTOR, ELECTRIC BRAKE
4.3 - TRANSMISSION (continued)

REF PART NO DESCRIPTION QTY

1 940987 Stop Nut, Transmission 1
2 943140 Hex Bolt 1
3 943143 Lock washer 1
4 943104 Transmission, Drive Motor, Brake Assembly 1
5 943139 Hex Bolt 5
6 943143 Lock washer 5
7 943165 Stop Bolt, Transmission 1
8 943143 Lock Washer 1
8A 943273 Stop Bracket, Transmission (if equipped) 1

PARTS LIST FOR FIGURE 4.6 -TRANSMISSION, DRIVE MOTOR, BRAKE ASSEMBLY

4.3.3 - REMOVAL OF THE TRANSMISSION, DRIVE MOTOR, BRAKE ASSEMBLY

( continued ) (Refer to Figure 4.5)

NOTE: The following work needs to be performed on a workbench in a clean environment.

11. Clean away debris from around the top surface of the Turntable Bearing Assembly (3) before
attempting to remove the Drive Motor (2). (refer to Figure 4.5)

12. Remove the eight Socket Head Cap Screws (4) and Flat Washers (5) securing the Motor
Mounting Plate to the Transmission. (refer to Figure 4.5)

13. Remove the Drive Motor (2) and Transmission (6) from the Turntable Bearing Assembly (3).
(refer to Figure 4.5)

CAUTION: When the Drive Motor has been removed, the Transmission Sump will be
exposed. Cover opening to prevent foreign objects from falling into the
transmission.

4.3.4 - REPLACEMENT OF THE TRANSMISSION, DRIVE MOTOR, BRAKE ASSEMBLY

(Refer to Figures 4.5 and 4.6)

NOTE: The following work needs to be performed on a workbench in a clean environment.

1. Clean externally the Turntable Bearing (3) and repack with grease.

2. Fit the Turntable Bearing (3) over the Spigot of the Transmission (6).

NOTE: The centering – locating face for connection of the Drive Motor must be perfectly clean
and undamaged.

3. Apply some Transmission oil to the new O-Ring (10) and insert it into the groove of the Drive
Motor Centring Seat.

CONDA S&P Manual 49

B – SERVICE AND PARTS
SECTION 4 – TRANSMISSION, DRIVE MOTOR, ELECTRIC BRAKE
4.3 - TRANSMISSION (continued)

4.3.4 - REPLACEMENT OF THE TRANSMISSION, DRIVE MOTOR, BRAKE ASSEMBLY

( continued ) (Refer to Figures 4.5 and 4.6)

4. Assemble the Drive Motor (2) cautiously into the transmission top section, taking care to engage
the teeth of the Motor Pinion (8) in the mating gear.

5. Turn the Motor to align the bold holes of the motor and transmission top section adequately.

6. Fasten the Drive Motor (2) to the Transmission (6) securing with the eight Socket Head Cap
Screws (4) and Lock Washers (5).

7. Torque the Screws (5) to 23 NM

8. Replace the Transmission and Drive Motor Assembly in reverse order as per 4.1.9 to 4.1.11
above. (Refer to Figure 4.6)

9. Assemble the Pivot Tubes as described in 3.2.4 above.

10. Assemble the Dash Panel as described in 3.2.12 above.

11. Assemble the Handle and Pivot Arm Assembly to the Pivot Tube as described in 3.2.8 above.

4.3.5 - REPAIR OF TRANSMISSION (Refer to Figure 4.5)

All SUMI CONDA models are fitted with the latest ZF Vertical Configuration DC drive transmission
incorporating premium helical and bevel cut gears and precision bearings, offering super quiet and
smooth performance and extended operating life.

NOTE: The transmission is a precision assembly therefore, does not have any serviceable parts.

If the transmission develops a problem, it needs to be replaced or returned to Osko Forklifts for
evaluation and possible repair.

4.4 - REPLACEMENT OF DRIVE WHEEL (Refer to Figure 4.5)

1. Ensure the emergency stop button is pressed to disconnect power& remove the key.

2. Check the 240V power lead to the Charger is turned Off & Disconnected

3. Disconnect the battery

4. Remove the Rear Cover.

5. Jack up the rear of the truck sufficient to access and remove the drive wheel.

6. Chock the wheels to prevent truck from moving.

7. Remove the five Nuts (18) and Lock washers (17) and slide the Drive Wheel (16) off the wheel
studs of the Transmission (6).

8. Fit the new Drive Wheel (16) over the studs of the Transmission (6).

9. Fit Lock Washers (17) and secure wheel with Nuts (18).

10. Torque the five Nuts (18) to 100 Nm.

CONDA S&P Manual 50

PART B – SERVICE AND PARTS
SECTION 5 – ELECTRICAL SYSTEM
5.1 – TRANSISTOR CONTROLLER

All CONDA Models are fitted with a fully programmable Curtis integrated traction and hydraulic system
controller, providing smooth and seamless operation of the separately excited traction motor and precise
control of the pump motor and lowering valve.

The controller is fully programmable and can be adjusted using a Curtis hand held programmer
( P/N 943150 and cable 943151) available from OSKO Forklifts.
The programmer can be used to alter certain parameters to suit particular applications, to test operation
and to diagnose faults.

CAUTION: The parameters for the controller have been set by the OSKO factory to comply with normal
operational requirements and to comply with the requirements of relevant Australian standards. These
parameters should only be altered by technicians trained by OSKO forklifts, to ensure that they are kept
within safe operating limits.

For details on the Curtis controller and recommended values for parameters, refer to the Installation and
Programming Manual P/N 942014.

Figure 5.2 shows the schematic wiring diagram of the Curtis Controller, Spy-Glass Gauge and Hand Held
Programmer.

5.2 – MULTI FUNCTION SPY- GLASS GAUGE

A MULTI-FUNCTION Curtis Spy-Glass Gauge is located on the dash panel to monitor and display battery
discharge, operating hours for key switch, traction motor and pump motor and error messages. It can
also display a spanner to indicate when programmed services are due.

Table 5.1 is a list of Error Codes with the explanation for each code. This information can be used to fast-
track diagnosis of faults and speed up repairs.

For details on the Spy-Glass Gauge display refer to Figure 5.1 below

SPY- GLASS DIAGNOSTICS

The eight-character LCD on the Spy-Glass displays a
continuous sequence of hour meter, battery state-of-charge
and fault messages.

Fault messages are displayed using the same codes that are
flashed by the controller LED. For example the LED flashes
3,2 for a welded main contactor.

and the corresponding Spy-Glass message is CODE 32

Hourmeter LED ( Green )
BDI LED ( Yellow )

Service LED ( Red )

FIGURE 5.1 – MULTI FUNCTION SPY-GLASS GAUGE

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PART B – SERVICE AND PARTS
SECTION 5 – ELECTRICAL SYSTEM
Table 5.1 – LIST OF ERROR CODES

Note: Only one fault is indicated at a time, and faults are not queued up.

CONTROLLER LED DIAGNOSTICS

A status LED is built into the 1297 controller. It is visible through a window in the label on top of the
controller. This status LED displays fault codes when there is a problem with the controller or with the
inputs to the controller. During normal operation, with no faults present, the status LED flashes steadily
on and off. If the controller detects a fault, a 2 digit fault identification code is flashed continuously until
the fault is corrected. For example, Code “3,2” – main contactor welded appears as

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PART B – SERVICE AND PARTS
SECTION 5 – ELECTRICAL SYSTEM

FIGURE 5.2 – SCHEMATIC WIRING DIAGRAM CURTIS CONTROLLER, SPY-GLASS GAUGE &
HAND HELD PROGRAMMER

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PART B – SERVICE AND PARTS
SECTION 5 – ELECTRICAL SYSTEM
5.3 - ELECTRICAL PANEL ASSEMBLY

REF PART NO DESCRIPTION QTY REF PART NO DESCRIPTION QTY

1 943105 Curtis Controller 1 15 943135 M4 x 8 Bolt 4
2 943102 Contactor 1 16 940725 M4 Flat Washer 9
3 008906 300V Fuse 1 17 943131 M6 x 16 Button HD 3
3A 942050 Fuse 1 18 943133 M6 Spring Washer 3
4 800069A Fuse Block 1 19 940875 Cable Clip 3
4A 942051 Fuse Holder 1 20 943134 M6 Flat Washer 3
5 944200-31 Bus Bar 1 21 941156 Spacer 1
6 944209 Terminal Connector 1 22 943237 M8 x 50 Bolt 2
7 943256 5 Bar Loop Strip 1 23 943120 M6 x 20 CSK 2
8 005401 Anderson Plug 1 24 943138 M8 Brass Washer 3
9 943103 Battery Charger 1 25 943234 M8 Brass Nut 2
10 009602 Horn 1 26 943233 M5 x 10 Socket HD 2
11 941470 M8 x 20 Bolt 1 27 943119 M5 Flat Washer 2
12 943138 M8 Flat Washer 2 28 940473 M4 x 12 Pan HD 2
13 943132 M8 Spring Washer 1 29 941604 M4 Spring Washer 2
14 940406 M8 Nut 1 30 934174 M6 x 35 Bolt CSK 2

FIGURE 5.3 – ELECTRICALHARDWARE ASSEMBLY

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PART B – SERVICE AND PARTS
SECTION 5 – ELECTRICAL SYSTEM
5.3 - ELECTRICAL PANEL ASSEMBLY ( Continued )

REF PART NO DESCRIPTION QTY REF PART NO DESCRIPTION QTY

32 943157 IEC Plug Cover 1 39 940724 M4 Nut 1
33 943110 IEC Plug 1 40 943132 SPDT Relay 1
34 941602 Power On/Off Switch 1 41 941603 M4x6 Bolt Pan HD 2
35 941062C Circlip 1 42 940717 M4x12 Pan HD Phillips 2
36 941602B Button 1 43 941079 M5 Nut 1
37 941602K Key 1 44 943118 M5 Spring Washer 1
38 943123 Switch Packer 1 45 943106 LCD Spy Glass Gauge 1
FIGURE 5.4 – ELECTRICAL HARDWARE DASH PANEL

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PART B – SERVICE AND PARTS
SECTION 5 – ELECTRICAL SYSTEM
5.4 - EMERGENCY POWER DISCONNECT & KEY SWITCH

REF PART NO. DESCRIPTION QTY

1 941602 TC Top Cover without Magnets 1
2 941602 TCS Top Cover Fixing Screws 2
3 941652 Moving Contact 1
4 941653 Fixed Contact Assembly 1
5 941602B Operating Knob 1
6 943274 M5 16mm Pan Head 2
7 941602C Circlip 1
8 941602W Wavy Washer 1
9 941602K Keys (2) 1
10 941651 Contact Kit ( 2 off item 4 & 1 off item 3)

FIGURE 5.5 EMERGENCY POWER DISCONNECT & KEY SWITCH

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PART B – SERVICE AND PARTS
SECTION 5 – ELECTRICAL SYSTEM
5.5 - MAIN CONTACTOR

REF PART NO DESCRIPTION QTY

1 943090 Fixed Contact Assembly 1
2 943091 Moving Contact Assembly 1
3 943092 Top Cover Moulding With Out Magnets 1
4 943093 Top Cover Fixing Screw 2
5 943094 Return Spring 1
6 943095 Ass. Coil & Frame With Out Bracket 1
7 943096 End Cap 1

FIGURE 5.6 – MAIN CONTACTOR

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PART B – SERVICE AND PARTS
SECTION 5 – ELECTRICAL SYSTEM
5.6 - CHARGER

The battery charger is a sealed unit requiring specialist repair. For this reason, no component
Spare parts are available.

If the battery charger is defective it should be replaced.

Figure 5-7 shows the location and function of the external components and connections to the charger.

If the charger needs to be replaced, proceed as follows:

1. Ensure that the 240V supply cord is disconnected from the mains.

2. Press the Emergency Disconnect Switch to disconnect the battery power.

3. Remove the Rear Access Cover.

4. Remove the defective charger and install the new charger on the mount plate.

5. Then ensure that the positive and negative output cables are connected with correct polarity and
are tight.

6. Plug in the charger 240V AC input cable connected to the 240V relay in the truck. Check that all
connections are tight.

7. Plug in the 240 Volt supply to the receptacle plug on the dash panel.

8. Turn on the power supply.

9. Check that the charger is ON and the “charge” LED on top of the charger is lit up.
Check that the cooling fan underneath the charger is operating.

10. Replace the Rear Access Cover.

11. Pull out the Emergency Disconnect switch to connect battery power.

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PART B – SERVICE AND PARTS
SECTION 5 – ELECTRICAL SYSTEM
5.6 - CHARGER (continued)

FIGURE 5.7 BATTERY CHARGER

5.7 - ELECTRICAL DIAGRAMS

(Refer to figures 5.8, 5.9 and 5.10)

Figure 5.8 shows the location and Part Numbers of the main cables of the Electrical Panel Assembly.

Figure 5.9 is the Electrical Diagram for all standard configuration CONDA models and illustrates the
location and relationships of the electrical components.

Figure 5.10 shows the layout of the Electrical Panel for CONDA models fitted with extra hydraulic
services and illustrates the location and relationships of the electrical components.

CONDA S&P Manual 59

PART B – SERVICE AND PARTS
SECTION 5 – ELECTRICAL SYSTEM
5.8 – MAIN CABLES - IDENTIFICATION & LOCATION

REF PART NO DESCRIPTION QTY

1 944200-04 Cable Assy – Curtis Contr –B-Trans A1 1
2 944200-05 Cable Assy – Curtis Traction- Trans A2 1
3 944200-06 Cable Assy - Curtis Pump – Pump -NEG 1
4 944200-07 Cable Assy - Curtis B- Pump-POS 1
5 944200-08 Cable Assy – Curtis B – Anderson NEG 1
6 944200-09 Cable Assy – Battery Switch - Anderson POS 1
7 944200-10 Cable Assy - Curtis B POS – Contactor Switch POS 1
8 944200-11 Cable Assy - Curtis F1 & F2 to Motor F2 & F1 1
9 944200-23 Cable Assy-Battery Switch POS to Fuse POS 1

FIGURE 5.8 – MAIN CABLES - IDENTIFICATION & LOCATION

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PART B – SERVICE AND PARTS
SECTION 5 – ELECTRICAL SYSTEM

Figure 5.9 - ELECTRICAL DIAGRAM STANDARD CONDA

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PART B – SERVICE AND PARTS
SECTION 5 – ELECTRICAL SYSTEM

Figure 5.10 - ELECTRICAL DIAGRAM CONDA WITH EXTRA

HYDRAULICS

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PART B – SERVICE AND PARTS
SECTION 5 – ELECTRICAL SYSTEM
5.9 - DRIVE MOTOR

5.9.1 - DRIVE MOTOR SERVICING (Refer to Figure 5.11)

The drive motor exposed surfaces should be cleaned at least once a month to assure proper cooling of
the motor. Use an air hose to blow dust off of the motor surfaces.

If the truck does not run and the drive motor is at fault, disconnect the battery and inspect brushes ( 5 ),
(Figure 5.11) and commutator (on armature). Replace brushes if they are worn.

5.9.2-INSPECTION AND REPLACEMENT OF DRIVE MOTOR BRUSHES

(Refer to Figure 5.11)

1. Ensure the emergency stop button is pressed to disconnect power& remove the key.

2. Check the 240V power lead to the Charger is turned Off & Disconnected

3. Disconnect the battery

4. Chock the wheels to prevent truck from moving.

5. Label and disconnect the four Cables (1) to the Drive Motor (2). (Refer Figure 4.5 )

6. Remove the Head Band Assembly (17) and inspect the Brushes (5) for even wear and good
commutation. Good commutation will be indicated by a dark brownish, polished Commutator and
an evenly polished Brush wearing surface.

7. Brushes (5) should have a maximum length of 28mm and a minimum length of 15mm. Replace
the Brushes (5) if any are worn to a length of 15mm or less, or show signs of overheating. (
Discoloured Brush Springs indicate Overheating ).

8. Measure Spring tension with a spring scale hooked under the Brush Spring at the Brush. Pull the
scale on a line opposite the line of force exerted by the Brush Spring and take the reading just as
the Spring leaves the Brush. Correct Brush Spring tension is between 0.99Kg and 1.56Kg. The
maximum value is for new Brushes or Brushes near maximum length. The minimum specified
tension is for Brushes near minimum acceptable length. Replace Springs Assembly (4) if Spring
tension is outside maximum or minimum limits.

9. Check the Commutator for damage and wear. If the Commutator appears rough, pitted, scored or
has signs of burning or arcing between the Commutator Bows, the Commutator must be replaced.
Small marks, rough spots or little imperfections on the Commutator can be removed with fine
sandpaper.

CAUTION: Make sure to remove any sandpaper particles or dust from the
Commutator before reassembly.

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PART B – SERVICE AND PARTS
SECTION 5 – ELECTRICAL SYSTEM
5.9 - DRIVE MOTOR (continued)

FIGURE 5.11 – DRIVE MOTOR ASSEMBLY

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PART B – SERVICE AND PARTS
SECTION 5 – ELECTRICAL SYSTEM
5.9 - DRIVE MOTOR (continued)

PARTS LIST FOR FIGURE 5.11 – DRIVE MOTOR ASEMBLY P/N: 943181

REF PART NO DESCRIPTION QTY

1 943181 Drive Motor Assembly - complete 1
2 943300 Head, Commutator End 1
3 943301 Hex Head Bolt 4
4 943302 Spring, Brush (Set of four) 1
5 943303 Brush (Set of four) 1
6 943304 Washer, Wave 1
7 943305 Bearing, Commutator end 1
8 943306 Brush Holder Assembly 1
9 943307 Brush Lead and Terminal Connector Assembly 1
10 943308 Housing and Windings Assembly 1
11 943309 Armature Assembly 1
12 943310 Circlip 1
13 943311 Bearing, Drive End 1
14 943312 Head, Drive End 1
15 943313 Hex Head Cap Screw 4
16 943314 Seal, Shaft, Drive End 1
17 943315 Headband Assembly 1

5.10 - PUMP MOTOR

5.10.1 - PUMP MOTOR SERVICING (Refer to Figure 5.12)

The pump motor exposed surfaces should be cleaned at least once a month to assure proper cooling of
the motor. Use an air hose to blow dust off of the motor surfaces.

If the truck does not lift and the pump motor is at fault, disconnect the battery and inspect Brushes and
Brush Springs ( 5 ), Figure 5.12) and Commutator (on armature). Replace Brushes if they are worn and
Brush Springs if the tension is insufficient. Remove rough spots on the commutator with fine sandpaper.

CAUTION: Make sure to remove any sandpaper particles or dust from the
commutator before reassembly.

5.10.2 - INSPECTION AND REPLACEMENT OF PUMP MOTOR BRUSHES

(Refer to Figure 5.12)

1. Ensure the emergency stop button is pressed to disconnect power and remove the Key.

2. Check the 240V power lead to the Charger is turned Off & Disconnected

3. Disconnect the battery

4. Chock the wheels to prevent truck from moving.

5. Label and disconnect the four Cables (1) to the Pump Motor (2).

6. Remove Rear Cover (8) to access the Brushes & Brush Springs (5).

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PART B – SERVICE AND PARTS
SECTION 5 – ELECTRICAL SYSTEM
5.10 - PUMP MOTOR (continued)

REF PART NO DESCRIPTION QTY

- 943281 Pump Motor Assembly – complete 1
1 943282 Bearing and Circlip Set 1
2 943283 Circlip Set 1
3 943284 Hex Head Bolt 2
4 943285 Stator 1
5 943286 Brush and Spring Set 1
6 943287 Brush Holder, Brush Spring and Brush Set 1
7 943288 Rear Bearing 1
8 943289 Rear Cover 1
9 943290 Armature 1

FIGURE 5.12 – PUMP MOTOR ASSEMBLY COMPLETE

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PART B – SERVICE AND PARTS
SECTION 5 – ELECTRICAL SYSTEM
5.11 – BATTERIES

The Standard CONDA is fitted with 2 x 12v 228AH Batteries P/N 003148

5.11.1 – BATTERY REMOVAL

Batteries are pulled out and lifted from battery compartment using the handles mounted on side of battery
case.

WARNING:
Batteries available for the lift truck vary in weight. A suitable hoist and sling
arrangement must be used to prevent injury or battery damage.

1 .Ensure the emergency stop button is pressed to disconnect power and remove the Key.
Check the 240V power lead to the Charger is turned Off & Disconnected

2. Disconnect battery cables ( 2, 3 and 4 ) from batteries. ( Refer Figure 5.13 )

3. Disconnect Anderson Plug (5) from Drive Connector (6) and place cables out of the way.

4. Use battery handle at exposed side of batteries to lift out of the chassis.

5.11.2 - BATTERY CABLE ASSEMBLY REPLACEMENT

1. Disconnect batteries as above (Paragraph 5.12.1).

2. Note routing of cables.

5. Pull cables (2, 3 & 4) up out of battery compartment.

6. Replace entire battery cable assembly (2, 3 and 4) if cables are damaged. Use a multimeter to
verify continuity.

7. Carefully route terminal end of cables (2) down into battery compartment.

9. Connect battery cables (2,3 and 4) to batteries.

10. Connect Anderson battery plug (5A) to Drive Connector (5B).

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PART B – SERVICE AND PARTS
SECTION 5 – ELECTRICAL SYSTEM

5.11 – BATTERIES

REF PART NO DESCRIPTION QTY

1 003148 Battery 228AH 2
2 944206 Cable Assembly Battery Positive to Anderson 1
3 944208 Cable Assembly Battery to Battery 1
4 944207 Cable Assembly Battery Negative to Anderson 1
5 005401 Anderson Plug Complete ( Male & Female ) 1

FIGURE 5.13 – BATTERY & CABLE ASSEMBLY

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PART B – SERVICE AND PARTS
SECTION 5 – ELECTRICAL SYSTEM
5.12 - HORN TESTING & REPLACEMENT

NOTE: The following procedure assumes the horn switch is operating properly.

1. With the Battery connected & the emergency stop switch turned on, press the horn
Button. ( Figure 3.1 – 19 )

2. If the horn does not sound, proceed as follows:

(a) Disconnect the battery

(b) Check the 240V power lead to the Charger is turned Off & Disconnected.
(c) Remove the rear cover
(d) Inspect for clean & tight electrical connections to the horn
(e) If required, tighten the connections and repeat the horn test (Step 1 above).

3. To Replace the horn, proceed as follows. ( Refer to Figure 5.14 )

(a) Perform steps 2a, 2b & 2c above.

(b) Tag & disconnect all electrical connections from the Horn (1)
(c) Remove Nut (4), lock washer (3) and flat washer (2) to release & remove the horn
(d) Install horn (1) & secure with lock washer, flat washer & Nut.
(e) Connect all electrical wires as noted in (3b) above.
(f) Replace rear cover.
(g) Re Connect battery

REF PART NO. DESCRIPTION QTY

1 009602 24V Horn 1
2 943138 M8 Flat Washer 2
3 943132 M8 Spring Washer 1
4 940406 M8 Nut 1
5 941470 M8 x 20 Bolt 1

Figure 5.14 HORN ASSEMBLY

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PART B - SERVICE AND PARTS
6.0 – REAR BODY AND MAST MODULES
6.1 - LIFT CYLINDER REMOVAL/ REPLACEMENT (Refer to Figure 6.1 )

1. Fully lower the lift carriage.

2. Ensure the emergency stop button is pressed to disconnect power and remove the Key.
Check the 240V power lead to the Charger is turned Off & Disconnected and Disconnect
the battery.

3. Remove the lower nut (15) on each Chain Bolt (14) which secure the lift chains to the Lift Cylinder
(1). Lay the two lift chains forward over the carriage. Capture lock washers (16) and retain for
reassembly.

4. Remove Bolts (13) and Lock Washers (11) and remove the Free Lift Clamp Bar (12), making sure
to capture the two Wear Spacers (18).

5. Remove Bolt (10), Lock Washer (11) Flat Washer (43) and Spacer (9) and lift off the Ram head
Assembly (3, 4, 5, 6, 7 & 44)

6. Remove Bolt (25), Lock Washer (23) and Flat Washer (41) from the cylinder support to release the
base of the cylinder.

7. The lift cylinder (1) can now be lifted clear of the truck.

NOTE: Disassembly of the lift cylinder is covered in Section 7.0

8. Replace the lift cylinder in the reverse order to above.

6.2 - CHAIN SHEAVE REMOVAL / REPLACEMENT (Refer to Figure 6.1)

1. Remove the Ram head Assembly (3, 4, 5, 6, 7 & 44) as per 6.1 steps 1 to 5.

2. Remove Circlips (7) to free Chain Sheaves (5), Roller Bearings (44) and Spacers (3).
The chain sheaves can be repaired or replaced as required. Before replacing chain sheaves,
lubricate with a General Purpose lithium based grease.

3. Reassemble in reverse order to above.

6.3 - LIFT CHAIN TENSION ADJUSTMENT (Refer to Figure 6.1)

When the lift chains are correctly adjusted, the forks should be 5mm clear of the floor.
If there is slack in any chain, that chain should be adjusted. Chains should be equally taut.

1. Fully lower the lift carriage.

2. Ensure the emergency stop button is pressed to disconnect power and remove the Key.
Check the 240V power lead to the Charger is turned Off & Disconnected and Disconnect
the battery.

3. Loosen the upper nuts (15) on Chain Adjusting Bolts (14) several turns.

4. Take up the slack by tightening the lower nut (15)

5. Secure adjustment by tightening the upper nuts (15). Use a spanner to prevent chain adjusting bolt
from turning when tightening nuts.

6. Torque Lower Nuts to 120 Nm.

CONDA S&P Manual 70
PART B - SERVICE AND PARTS
6.0 – REAR BODY AND MAST MODULES

REF PART NO DESCRIPTION QTY REF PART NO DESCRIPTION QTY

1 5215XXT Cylinder 2”Barrell 1-1/2” Rod 1 22 943147 Wheel Stud & Nut 5
or 5317XXT Cylinder 2-1/2 ”Barrell.1-3/4” Rod 1 23 077213 Lock Washer ½” 10
2 401046A Mast Roller 8 24 943166 Spring Washer M12x4x 2.5 5
3 053012A Shim A/R 25 063705 HexHd Set Screw½” UNC 1” 1
4 01290A Ramhead 1 26 943238 Safety Screen 1
5 074251A Chain Sheave 2 27 943167 Flat Washer M12-12x 32O.D 5
6 051155 Bearing Needle Roller 2 28 282500 Tube Pressure A/R
7 061725 Snap Ring External 25mm 2 29 800125 Flow Control Fitting 1
8 100016 Wear Spacer- Ramhead 2 30 941941LH Cover Switch 2
9 940191 Spacer Ramhead Screw 1 31 057173 1500Kg ITA Class II Fork 2
10 941185 Socket Head Cap Screw 1 32 950051 ITA Class 2A Carriage 1
11 077211 Lock Washer Split 1 33 V30000 Load Backrest 1
12 239520 Free Lift Clamp Bar 1 34 270306-3 Axle Load Wheel 2
13 064607 Screw Hex Hd 3/8 UNC x11/4” 4 35 060972 Roll Pin 2
14 402051 Chain Bolt 4 36 061719 Circlip ¾ External 2
15 059445 Hex Nut 5/8 UNF 8 37 940774 Load Wheel 2
16 077215 Lock Washer 5/8” 4 38 051152 Bearing – Load Wheel 4
17 060402 Cotter Pin 4 39 077010 Flat Washer ¾” 4
18 402055 Chain Pin 4 40 941186 Wheel & Bearing Assembly
19 402034 Lift Chain *** Metres 2 41 077076 Square Washer 1
20 005405 Strain Relief 1 42 941677 Elbow 90 Deg. 1/4” Tube 1
21 020703 Cut Out Switch 1 43 051155 Bearing Needle Roller 2

XX Varies with Lift Height *** Varies with Lift Height

FIGURE 6.1 ADJUSTABLE FORKS MAST & CARRIAGE ASSEMBLY

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 PART B - SERVICE AND PARTS
6.0 – REAR BODY AND MAST MODULES

REF PART NO DESCRIPTION QTY REF PART NO DESCRIPTION QTY

1 5215XXT Cylinder 2”Barrell.1-1/2” Rod 1 22 943147 Wheel Stud & Nut 5
or 5317XXT Cylinder 2-1/2 ”Barrell.1-3/4” Rod 1 23 077213 Lock Washer ½” 10
2 401046A Mast Roller 8 24 943166 Spring WasherM12x4x 2.5 5
3 053012A Shim A/R 25 063705 Hex Hd Set Scr ½” UNC 1” 1
4 01290A Ramhead 1 26 943238 Safety Screen 1
5 074251A Chain Sheave 2 27 943167 Flat Wshr M12-12x 32O.D 5
6 051155 Bearing Needle Roller 2 28 282500 Tube Pressure A/R
7 061725 Snap Ring External 25mm 2 29 800125 Flow Control Fitting 1
8 100016 Wear Spacer- Ramhead 2 30 941941LH Cover Switch 2
9 940191 Spacer Ramhead Screw 1 31 051155 Bearing – Needle Roller 2
10 941185 Socket Head Cap Screw 1 32 950052 Weldment Carriage (680mm) 1
11 077211 Lock Washer Split 1 or 950052N Weldment Carriage (560mm) 1
12 239520 Free Lift Clamp Bar 1 33 270306R Load Wheel 4
13 064607 Screw Hex Hd 3/8 UNC x1-1/4” 4 34 060972 Roll Pin 2
14 402051 Chain Bolt 4 35 941225 Circlip 20mm 4
15 059445 Hex Nut 5/8 UNF 8 36 078435R Load Wheel 4
16 077215 Lock Washer 5/8” 4 37 F190 Bearing – Load Wheel 8
17 060402 Cotter Pin 4 38 941221 Spacer 20mmFlat 8
18 402055 Chain Pin 4 39 078409R Wheel & Bearing Assembly 4
19 402034 Lift Chain *** Metres 2 40 077076 Square Washer 1
20 005405 Strain Relief 1 41 941677 Elbow 90 Deg. 1/4” Tube 1
21 020703 Cut Out Switch 1

XX Varies with Lift Height *** Varies with Lift Height

FIGURE 6.2 RIGID FORK-OVER STRADDLE MAST & CARRIAGE ASSEMBLY

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PART B - SERVICE AND PARTS
6.0 – REAR BODY AND MAST MODULES
6.4 - MAST LUBRICATION PROCEDURE - ALL MASTS

1. Apply Lithium base general purpose grease with a brush to full length of masts where rollers
touch.

2. All mast and Carriage Roller bearings are sealed and require no lubrication.

6.5 - REAR BODY COVERS

REF PART NO DESCRIPTION QTY REF PART NO DESCRIPTION QTY

1 943261 Rear Cover 1 9 943114 Door Hold 1
2 943112 Budget Lock 2 1 10 943113 Door Hold SM Plunger 1
3 943163 Packer Rear Latch 1 11 943158 Packer Top Cover Latch 1
4 941079 M5 Hex Nut 4 12 943169 M4 x 24mm CSK Screw 2
5 943119 M5 Washer ZP 4 13 940724 M4 Hex Nut 2
6 943112K Key 1 14 940725 M4 Washer ZP 2
7 943260 Top Cover 1 15 941604 M4 Spring Washer 2
8 943115 Buffer Retainer 1

FIGURE 6.3 - REAR BODY COVERS

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PART B - SERVICE AND PARTS
6.0 – REAR BODY AND MAST MODULES
6.6 - ADD-ON BODY, COVERS & COUNTERWEIGHT

REF PART NO DESCRIPTION QTY

1 950000 Weldment Body CONDA 1
2 943147 Wheel Stud & Nut 5
3 943166 M12x4.00 x2.50 Spring Washer ZP 5
4 943167 M12 Flat Washer 32mmOD ZP 5
5 003148 228AH Deep Cycle Battery 2
6 945210 Battery Stands 2

FIGURE 6.4 – REAR BODY & MAST

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PART B - SERVICE AND PARTS
6.0 - REAR BODY AND MAST MODULES
6.7 - LOAD WHEEL REPLACEMENT (REFER TO FIGURE 6.4 )
1. Unload the truck and block the drive wheel.
2. Raise the forks approximately 300mm and chock the carriage to prevent it from lowering.
3. Ensure the emergency stop button is pressed to disconnect power and remove the Key.
Check the 240V power lead to the Charger is turned Off & Disconnected and Disconnect
the battery.
4. Raise the front of the lift truck, with a jack or other lift truck and place supporting boards or steel
bars under the body immediately behind the wheel housing to hold wheel at least 20 mm off floor.
5. Lower the lift truck on to the support.
6. Remove the Circlip (4) and remove the load wheel axle (1). The load wheel and bearing assembly
(5), and spacers (2) will then fall out.
7. Reassemble the new load wheel and bearing assembly (5) and spacers (2) on the axle (1) and
secure with roll pin (3) and Circlip (4).
7. Check wheel for free rotation.

REF PART NO DESCRIPTION QTY

1 270306-3 Load Wheel Axle 1
2 077010 Spacer A/R
3 060972 Roll Pin 1
4 061719 Circlip 1
5 941186 Load Wheel & Bearing Assembly 1
6 940774 Load Wheel 1
7 051152 Bearing 2

FIGURE 6.5 LOAD WHEEL ASSEMBLY

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7.0 - HYDRAULICS
The following table lists the lift cylinders fitted to the CONDA two stage models.

TABLE 7.1 LIST OF 2 STAGE LIFT CYLINDERS

PART NO. DESCRIPTION QTY. BARREL ROD

521525T Lift Cylinder – CONDA 1.3 with Lift Height 2.5m 1 2in 1-1/2in
521530T Lift Cylinder – CONDA 1.3 with Lift Height 3.0m 1 2in 1-1/2in
521535T Lift Cylinder - CONDA 1.3 with Lift Height 3.5m 1 2in 1-1/2in
521540T Lift Cylinder - CONDA 1.3 with Lift Height 4.0m 1 2in 1-1/2in

531725T Lift Cylinder - CONDA with Lift Height 2.5m 1 2-1/2in 1-3/4in
531730T Lift Cylinder - CONDA 1.5 with Lift Height 3.0m 1 2-1/2in 1-3/4in
531735T Lift Cylinder - CONDA 1.5 with Lift Height 3.5m 1 2-1/2in 1-3/4in
531740T Lift Cylinder - CONDA 1.5 with Lift Height 4.0m 1 2-1/2in 1-3/4in
531745T Lift Cylinder – CONDA 1.5 with Lift Height 4.5m 1 2-1/2in 1-3/4in
531750T Lift Cylinder- CONDA 1.5 with Lift Height 5.0m 1 2-1/2in 1-3/4in

7.1 - HYDRAULIC CYLINDER (refer to Figure 7.1)

7.1.1 - REPAIR OF HYDRAULIC CYLINDER - PART NO. 5215XXT (REFER TO FIGURE 7.1)

For lift cylinder removal, refer to Section 6.0, para. 6.1.

For cylinder disassembly, proceed as follows:

1. Secure cylinder in a vice.

CAUTION: Use proper pipe vice with non marking jaws to prevent damage to cylinder.

2. Unscrew gland nut (4) using a strap wrench and remove.

3. Remove fitting (7), ball (8) and spring (9) from bottom of cylinder.

4. The gland (3) is now free to slide out of the cylinder barrel (1). Remove gland and then remove
cylinder rod.

5. Inspect Rod and Barrel for wear or damage. If damaged, replace. If not, fit new seal kit (11) and
assemble in the reverse of the above.

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 PART B - SERVICE AND PARTS
7.0– HYDRAULICS

7.1 - HYDRAULIC CYLINDER

REF DESCRIPTION PART NO.

1 Barrel V600**T
2 Rod V603**T
3 Gland 940801
4 Gland Nut 940802
5 Piston 940800
6 Spacer 940806
7 Fitting 800125
8 Ball 810002
9 Spring 810001
10 Piston Nut 810021
11 Seal Kit 940595
12 Roll Pin 810005

** Varies with Lift Height

FIGURE 7.1 LIFT CYLINDER - PART NO. 5215XXT

All CONDA 1.3 MODELS TO 4.0 METRE LIFT HEIGHT
(These cylinders have 2in barrel, 1-1/2in piston rod)

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PART B - SERVICE AND PARTS
7.0 - HYDRAULICS
7.1.2 - REPAIR OF HYDRAULIC CYLINDER - PART NO. 5317XXT (REFER TO FIGURE 7.2)

NOTE: This lift cylinder is used for CONDA 1.5 and 1.3 – 4.5 Models and can be easily
identified by the 2 1/2 inch dia. barrel and 1-3/4 inch dia. piston rod.

For lift cylinder removal, refer to Section 6.0, paragraph 6.1.

For cylinder disassembly, proceed as follows:

1. Secure cylinder in a vice.

CAUTION: Use proper pipe vice with non marking jaws to prevent damage to cylinder.

2. Unscrew gland nut (4) using a strap wrench and remove.

3. Remove fitting (7), ball (8) and spring (9) from bottom of cylinder.

4. The gland (3) is now free to slide out of the cylinder barrel (1). Remove gland and then remove
cylinder rod.

5. Inspect Rod and Barrel for wear or damage. If damaged, replace. If not, fit new seal kit (11) and
assemble in the reverse of the above.

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 PART B - SERVICE AND PARTS
SECTION 7.0 – HYDRAULICS

FIGURE 7.2 LIFT CYLINDER

REF DESCRIPTION PART NO.

1 Barrel V630**T
2 Rod V631**T
3 Gland 941842
4 Gland Nut 941843
5 Piston 941844
6 Spacer 941845
7 Fitting 800125
8 Ball 810002
9 Spring 810001
10 Piston Nut 810021
11 Seal Kit 940601
12 Roll Pin 810005

** Varies with Lift Height

FIGURE 7.2 LIFT CYLINDER P/N 5317XXT – CONDA 1.5 MODELS

(These cylinders have 2-1/2in barrel, 1-3/4in piston rod)

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PART B - SERVICE AND PARTS
7.0 - HYDRAULICS
7.3 - HYDRAULIC PUMP AND MOTOR ASSEMBLY:

NOTE: Pump Motor repair is covered in Section 5.0.

Hydraulic pump is not repairable. If the pump becomes defective, remove pump from pump motor and
replace with new pump - P/N 943320.for CONDA 1.3 Models & P/N 943281 for CONDA 1.5 Models

REF PART NO DESCRIPTION QTY REF PART NO DESCRIPTION QTY

1 943320 Pump CONDA 1.3 1 10 943326 Motor & Pump Coupling 1
OR 943281 Pump CONDA 1.5 1 11 943327 Spacer 1
2 943280 O Ring 1 12 943328 Packing for Motor 1
3 943322 Containment Valve 1 13 943330 Return Tube 1
4 943231 Proportion Lower Valve 1 14 943331 Return Tube 1
5 943321 M20X1.5 O Ring Plug 1 15 943333 O Ring 1
6 943323 Pressure Relief Adjuster 1 16 943334 Suction Tube 1
7 943324 Pressure Valve Cover 1 17 943335 Suction Filter 1
8 943325 Flange Version A 1 18 943233 Cap Screws 3
9 943281 Pump Motor Assembly 1

FIGURE 7.3 HYDRAULIC PUMP AND MOTOR ASSEMBLY

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PART B - SERVICE AND PARTS
7.0 - HYDRAULICS
7.4 - PROPORTIONAL LOWER SOLENOID VALVE WITH MANUAL OVERIDE : P/N 943231
This valve is used on all CONDA models except those fitted with Side Shift.The remote lower valve is
located on the flange of the Pump and Motor Assembly.
This valve is actuated normally using the lower button in the control handle.
For EMERGENCY LOWERING refer to 7.5 below.
If defective, disassemble and check for any foreign matter in the valve. If still defective, fit new valve, P/N
943231.

7.5 - EMERGENCY LOWER OF THE CARRIAGE – MANUAL OVERRIDE

All standard CONDA Models are fitted with a manual override valve to allow the carriage
( and load) to be lowered to the floor, if for some reason, the truck will not lower normally.
i.e. There is no power to the Proportional Lower Solenoid Valve.

To operate the Manual Override Valve, proceed as follows. ( refer to Fig 7.4)

.1 - Press the emergency stop button to disconnect the Battery Power and remove the key.
Ensure that the Battery Charger 240V supply lead is turned Off and disconnected.

.2 - Disconnect the Battery.

.3 - Remove the rear access cover ( refer to Fig 6.2)

CAUTION : Check that the area under the forks is clear

4 - Press the red Manual Lower Control (24) inwards and rotate it anticlockwise half a turn
to allow the carriage to be lowered to the floor. When the carriage is fully lowered, press
the Manual Lower Control (24) inwards and rotate it clockwise half a turn to return it to the
normal operating position.

NOTE: Some trucks are fitted with a Manual Lower Valve (22) .
To lower the carriage on these models, turn the valve handle anti-clockwise. When fully
lowered, close the Manual Lower Valve to restore it to normal operating position.

CAUTION: Before attempting to use the truck again, arrange for an authorised
Technician to make repairs as necessary to restore the unit to correct
operation.

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PART B - SERVICE AND PARTS
7.0 - HYDRAULICS

FIGURE 7.4 HYDRAULIC LAYOUT

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PART B - SERVICE AND PARTS
7.0 - HYDRAULICS

REF PART NO. DESCRIPTION QTY

1 950020 Hydraulic Tank 1
2 025501B Elbow 1/4 in TUBE –1/8in BSP 2
3 076701 Vent for Transmission 1
4 026302 Plug 3/8 BSP 1
5 943107 24V Pump & Motor Assembly CONDA 1.3 Model 1
or 943101 24V Pump & Motor Assembly CONDA 1.5 Model
6 943162 M6 x 35 SCK HD Cap Screw ZP 4
7 940423 Plug 1/4in BSPT Pressure Type 1
8 029914A Adaptor 90 Deg M-F 9/16in JIC 1
9 941333 Elbow 90 Deg M-M 1/4in BSP- 9/16in JIC 1
10 943231 20V DC Coil w/- Manual Override 1
11 H504009 Hydraulic Hose 1
12 941055 Nipple 3/8in NTPF x 9/16in JIC 1
13 047110 Flow Control Valve 3.5 GPM CONDA 1.3 Model 1
or 047104 Flow Control Valve 5 GPM CONDA 1.5 Model 1
14 941481 Nipple 3/8in NPTF x 9/16in JIC Swivel FM 1
15 800125 Flow Control Fitting 1
16 941677 Elbow 90 Deg 1/4in TUBE 1
17 282500 Breather Line 4m
18 5215XXT Lift Cylinder CONDA 1.3 Model 1
or 5317XXT Lift Cylinder CONDA 1.5 Model 1
19 940562 Tee 9/16in F JIC x 9/16in M JIC x 9/16in M JIC 1
20 T101040 Hydraulic Tube Assembly 1
21 943161 Male Adaptor 9/16in JIC to 1/8in BSP 1
22 943160 Needle Valve 1/8in BSP 1
23 943159 Elbow 90 Deg 1/8in BSP 1

XX Varies with Lift Height

PARTS LIST: FIGURE 7.4 HYDRAULIC LAYOUT

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 PART B - SERVICE AND PARTS
7.0 – HYDRAULICS
7.6 - TWO SPOOL HYDRAULIC CONTROL VALVE P/N 941752: (Refer Figure 7.5)
( ONLY FOR CONDA 1.5 FITTED WITH SIDE SHIFT )

The Hydraulic Valve is a precision valve and should last the life of the fork-lift. Should it become
defective, for safety reasons, it is recommended that the entire unit be replaced.
An exploded view of the hydraulic valve is shown in Figure 7.5. This should be used for reference when
disassembling and assembling the valve.

REF PART NO DESCRIPTION QTY REF PART NO DESCRIPTION QTY

REF 941752 Two Spool Valve ( Complete ) REF 941440 O-Ring Kit – Hydraulic Valve 1
1 941436 Handle 2 6 942010 Screw Valve Adaptor Block 2
2 941437 Lever Assembly 2 7 942040 O - Ring CR13 2
3 941407 Micro Switch Assembly 1 8 942009 Valve Adaptor Block 1
4 941438 Solenoid 1 9 940441 Plug 1/8” BSPT 1
5 941439 Pressure Relief Cartridge 1 10 942039 O – Ring CR21 x 3 2

FIGURE 7.5 TWO SPOOL HYDRAULIC CONTROL VALVE

CONDA 1.5 MODEL WITH SIDE SHIFT
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 PART B - SERVICE AND PARTS
7.1 – HYDRAULICS
7.7 – OPTIONAL SIDE SHIFT HYDRAULIC SYSTEM : (Refer Figure 7.6)
( ONLY AVAILABLE FOR CONDA 1.5 MODEL )

This Side Shift Hydraulic Service can be adapted to accommodate other Hydraulic attachments if
required.

REF PART NO DESCRIPTION QTY REF PART NO DESCRIPTION QTY

1 950020 Hydraulic Tank 1 24 H5040** Hose -Valve to Mast 2
2 REF: Hydraulic Spool Valve 1 25 H305502 Hose- Mast to Side Shift Cylinder 1
3 950051S Carriage Side Shift 1 26 800125 Flow Control Fitting 1
4 940433 Side Shift 1 27 H504008 Hose- Valve to Lift Cylinder 1
5 501290RA Ramhead 1 29 941333 Elbow 90deg mm1/4 BSP -9/16 JIC 2
6 941953 Sheave Double 1 30 943101 24V Pump & Motor – 3.8cc (1.5 on) 1
7 052955 Shoulder Bolt 1 OR 943107 24V Pump & Motor – 3.2cc (1.3 on) 1
8 051152 Bearing 3/4 “ I/Dia` 2 31 025501B Elb 90 deg 1/4 ‘Tube- 1/8”BS 2
9 950080 Weldment Valve Bracket 1 32 282500 Breather Line A/R
10 943142 M8X25 Hex HD Bolt ZP 1 33 941677 Elbow 90deg mm1/4 Tube 1
11 943138 M8 Flat Washer ZP 1 34 064607 Hex Head Screw 3/8” x 11/4” UNC 4
12 943137 M8 Spring Washer ZP 1 35 077211 Lock Washer Split 3/8” x 1/8” x 3/32” 6
13 940425 3/8”BSPx 9/16 JIC Nip. 7 36 100016 Wear Spacer Ramhead 2
14 940426 Elbow 3/8”BSPx9/16”JIC 1 37 239520 Free Lift Clamp Bar 1
15 940406 M8 Hex Nut 1 38 077010 Flat Washer ¾’ ID 2
16 029914A Adaptor 90deg M-F 9/16” 10 39 074251A Chain Sheave 2
17 941900 Nipple Restricted 1 40 061725 Snap Ring External 25mm 2
18 191163B Poly Body 1 41 051155 Needle Roller Bearing Chain Sheave 2
19 191163C Cover Body 1 42 053012A Steel WASHER Brt 1’IDx 17/8”OD 6
20 063563 Hex. Head Bolt 1 43 941055 Adaptor 3/8”NPTF x 9/16” JIC 1
21 025528 3/8”NPTFx 9/16”JIC Elb 1 44 047104 Flow Control Valve 1
22 H504010 Hose - Pump to Valve 2 45 941481 3/8” NPTF x 9/16 JIC Nipple 1
23 H305603-10 Hose- Mast to S/Shift 1 H** Varies with the Lift Height of the Truck

FIGURE 7.6 – PARTS LIST OPTIONAL SIDE SHIFT

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