Condor 3887G 4887G Self-Propelled Elevating Work Platform Operator's Manual - PDF DOWNLOAD

(\ SELF-PROPELLED ELEVATING WORK PLATFORM

MODELS 3887G/4887G OPERATOR'S MANUAL

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3887G

4887G

SHIPPING ADDRESS

MAILING ADDRESS

CALAVAR CORPORATION 8300 IMPERIAL DRIVE WACO, TEXAS 76712 (817) 666-4545

CALAVAR CORPORATION P. O. Box 21447 WACO, TEXAS 76702-1447 (817) 666-4545 MANUAL 92328-001 SEPTEMBER 1995

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INTRODUCTION

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

THE OPERA TOR'S MANUAL MUST BE RETAINED ON THE CONDOR® A T ALL TIMES.

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

It is YOUR RESPONSIBILITY to follow procedures while operating the CONDOR®. The manufacturer of this CONDOR® cannot control the wide range of applications that may be used in carrying out a variety of jobs. Therefore, it is THE USER'S RESPONSIBILITY to consider all personnel when making decisions regarding the CONDOR®'s intended use.

It is also YOUR RESPONSIBILITY to understand and obey all federal, state, and local regulations regarding the operation and use of aerial work platforms. A copy of the ANSI/SIA Manual of Responsibilities is attached for your use: ANSI/SIA A92.5-1992 is provided for BoomSupported Elevating Work Platforms, and ANSI/SIA A92.6-1990 is provided for Self-Propelled Elevating Work Platforms.

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

DO NOT AL TER OR MODIFY THIS CONDOR® WITHOUT PRIOR WRITTEN APPROVAL FROM THE MANAGEMENT OF CALA VAR CORPORATION

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

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NOTE:

Please refer to the Calavar Parts section of the Operation, Maintenance, & Parts Manual for information pertaining to your CONDOR®.

MANUAL 92328-001 SEPTEMBER 1995

( CONDOR® SERVICE INFORMATION

1. H you need assistance or have any service or maintenance questions, Calavar service and parts personnel are always available by phone or fax. The telephone numbers are: (817) 666-4545 Telephone (817) 666-5125 Voice Mail (800) 443-5803 FAX

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

3. Service and maintenance are not a substitute for trained, qualified service technicians.

Calavar conducts service schools on a continuing basis. Call any of our service or sales persons for a schedule. Remember, training of mechanics is the responsibility of their employer, but Calavar Service Schools help you provide this training.

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

CALAV AR CORPORATION

( 8300

ii

IMPERIAL DRIVE,

P.o. Box 21447,

WACO. TEXAS 76702-1447-

817-666-4545, 817-666-4544 FAX

CONDOR® MODELS 3887G/4887G

OPERATOR'S MANUAL

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TABLE OF CONTENTS

INTRODUCTION ......................................................................................................... i SERVICE INFORMATION ............................................................................................ ii

TABLE OF CONTENTS .............................................................................................. 1

I.

PREPARATION. INSPECTION. AND MAINTENANCE .••.•...•..•••.•..••...•.•.•.•..•..•.•...•...... 2

A. B. :;;;,C. D. E.

C

Overall Machine Condition ............................................................•.............

Lower Control Station .................................................................................

Platform & Upper Control Station ................................................................

Hydraulic System ......................................................................................

Batteries ............................................... ~........... ....... .................. ... . ..... .. ....

2 2 3 3 3

II.

RATED WORK LOAD ...................................................................................... 3

III.

OPTIONAL EQUIPMENT .................................................................................. 3

IV.

LOWER CONTROLS ........................................................................ ~............... 4

V.

UPPER CONTROLS ......................................................................................... 5

VI.

EMERGENCY LOWERING PROCEDURE ••••••••••••.•••.••..•.••...•..•••••.•...•.•.•.......•....••.. 6

VII.

MOVING FROM JOB SITE TO JOB SiTE ............................................................ 6

A. B. C. D.

Loading & Unloading .................................................................................. 6 Ramp Method ............................................................................................ 6 Forklift Loading/Unloading Method ............................................................... 7 Transporting ............................................................................................. 7

ANSI/SIA 92.6 - 1990 MANUAL OF RESPONSIBILITIES

(\ MANUAL 92328-001 SEPTEMBER 1995

IMPORTANT: A COpy OF THE ANSI/SIA 92.6·1990 MANUAL OF RESPONSIBILITIES IS ATTACHED TO THIS OPERATOR'S MANUAL. IT CONTAINS IMPORTANT OPERATING INFORMATION FOR THIS CONDOR®. READ BEFORE OPERATING THIS CONDOR®.

I.

PREPARATION, INSPECTION, AND MAINTENANCE

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A. OVERALL MACHINE CONDITION TIRES AND WHEELS:

Before putting the CONDOR® into service, all personnel must receive proper training and instruction regarding the operation, service, and maintenance of the CONDOR®. All operators and maintenance personnel should read and understand all portions of the operator's manual and should follow all procedures for the proper operation of all functions and controls.

The condition of the CONDOR® is very important, as it directly affects the operator as well as others.

Defective components, structural damage, missing parts, and malfunctioning equipment jeopardize all personnel and may cause excessive damage to the CONDOR®. A poorly maintained CONDOR® could become the greatest occupational hazard you may encounter.

The operator must perform a thorough walkaround inspection each day prior to operating the CONDOR®, Any damage or faulty operation should be reported immediately. A DO NOT OPERATE tag outlining the problem should be attached to the lower control station and any discrepancies should be corrected before operating the CONDOR®.

More detailed inspections should be performed at the intervals specified in this Operator's Manual, and after any components have been repaired or replaced.

KNOW THE CONDOR® AND ITS CAPABILITIES. REPORT ANY UNUSUAL OPERATION, SUCH AS ERRATIC SWAY OR MOTION OF THE ARMS OR PLATFORM. The daily inspection of the CONDOR® should include the following:

D

Inspect for proper tire pressure, cracks, tears, cuts, or missing or loose lug nuts (a rust line running down the rim from the lug nut indicates a loose lug nut.

MISSING, BROKEN, OR DAMAGED PARTS:

D

Inspect cylinder mounting pins, pivot pins, pin retainers, wear pads, bolts, nuts, and washers.

STRUCTURAL CONDITION:

D

Inspect for structural damage or cracked welds on all structural components, paying particular attention to major structural groups (arms, platform, chassis).

STEERING:

D

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Inspect tie rod ends and steering cylinder for proper and secure mounting.

DECALS:

D

Be sure that all instructional and cautionary decals are in place and are clearly legible.

B. LOWER CONTROL STATION

D

Inspect electrical installations for loose, broken, or frayed wires and cables.

D

Verify that all functions operate properly and that controls return freely to center (neutral position) when actuated and released.

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MANUAL 92328-001 SEPTEMBER 1995

C. PLATFORM & UPPER CONTROL STATION

D D

D D

Inspect electrical installations for loose, broken, or frayed wires and cables.

Verify that entry point bars and chains are functional and secure.

Verify that footswitch operates properly and that guard is in place.

Re-check the structural condition of the platform, paying close attention to pins, railings, and floor.

D

Check the red stop button-its purpose is to disconnect power to the controls in an emergency.

D

Verify that all control levers return freely to center (neutral position) when actuated and released.

II. RATED WORK LOAD The rated work loads of the CONDOR® are as follows: Models 3887G-2,000 Ibs. (908 kg.); Model 4887G-1,500 Ibs. (681 kg.).

The platform will support a combined weight equal to the CONDOR®'s rated work load, which includes personnel, tools, and equipment, throughout the working envelope of the CONDOR®.

III. OPTIONAL EQUIPMENT The following options are available on CONDOR® Models 3887G, and 4887G:

D. HYDRAULIC SYSTEM Check the hydraulic tank fluid level with the arms lowered. Maintain a full level of fluid-to the mark on the dipstick or sight glass (if equipped), or within one inch of the top of the tank. Add Shell Tellus T-32 Hydraulic Oil if required.

D

Verify that the breather cap is clean, undamaged, and properly installed on the hydraulic tank.

D D

Che.ck for leaks at all fittings, valves, and controls.

Check all hydraulic hoses and tubes for damage or kinks, and ensure proper routing to avoid pinch points.

E. BATTERIES

D

Check battery electrolyte level, and ensure that all caps are present and tight on batteries.

D

Inspect all battery cable connections for security and cleanliness.

MANUAL 92328-001 SEPTEMBER 1995

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FORWARD-REVERSE DRIVE ALARM

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MOTION/MOVEMENT ALARM

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STROBE LIGHT

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5° MULTI-AXIS SLOPE ALARM

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HYDRAULIC STABILIZERS (3887G)

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110-V EXTENSION TO PLATFORM

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DIESEL ENGINE (HATZ 2M40Z)

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LP/GAS DUAL FUEL (VAPOR)

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LP/GAS DUAL FUEL (LIQUID)

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SINGLE SPCL PAINT COLOR-ENAMEL

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FOAM-FILLED TIRES

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4-WHEEL DRIVE

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HOUR METER

•

ADDITIONAL OPRISVC/PRTS MANUAL

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IV. LOWER CONTROLS The lower controls are located on the chassis, adjacent to the engine, to operate all functions except DRIVE and STEER. The lower controls are as follows:

( OPERATING INSTRUCTIONS • lURN KEY TO LOWER POSITION TO OPERATE FROM GROUND. • START ENGINE. • DEPRESS AND HOLD -THROTILE" BUnON WHILE MOVING PLATFORM UP OR DOWN. • lURN KEY TO UPPER POSITION TO OPERATE FROM PLATFORM. • lURN ENGINE OFF WITH KEY. • IN AN EMERGENCY, PUSH RED BUnON. TO OPERATE, BUnON MUST BE PULLED OUT.

THROTTLE

EMERGENCY PUSH TO STOP RAISE

[!]@ o ~

SWITCH TO MOVE PLATFORM

LOWER CHOKE

START UPPER

OFF LOWER 54521

GAS

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[CIRCUIT BREAKER]

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THROTTLE:

This pushbutton switch brings the engine to operating speed, and must be depressed and held in order to raise or lower the platform.

•

EMERGENCY STOP:

This red push-pull switch must be pulled out (ON) prior to operating the controls. This switch will stop all powered motion in an emergency.

•

RAISE/LOWER:

This toggle switch is used to raise and lower the platform. The switch will return to neutral (center position) when released.

•

CIRCUIT BREAKER:

A resettable 20-amp circuit breaker serves all control circuits. It may be pulled out to de-energize all controls.

•

LP/GAS (OPTIONAL): If the CONDOR® is equipped with an optional dual fuel system, then this twoposition toggle switch is provided to select either gasoline or propane as the fuel source.

•

CHOKE:

This switch may be engaged, while starting the engine, after long periods of non-use or when the engine is difficult to start.

•

START:

Depress this pushbutton switch to start the engine.

•

KEY SWITCH:

This 3-position (UPPER/OFF/LOWER) key switch allows the operator to select either the lower or upper controls for the operation of the CONDOR®.

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MANUAL 92328-001 SEPTEMBER 1995

V. UPPER CONTROLS

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The upper controls allow operation of all functions of the CONDOR®. The FOOTSWITCH must be depressed and held while operating functions from the upper control station. The upper controls are as follows:

EMERGENCY STEERING

PLATFORM

JACKS

START

CHOKE

DRIVE CONTROLS--

~®~o©o®~~ - - SPEED - - -

PUSH TO STOP

.....

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STEERING (L/R): This switch is used to turn the steering wheels. Move the switch to the right and the CONDOR® will steer to the right, move the switch to the left and the CONDOR® will steer to the left, both, in forward and reverse. The switch will return to neutral (center position) when released; however, the steering wheels are not automatically self-centering. Therefore, to go straight again after a turn, move the switch in the opposite direction. Release the switch when the CONDOR® steers in the desired direction.

•

PLATFORM RAISE/LOWER: This toggle switch is used to raise and lower the platform. The switch will return to neutral (center position) when released.

•

JACKS-UP/DOWN (OPTIONAL): When the CONDOR® is equipped with optional outriggers and jacks, then this two-position toggle switch is provided to raise and to lower the jacks. The switch will return to netural (center position) when released.

•

START:

•

EMERGENCY STOP: This red push-pull switch must be pulled out (ON) prior to operating the controls. This switch will stop all powered motion in an emergency.

•

CHOKE: This switch may be engaged, while starting the engine, after long periods of non-use or when the engine is difficult to start.

•

HIGH/LOW (OPTIONAL WITH FOUR-WHEEL DRIVE): select HIGH or LOW drive speed range.

•

FAST/CREEP: This two-position toggle switch is used to select FAST or CREEP speed. If the CONDOR® is equipped with optional four-wheel drive, then a three-position switch is provided to select a medium speed in conjunction with the optional HIGH/LOW speed switch.

•

FORWARD/REVERSE: This toggle switch is used to select the direction of drive travel. FORWARD and REVERSE relate to the orientation of the operator while facing the control panel.

Depress this pushbutton switch to start the engine.

This two-position toggle switch is used to

OPERA TING INSTRUCTIONS •

TURN KEY, ON LOWIER CONTROL PANEL. TO 'UPPER" POSITION TO OPERATE fROM PLATfORM.

• IN AN EMERGENCY. PUSH REO BUTTON. TO OPERATE FROM PLATfORM. BOTH RED BUTTONS, ON LOVIER AND ON UPPER CONTROLS. MUST BE PUUED OUT. • START ENGlN!. USE CHOKE OR GLO\WlUGS AS REOUIRED. KEEP fOOT orr SV.UCH "'EN STARTING. • PUT fOOT ON SWITCH TO MOVE CONDOR. TAKING FOOT OFT SWITCH, STOPS ALL POWIERED MOVEYENT. • ALL MOVEMENT IS CONTROlLED BY TOGGLE SWITCHES THAT RETURN TO NEUTRAL "'EN LET GO. • STEERING IS NOT AUTOMATlCAUY SElf-CENTERING. BE SIUR£ THE STEERING "'EELS POINT IN THE DIRECTION YOU WANT BEFORE LETTING GO Of THE STEER SWITCH.

• DRIVE SPEED IS SELECTED BY A TWO-POSITION "HIGH/LOW" SWITCH. THE fOUR-WHEEL DRIVE OPTION HAS AN ADDITIONAL THREE POSITION "fAST/NEUTRAL/CREEP" SWITCH. ALLOWING SIX SPEEDS. • UMIT SWITCHES AUTOMATlCAUY CUT BACK THE SPEED. AS THE PLATfORM IS RAISED. • BRAKES ARE NORM AU Y SPRING-APPLIED AND ARE AUTOMATICALLY RELEASED "'ENEVER THE ORIVE SWITCH IS PUSHED.

• ON CONDORS WITH JACKS, UWIT SWITCHES ALLOW THE PLATfORM TO BE RAISED ALL THE WAY uP ONLY "'EN THE JACKS ARE OOWN. • TURN ENGINE OFf WITH KEY ON LOWIER CONTROL PANEL

$4710

MANUAL 92328-001 SEPTEMBER 1995

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VI. EMERGENCY LOWERING

Before loading and unloading, inspect the CONDOR® for any physical damage or defects.

The EMERGENCY LOWERING SYSTEM should only be used if the battery (ies) is (are) totally discharged or if there is an "OPEN" failure in the wiring from the battery to lower controls and on to the lowering valves. There are three valves, one on each cylinder and one lowering in the main valve.

The means used to load and unload should be of sufficient strength to withstand the weight of the CONDOR®: 3887G

8,285 Ibs

(3,758 kg.)

4887G

9,150 Ibs

(4,150 kg.)

To operate the Emergency System, follow the instructions on decals 55007 and 55008, shown below: B. RAMP METHOD

EMERGENCY LOWERING 1. CHECK THAT NEEDLE VALVE. IN MAIN VALVE. IS COMPLETELY CLOSED.

BY TURNING ITS HANDLE CW O. 2. PUSH RED KNURLED KNOB AND TWIST CCW 0 .

KNOB IS ON VALVE AT UPPER LIFT CYLINDER. 3. PUSH RED KNURLED KNOB AND TWIST CCW 0 .

KNOB IS ON VALVE AT LOWER LIFT CYLINDER. 4. ONLY AFTER DOING STEPS 1.2.&3. IN SEQUENCE. OPEN NEEDLE VALVE. TURNING HANDLE CCW 0 .

TO LOWER PLATFORM. 5. WHEN PLATFORM IS DOWN. RESET VALVES AT CYLINDERS BY TWISTING RED KNOBS CW 0 AND CLOSE NEEDLE VALVE.

I

Ensure that the ramp being used is capable of handling the weight of the CONDOR®. The ramp should be set at an angle no steeper than the machine's rated gradeability (SEE CHART BELOW):

MODEL

A\ CAU1~ON I FOLLOW INSTRUCTIONS, ON DECAL AT VALVE IN CHASSIS, FOR EMERGENCY LOWERING.

GRADEABILITY (0)

(%)

3887G (2WD) 3887G (4WD)

14 14

26 26

4887G (2WD) 4887G (4WD)

14 14

26 26

Before driving the CONDOR® on the ramp, be sure that the CONDOR® is in LOW speed by lowering the platform completely. (NOTE:Raising the platform slightly will put the CONDOR® into HIGH speed, and raising the platform completely will result in CREEP speed.) Test the DRIVE/STEER control and the brake system.

55008

Drive up or down on the ramp slowly, allowing for steering corrections to be made. Keep the CONDOR® in alignment with the ramp and the carrier throughout loading and unloading procedures.

VII. MOVING FROM JOB SITE TO JOB SITE A. LOADING AND UNLOADING Although the CONDOR® is small compared with larger construction equipment, it requires the same level of care and attention in loading and unloading as does larger, heavier equipment. At no time should the CONDOR®' s weight be underestimated.

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MANUAL 92328-001 SEPTEMBER 1995

C. FORKLIFT LOADING/UNLOADING METHOD

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Ensure that the forklift has sufficient capacity to handle the weight of the CONDOR® (as specified above). The forks should be long enough to extend across the full width of the frame, and should be positioned as close to the tires as is possible. DO NOT ATTEMPT TO LIFT THE CONDOR® FROM EITHER END. The CONDOR® should only be raised to a height sufficient to clear any obstructions. With the forklift carrying the CONDOR®, keep travel to a minimum and always set the CONDOR® down gently.

D. TRANSPORTING The CONDOR® may be transported easily and safely to and from the job site if the following procedures are observed: •

Block all wheels to prevent forward and reverse motion.

• Tie down the CONDOR® with chains or cables threaded through the tie-down holes only. DO NOT CHAIN OR STRAP OVER THE PLATFORM OR GUARD RAILS. Severe damage may result from securing the CONDOR® improperly.

• ALWAYS TURN OFF THE POWER AT THE LOWER CONTROL STATION.

CALIFORNIA

Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

MANUAL 92328-001 SEPTEMBER 1995

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ATTENTION MANUAL OF RESPONSIBILITIES for Dealers, Owners, JJsers, Operators, Lessors and Lessees of ANSIISIA A92.6-1990 Self-Propelled Elevating Work Platforms

WARNING

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FAILURE TO COMPLY with your REQUIRED RESPONSmILITIES in the use and operation of the Aerial Platform could result in DEATH OR SERIOUS INJURY.

IMPORTANT You are required by ANSI/SIA A92.6-1990 to read and understand YOUR RESPONSmILITIES before you use or operate this Aerial Platform.

This Manual and the manufacturer's operation and safety manuals are considered integral parts of the Aerial Platform and are VITAL TO COMMUNICATE NECESSARY SAFETY INFORMATION to users and operators. They MUST BE KEPT ON THE AERIAL PLATFORM in the storage compartment.

The operation of any aerial platform is subject to certain HAZARDS that can be protected against only by the exercise of INTELLIGENCE, CARE, AND COMMON SENSE. It is essential to have COMPETENT, CAREFUL PERSONNEL, TRAINED in the INTENDED USE, SAFE OPERATION, MAINTENANCE AND SERVICE of this type of equipment.

The USER and OPERATOR MUST MAKE DECISIONS on the maintenance, use and operation of the Aerial Platform with due consideration for the fact that the SAFETY OF THE OPERATOR AND OTHER PERSONNEL is dependent on those decisions.

FAILURE TO COMPLY with your REQUIRED RESPONSmILITIES in the use and operation of the Aerial Platform could result in DEATH OR SERIOUS INJURY. Refer to the manufacturer's operation and safety manual for the INTENDED USE of the aerial platform and for further INFORMATION ON SAFE USE AND OPERATION. The ANSIISIA A92.6-1990 standard for Self-Propelled Elevating Work Platforms became effective January 2, 1992. This Manual incorporates sections from that standard as follows: Definitions Responsibilities of Dealers Responsibilities of Owners Responsibilities of Users Responsibilities of Operators Responsibilities of Lessors Responsibilities of Lessees Typical Examples of Equipment Covered Minimum Safe Approach Distance Published by

Scaffold Industry Association, Inc. 14039 Shennan Way, Van Nuys, California 91405-2599 Copyright © 1992 by Scaffold Industry Association, Inc. All rights reserved.

No part of this publication may be reproduced in any form, in an electronic retrieval system or othetwise, without the prior written permission of the publisher.

Printed in the United States of America

Section Section Section Section Section Section Section Figure Figure

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6 7 8 9

10 1 3

Page Page Page Page Page Page Page Page Page

1 1 2 3

6 8 8 9

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Single copy list price••••••••$ 4.95

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IRESPONSmILITIES MANUAL 3. Definitions

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aerial platform. A mobile device that has an adjustable position platform, supported from ground level by a structure. authorized personnel (authorized person). Personnel approved as assigned to perform a specific type of duty or duties at a specific location or locations at a work site. base. The relevant contact points of the aerial platform that form the stability fulcrum (e.g. wheels, casters, outriggers, stabilizers). chassis. The integral part of the aerial platform that provides mobility and support for the elevating assembly. configuration. All positions in which an aerial platform or any part thereof can be placed within its intended operating limits. dealer. A person or entity who buys from a manufacturer or distributor and who generally sells, rents, and services aerial platforms. delivery. Transfer of care, control, and custody of the aerial platform from one person or entity to another person or entity. directional controls. Controls that initiate functions that affect movement of the platform or the aerial platform. elevating assembly. The mechanisms used to position the platform relative to the aerial platform chassis. guardrail system. A vertical barrier erected to prevent personnel from falling to lower levels. hazardous location. Any location that contains, or has the potential to contain, an explosive or flammable atmosphere as defined by ANSIINFPA 505. instability. A condition of an aerial platform in which the sum of the moments that tend to overturn the unit exceeds the sum of the moments tending to resist overturning. insulated platform. A platform designed and tested to meet the specific electrical insulation ratings consistent with the manufacturer's identification plate. interlock. A control or mechanism that, under specified conditions, automatically allows or prevents the operation of another control or mechanism. manufacturer. A person or entity who makes, builds, or produces an aerial platform. maximum travel height. The maximum platform height or the most adverse configuration(s) with respect to stability in which travel is permitted by the manufacturer. modification. ModificatioQ., modifies: To make a change(s) to an aerial platform that affects the operation, stability, safety factors, rated load or safety of the aerial platform in any way. operator. A qualified person who controls the movement of the aerial platform. outriggers. Devices that increase the stability of the aerial platform and that are capable of lifting and leveling the aerial platform.

Reprint from ANSI/SIA A92.6-1990 override. To take over aerial platform movement control functions at the upper control station by those at the lower control station. owner. A person or entity who has possession of an aerial platform by virtue of proof of purchase. passive. Automatically performed and not requiring any specific operator action to accomplish. platform. The portion of an aerial platform intended to be occupied by personnel with their necessary tools and materials. platform height. The vertical distance measured from the floor of the platform to the surface upon which the machine is being supported. powered functions. Those which control motion of the platform or the aerial platform and are caused by electromechanical, hydraulic or pneumatic forces. qualified person. A person, who by reason of knowledge, experience, or training is familiar with the operation to be performed and the hazards involved. rated work load. The designed carrying capacity of the aerial platform as specified by the manufacturer. shall. The word "shall" is to be understood as being mandatory. stability/stable. A condition of an aerial platform in which the sum of the moments that tend to overturn the unit is less than or equal to the sum of the moments tending to resist overturning. stabilizers. Devices that increase the stability of the aerial platform but are not capable of lifting or leveling the aerial platform. unintended motion or motion unintended by operator. Motion of the aerial platform or platform . without activation or any control. unrestricted rated work load. The maximum designed carrying capacity of the aerial platform allowed by the manufacturer in all operating configurations. user. A person(s) or entity who has care, control and custody of the aerial platform. This person or entity may also be a dealer, owner, lessor, lessee, or operator.

NOTE: Operating and maintenance manuals covered in Section 4 of ANSI/SIA A92.6, and referred to in this document, should be obtained from the manufacturer of the aerial platform.

15. Responsibilities of Dealers 5.1 Basic Principles. Sound principles of safety, training, inspection, maintenance, application, and operation consistent with all data available regarding the parameters of intended use and expected environment shall be applied in the training of operators, in maintenance, application, safety provisions and operation

PAGE 1

IRESPONSmILITIES MANUAL of the aerial platform with due consideration of the knowledge that the aerial platform will be carrying personnel.

S.2 Manuals. Dealers shall keep and maintain a copy(ies) of the operating and maintenance manual(s) required in 4.16.1. The operating manual(s) shall be provided with each rental, lease or sale delivery. The manual(s) shall be stored in the location required by 4.16.2. The manual(s) is considered an integral part of the aerial platform and is vital to communicate necessary safety information to users and operators. In addition, parts and maintenance manuals shall be provided with each sale delivery.

S.3 Predelivery Preparation. Aerial platforms shall be inspected, serviced and adjusted to manufacturer's requirements prior to each delivery by sale, lease or rental.

S.4Maintenance Safety Precautions.

Before adjustments and repairs are started on an aerial platform, the following precautions shall be taken as applicable: (1) Powerplant stopped and starting means rendered inoperative (2) All controls in the "Off' position and all operating systems secured from inadvertent motion by brakes, blocks or other means (3) Elevating assembly and platform lowered down to the full down position, if possible, or otherwise secured by blocking or cribbing to prevent dropping (4) Hydraulic oil pressure relieved from all hydraulic circuits before loosening or removing hydraulic components (5) Safety props or latches installed where applicable as prescribed by the manufacturer S.S Replacement Parts. When parts or components are replaced, they shall be identical or equivalent to original aerial platform parts or components.

S.6 Training. Whenever a dealer directs or authorizes an individual to operate an aerial platform, the dealer shall ensure that the individual has been trained under the direction of a qualified person in accordance with the manufacturer's operating manual and requirements listed in Section 8 of this standard before operating the aerial platform.

S.6.1 Training on Delivery. Manufacturer's operating instruction and required training of the proper use and operation of the aerial platform shall be provided upon each delivery by sale, lease, or rental.

S.7 Operation. When a dealer operates an aerial platform in sales demonstrations or for other beneficial use, the dealer shall assume the responsibilities of users as specified in Section 7 and the operating personnel shall assume the responsibilities of operators as specified in Section 8 of this standard.

5.8 Assistance to Owners and Users. If a dealer is unable to answer an owner's or user's question(s) relating to rated capacity, intended use, maintenance, repair, inspection, or operation of the aerial platform, the dealer

Reprint from ANSI/SIA A92.6-1990 shall obtain the proper information from the manufacturer and provide that information to the owner or user.

S.9 Record Retention. Dealer(s) shall retain the following records for at least 3 years: (1) Name and address of the purchaser of each aerial platform by serial number and date of delivery (2) Records of the person(s) trained upon each delivery of an aerial platform (3) Records of the predelivery preparation performed prior to each delivery S.10 Modifications. Modification or alteration of an aerial platform shall be made only with prior written permission of the manufacturer.

S.11 Manufacturer's Safety Bulletins. The dealer shall comply with safety-related bulletins as received from the manufacturer.

6. Responsibilities of Owners 6.1 Basic Principles. Sound principles of safety, training, inspection, maintenance, application, and operation consistent with all data available regarding the parameters of intended use and expected environment shall be applied in the performance of the responsibilities of owners with due consideration of the knowledge that the aerial platform will be carrying personnel.

6.2 Manuals. Owners shall keep and maintain a copy(ies) of the operating and maintenance manual(s) required in 4.16.1 of this standard. The operating manual(s) shall be provided with each rental, lease or sale delivery and shall be stored in the weather resistant storage compartment required by 4.16.2 of this standard.

These manual(s) are considered an integral part of the aerial work platform and are vital to communicate necessary safety information to users and operators. In addition, parts and maintenance manuals shall be provided with each sale delivery.

6.3 Maintenance. The owner of an aerial platform shall arrange that the maintenance specified in this standard is properly performed on a timely basis. The owner shall establish a preventive maintenance program in accordance with the manufacturer's recommendations and based on the environment and severity of use of the aerial platform. The owner shall arrange that frequent and annual inspections are performed. All malfunctions and problems identified shall be corrected before the aerial platform is returned to service.

6.4 Predelivery Preparation. Aerial platforms shall be inspected, serviced, and adjusted to manufacturer's requirements prior to each delivery by sale, lease or rental.

6.5 Frequent Inspection. The owner of an aerial platform shall cause a frequent inspection to be performed on an aerial platform: (1) That has been in service for three (3) months or 150 hours whichever comes first;

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(2) That has been out of service for a period longer than three months; The inspection shall be made by a person qualified as a mechanic on the specific make and model of the aerial platform. The inspection shall include all items specified by the manufacturer for a frequent inspection and shall include but not be limited to the following: (3) All functions and their controls for speed(s), smoothness, and limits of motion; (4) Lower controls including the provisions for overriding of upper controls; (5) All chain and cable mechanisms for adjustment and worn or damaged parts; (6) All emergency and safety devices; (7) Lubrication of all moving parts, inspection of filter element(s), hydraulic oil, engine oil, and coolant as specified by the manufacturer; (8) Visual inspection of structural components and other critical components such as fasteners, pins, shafts and locking devices; (9) Placard, warnings and control markings; (10) Additional items specified by the manufacturer.

The owner shall not place the aerial platform into service until all malfunctions and problems have been corrected.

6.6 Annual Inspection. The owner of an aerial platform shall cause an annual inspection to be performed on the aerial platform no later than 13 months from the date of the prior annual inspection. The inspection shall be performed by a person(s) qualified as a mechanic on the specific make and model of the aerial platform. The inspection shall include all items specified by the manufacturer for an annual inspection.

Before 6.7 Maintenance Safety Precautions. adjustments and repairs are started on an aerial platform, the following precautions shall be taken as applicable: (1) Powerplant stopped and starting means rendered inoperative (2) All controls in the "off' position and all operating systems secured from inadvertent motion by brakes, blocks, or other means (3) Elevating assembly and platform lowered to the full down position, if possible, or otherwise secured by blocking or cribbing to prevent dropping (4) Hydraulic oil pressure relieved from all hydraulic circuits before loosening or removing hydraulic components (5) Safety props or latches installed where applicable as prescribed by the manufacturer 6.8 Replacement Parts. When parts or components are replaced, they shall be identical or equivalent to original aerial platform parts or components.

6.9 Maintenance Training. The owners shall train their maintenance personnel in inspection and maintenance of the aerial platform in accordance with 6.3, 6.4, 6.5, 6.6, 6.7, 6.8 and 6.10 of this standard, and with the manufacturer's recommendations.

Reprint from ANSI/SIA A92.6-1990 6.10 Operator Training. An owner who directs or authorizes an individual to operate an aerial platform shall ensure that the individual has been trained in accordance with the manufacturer's operating manual and requirements listed in Section 8 of this standard before operating the aerial platform.

Manufacturer's operating instructions and required training on the proper use and operation of the aerial platform shall be provided upon each delivery by sale, lease or rental.

6.11 Operation. When an owner operates an aerial platform, the owner shall have the responsibilities of users as specified in Section 7 of this standard and his operating personnel shall have responsibilities of operators as specified in Section 8 of this standard.

6.12 Assistance to Users and Operators. If an owner is unable to answer a user's or operator's question(s) relating to rated capacity, intended use, maintenance, repair, inspection, or operation of the aerial platform, the owner shall obtain the proper information from the dealer or manufacturer and provide that information to the user or operator.

6.13 Record Retention. The owner shall retain the following records for at least 3 years: (1) Name and address of the purchaser of each aerial platform by serial number and date of delivery; (2) Records of the person(s) trained upon each delivery of an aerial platform; (3) Written records of the frequent 'and annual inspections performed by the owner. The record shall include deficiencies found, corrective action and identification of the person(s) performing the inspection and repairs.

(4) Records of the predelivery preparation performed prior to each delivery.

6.14 Modifications. Modification or alteration of an aerial platform shall be made only with prior written permission of the manufacturer.

6.15 Manufacturer's Safety Bulletins. The owner shall comply with safety-related bulletins as received from the manufacturer or dealer.

7. Responsibilities of Users 7.1 Basic Principles. The information in this standard must be supplemented by good job management, safety control, and the application of sound principles of safety, training, inspection, maintenance, application, and operation, consistent with all data available regarding the parameters of intended use and expected environment.

Since the user has direct control over the application and operation of aerial platforms, conformance with good safety practices in this area is the responsibility of the user and the operating personnel, including the operator.

Decisions on the use and operation of the aerial platform must always be made with due consideration for the fact

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IRESPONSmILITIES MANUAL that the aerial platform will be carrying personnel whose safety is dependent on those decisions.

7.2 Manuals.

Users shall keep and maintain a copy(ies) of the operating and maintenance manual(s) required in 4.16.1 of this standard. The operating manual(s) shall be provided with each rental, lease or sale delivery and shall be stored in the weather resistant storage compartment required by 4.16.2 of this standard.

The manual is considered an integral part of the aerial platform and is vital to communicate necessary safety information to users and operators. In addition, parts and maintenance manuals shall be provided with each sale delivery.

7.3 Inspection and Maintenance. Users shall inspect and maintain the aerial platform as required to ensure proper operation. The frequency of inspection and maintenance shall be determined by the manufacturer's recommendations and be compatible with operating conditions and the severity of the operating environment.

Aerial platforms that are not in proper operating condition shall be immediately removed form service until repaired.

Repairs shall be made by a qualified person and the repairs shall be in conformance with the manufacturer's recommendations.

7.3.1 Frequent Inspection. An inspection as outlined in section 6.5 of this standard shall be conducted.

7.3.2 Annual Inspection. An inspection as outlined in section 6.6 of this standard shall be conducted.

7.3.3 Prestart Inspection. Before use each day or at the beginning of each shift, the aerial platform shall be given a visual inspection and functional test including but not limited to the following: (1) Operating and emergency controls (2) Safety devices (3) Personal protective devices (4) Air, hydraulic and fuel system leaks (5) Cables and wiring harness (6) Loose or missing parts (7) Tires and wheels (8) Placards, warnings, control markings, and operating manual(s) (9) Outriggers, stabilizers, and other structures (10) Guardrail system (11) Items specified by the manufacturer 7.3.4 Maintenance Safety Precautions.

Before adjustments and repairs are started on an aerial platform, the following precautions shall be taken as applicable: (1) Powerplant stopped and starting means rendered inoperative (2) All controls in the "Off" position and all operating systems secured from inadvertent motion by brakes, blocks, or other means (3) Elevating assembly and platform lowered to the full down position, if possible, or otherwise secured by blocking or cribbing to prevent dropping

Reprint from ANSI/SIA A92.6·1990 (4) Hydraulic oil pressure relieved from all hydraulic circuits before loosening or removing hydraulic components (5) Safety props or latches installed where applicable as prescribed by the manufacturer 7.4 Replacement Parts. When parts or components are replaced, they shall be identical or equivalent to the original aerial platform parts or components.

7.S Maintenance Training. The user shall train the maintenance personnel in inspection and maintenance of the aerial platform in accordance with sections 7.3, 7.3.1, 7.3.2, 7.3.3, and 7.3.4 of this standard and with the manufacturer's recommendations.

7.6 Operator Training. Whenever a user directs or authorizes an individual to operate an aerial platform the user shall ensure that the individual has been trained in accordance with the manufacturer's operating and maintenance manual, the user's work instructions, and the requirements listed in Section 8 of this standard before operating the aerial platform.

7.6.1 Model Training. The operator shall be trained either on the same model of aerial platform or one having operating characteristics and controls consistent with the one to be used during actual work site operation. Under the direction of a qualified person, the trainee shall operate the aerial platform for a sufficient period of time to demonstrate proficiency and knowledge in the actual operation of the aerial platform. Care shall be taken to ensure the area of such operation has a minimum of obstacles and is conducive to training. Only properly trained and authorized personnel shall be permitted to operate the aerial platform.

7.6.2 Trainee Records. A record of the trainee's aerial platform instruction shall be maintained by the user for at least 3 years.

7.7 Before Operation. Before authorizing an operator to operate an aerial platform, the user shall ensure that the operator has: (1) Been instructed by a qualified person in the intended purpose and function of each control (2) Read and understood the manufacturer's operating instruction(s) and user's safety rules, or been trained by a qualified person on the contents of the manufacturer's operating instruction(s) and user's safety rules (3) Understood by reading or having a qualified person explain all decals, warnings, and instructions displayed on the aerial platform (4) Been informed that the purpose for which the aerial platform is to be used is within the scope of the intended applications defined by the manufacturer 7.8 Workplace Inspection. Before the aerial platform is used and during use, the user shall check the area in which the aerial platform is to be used for possible hazards such as, but not limited to: (1) Drop-offs or holes (2) Bumps and floor obstructions (3) Debris PAGE 4

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(4) Overhead obstructions and high voltage conductors (5) Hazardous locations (6) Inadequate surface and support to withstand all load forces imposed by the aerial platform in all operating configurations (7) Wind and weather conditions (8) Presence of unauthorized persons (9) Other possible unsafe conditions 7.9 During Operation. The aerial platform shall be used in accordance with this standard. The user shall direct his operating personnel and supervise their operation to ensure that the following is adhered to prior to each movement of the aerial platform and each repositioning of the platform: (1) The aerial platform is operated on a surface within the limits specified by the manufacturer (2) The outriggers, stabilizers, extendable axles, or other stability enhancing means, are used as required by the manufacturer (3) The guardrails are installed and access gates or openings are closed per manufacturer's instructions (4) The load and its distribution on the platform and any platform extension are in accordance with the manufacturer's rated capacity for that specific configuration (5) There is adequate clearance from overhead obstructions (6) The minimum safe approach distances (MSAD) to energized power lines and parts, as listed in Table One of Figure 3 are maintained. See page [10] (7) The precautions defined in sections 7.3.3, 7.7, 7.8, 7.9, 7.10 and 7.11 of this standard are followed during operation of the aerial platform 7.10 Determination oCHazardous Locations. It shall be the responsibility of the user to determine the hazard classification of any particular atmosphere or location according to ANSIINFPA 505-1987.

Aerial Platforms operated in hazardous locations shall be approved in accordance with, and of the type required,

by ANSIINFPA 505-1987.

7.11 Warnings and Instructions. The user shall direct his operating personnel and supervise their work to ensure operation of the aerial platform in compliance with this standard.

7.11.1 Personnel Footing. Personnel shall maintain a frrm footing on the platform floor while working thereon.

Use of planks, ladders, or any other device on the aerial platform for achieving additional height or reach shall be prohibited.

7.11.2 Other Moving Equipment.

When other moving equipment and vehicles are present, special precautions shall be taken to comply with local ordinances or safety standards established for the workplace. Warnings such as, but not limited to, flags, roped-off areas, flashing lights, and barricades shall be used.

I

Reprint from ANSI/SIA A92.6-1990 7.11.3 Reporting Problems or Malfunctions. The operator shall immediately report to the supervisor any problems or malfunctions that become evident during operation. Any problems or malfunctions that affect the safety of operations shall be repaired prior to continued use.

7.11.4 Altering SaCety Devices. Altering or disabling of interlocks or other safety devices shall be prohibited.

7.11.5 Entanglement. Care shall be taken to prevent rope, electric cords and hoses from becoming entangled in the aerial platform.

7.11.6 Capacity Limitations. Rated capacities shall not be exceeded when loads are transferred to the platform at any height.

7.11.7 Work Area. The operator shall ensure that the area surrounding the aerial platform is clear of personnel and equipment before lowering the platform.

7.11.8 Fueling. The engine shall be shut down while fuel tanks are being filled. Fueling shall be done in a well-ventilated area free of flame, sparks, or other hazards that may cause fire or explosion.

7.11.9 Battery Charging. Batteries shall be charged in a well-ventilated area free of flame, sparks, or other hazards that may cause fire or explosion.

7.11.10 Improper Platform Stabilization. The aerial platform shall not be positioned against another object to steady the platform.

7.11.11 Misuse as a Crane. The aerial platform shall not be used as a crane.

7.11.12 Unusual Operating Support Conditions. The aerial platform shall not be operated from a position on trucks, trailers, railway cars, floating vessels, scaffolds, or similar equipment unless the application is approved in writing by the manufacturer.

7.11.13 Travel Speeds. Under all travel conditions, the operator shall limit travel speed according to conditions of ground surface, congestion, visibility, slope, location of personnel, and other factors causing hazards of collision or injury to personnel.

7.11.14 Elevated Driving Requirements. Before and during driving while the platform is elevated, the operator shall: (1) Maintain a clear view of the path of travel (2) Maintain a safe distance from obstacles, debris, drop-offs, holes, depressions, ramps, and other hazards to ensure safe elevated travel (3) Maintain a safe distance from overhead obstacles 7.11.15 Stunt Driving. Stunt driving and horseplay shall not be permitted.

7.11.16 Unauthorized Use. Means shall be used to protect against use by unauthorized person(s).

7.12 Operation oC the Aerial Platform. If a user is also the operator of an aerial platform, the user shall have the responsibilities of operators specified in Section 8 of this standard as well as responsibilities of users as specified in Section 7 of this standard.

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IRESPONSmILITIES MANUAL 7.13 Assistance to Operator. If a user is unable to answer an operator's question(s) relating to rated capacity, intended use, maintenance, condition, or safety of operation of the aerial platform, the user shall obtain the proper information from the dealer, owner, or manufacturer and provide that information to the operator before use of the aerial platform in the application of concern.

7.14 Shutdown oC Aerial PlatCorm. The user shall authorize and direct the operating personnel to cease operation of the aerial platform in case of any suspected malfunctions of the aerial platform, or any hazard or potentially unsafe condition that may be encountered, and to request further information as to safe operation from the owner, dealer, or manufacturer before further operation of the aerial platform.

7.15 Record Retention. The user shall retain the following records for at least 3 years: (1) Records of the operator(s) trained on each model of an aerial platform; (2) Written records of the frequent and annual inspection shall be kept by the user when performing the inspections. The records shall include the date of inspection, any deficiencies found, the corrective action recommended and identification of the person(s) performing the inspection.

(3) Written records of all repairs accomplished on the aerial platform, including the date of any such repair, a description of the work accomplished and the identification of the person(s) performing the repair.

7.16 Modifications. Modification or alteration of an aerial platform shall be made only with prior written permission of the manufacturer.

7.17 ManuCacturer's SaCety Bulletins. The user shall comply with safety-related bulletins as received from the manufacturer, dealer or owner.

8. Responsibilities of Operators 8.1 Basic Principles. The information in this standard shall be supplemented by good judgment, safety control, and caution in evaluating each situation. Since the operator is in direct control of the aerial platform, conformance with good safety practices in this area is the responsibility of the operator. The operator shall make decisions on the use and operation of the aerial platform with due consideration for the fact that his or her own safety as well as the safety of other personnel on the platform is dependent on those decisions.

8.2 Manuals. The operator shall ensure that the operating and safety manuals delineating the responsibilities of dealers, owners, lessors, lessees, users, and operators, are stored on the aerial platform in the weather resistant storage compartment provided. The operator shall be familiar with the manuals and consult

Reprint from ANSI/SIA A92.6-1990 them when questions arise with respect to the aerial platform.

8.3 Prestart Inspection. Before use each day or at the beginning of each shift, the aerial platform shall be given a visual inspection and functional test including but not limited to the following: (1) Operating and emergency controls (2) Safety devices (3) Personal protective devices (4) Air, hydraulic, and fuel system leaks (5) Cables and wiring harness (6) Loose or missing parts (7) Tires and wheels (8) Placards, warnings, control markings, and operating manual(s) (9) Outriggers, stabilizers and other structures (10) Guardrail system (11) Items specified by the manufacturer 8.4 Problems or Malfunctions. Any problems or malfunctions that affect the safety of operations shall be repaired prior to the use of the aerial platform.

8.5 Training. The operator shall be trained either on the same model of aerial platform or one having operating characteristics and controls consistent with the one to be used during actual work site operation. Under the direction of a qualified person, the trainee shall operate the aerial platform for a sufficient period of time to demonstrate proficiency and knowledge in the actual operation of the aerial platform. Care shall be taken to ensure the area of such operation has a minimum of obstacles and is conducive to training. Only properly trained and authorized personnel shall be permitted to operate the aerial platform.

8.6 BeCore Operation. Before being authorized to operate the aerial platform, the operator shall have: (1) Been instructed by a qualified person in the intended purpose and function of each of the controls (2) Read and understood the manufacturer's operating instruction(s) and user's safety rules, or been trained by a qualified person on the contents of the manufacturer's operating instruction(s) and user's safety rules.

(3) Understood by reading or by having a qualified person explain all decals, warnings, and instructions displayed on the aerial platform 8.7 Workplace Inspection. Before the aerial platform is used and during use, the operator shall check the area in which the aerial platform is to be used for possible hazards such as, but not limited to: (1) Drop-offs or holes (2) Bumps and floor obstructions (3) Debris (4) Overhead obstructions and high voltage conductors (5) Hazardous locations (6) Inadequate surface and support to withstand all load forces imposed by the aerial platform in all operating configurations

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(7) Wind and weather conditions (8) Other possible unsafe conditions 8.8 During Operation. The aerial platform shall be used in accordance with this standard. Before each elevation of the platform, the operator shall ensure: (1) The aerial platform is operated on a surface within the limits specified by the manufacturer (2) Outriggers, stabilizers, extendable axles, or other stability enhancing means, are used as required by the manufacturer (3) Guardrails are installed and access gates or openings are closed per manufacturer's instructions (4) The load and its distribution on the platform and any platform extension(s) are in accordance with the manufacturer's rated capacity for that specific configuration (5) There is adequate clearance from overhead obstructions (6) The minimum safe approach distances (MSAD) to energized power lines and parts, as listed in Table 1 of Figure 3, are maintained. See page [10] (7) All personnel on the platform are wearing safety gear as required at all times 8.9 Determination of Hazardous Locations. It shall be the responsibility of the user to determine the hazard classification of any particular atmosphere or location according to ANSIINFPA 505.

8.9.1 Hazardous Location Operating Requirements.

Aerial platforms operated in hazardous locations shall be approved and of the type required by ANSIINFPA 505.

8.10 Operator Warnings and Instructions. The operator shall ensure the operation of the aerial platform in compliance with the following: 8.10.1 Personnel Footing. Personnel shall maintain a firm footing of the platform floor while working thereon.

Use of planks, ladders, or any other devices on the platform for achieving additional height or reach shall be prohibited.

8.10.2 Precaution for Other Moving Equipment.

When other moving equipment and vehicles are present, special precautions shall be taken to comply with local ordinances or safety standards established for the workplace. Warnings such as, but not limited to flags, roped off areas, flashing lights, and barricades shall be used.

8.10.3 Reporting Problems or Malfunctions. The operator shall immediately report to a supervisor any problems or malfunctions that become evident during operation. Any problems or malfunctions that affect the safety of operations shall be repaired prior to continued use.

8.10.4 Reporting Potentially Hazardous Locations.

The operator shall immediately report to a supervisor any potentially hazardous location(s) (environment) that become evident during operation.

8.10.5 Hazardous Location Operation. Operation of aerial platforms that are not approved and marked for

Reprint from ANSI/SIA A92.6·1990 operation in a hazardous location shall be prohibited.

8.10.6 Entanglement. Care shall be taken to prevent rope, electric cords, and hoses, etc., from becoming entangled in the aerial platform.

8.10.7 Capacity Limitations. Rated capacities shall not be exceeded when loads are transferred to the platform at any height.

8.10.8 Work Area. The operator shall ensure that the area surrounding the aerial platform is clear of personnel and equipment before lowering the platform.

8.10.9 Fueling. The engine shall be shut down while fuel tanks are being filled. Fueling shall be done in a well-ventilated area free of flame, sparks, or other hazards that may cause fire or explosion.

8.10.10 Battery Charging. Batteries shall be charged in a well-ventilated area free of flame, sparks, or other hazards that may cause fire or explosion.

8.10.11 Improper Platform Stabilization. The aerial platform shall not be positioned against another object to steady the platform.

8.10.12 Misuse as a Crane. The aerial platform shall not be used as a crane.

8.10.13 Unusual Operating Support Conditions. The aerial platform shall not be operated from a position on trucks, trailers, railway cars, floating vessels, scaffolds, or similar equipment unless the application is approved in writing by the manufacturer.

8.10.14 Travel Speeds. Under all travel conditions, the operator shall limit travel speed according to conditions of ground surface, congestion, visibility, slope, location of personnel, and other factors causing hazards of collision or injury to personnel.

8.10.15 Elevated Driving Requirements. Before and during driving while the platform is elevated, the operator shall: (1) Maintain a clear view of the path of travel (2) Maintain a safe distance from obstacles, debris, drop-offs, holes, depressions, ramps, and other hazards to ensure safe elevated travel (3) Maintain a safe distance from overhead obstacles 8.10.16 Stunt Driving. Stunt driving and horseplay shall not be permitted.

8.10.17 Security. The operator shall implement means provided to protect against use by unauthorized person(s).

8.10.18 Altering Safety Devices. Altering or disabling of interlocks or other safety devices shall be prohibited.

8.10.19 Driving on Slopes. The aerial platform shall not be driven on grades, side slopes or ramps exceeding those for which the aerial platform is rated by the manufacturer.

8.10.20 Snagged Platform. If the platform/basket or supporting assembly becomes caught, snagged, or otherwise prevented from normal motion by adjacent structures or other obstacles such that control reversal does not free the platform, all personnel shall be removed from the platform/basket before attempts are made to free the platform using chassis controls.

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IRESPONSmILITIES MANUAL 8.11 Assistance to Operator.

If an operator encounters any suspected malfunction of the aerial platform, or any hazard or potentially unsafe condition relating to capacity, intended use or safe operation of the aerial platform, the operator shall cease operation of the aerial platform and request further information as to safe operation from management, or from the owner, dealer, or manufacturer, before further operation.

8.12 Modifications. Modification or alteration of an aerial platform shall be made only with prior written permission of the manufacturer.

9. Responsibilities of Lessors 9.1 Basic Principles. Sound principles of safety, training, inspections, maintenance, application, and operation consistent with all data available regarding the parameters of intended use and expected environment shall be applied in the performance of responsibilities of lessors with due consideration of the knowledge that the aerial platform will be carrying personnel.

9.2 Lessor. A lessor is a person(s) or entity who leases, rents, loans, or otherwise provides an aerial platform to another party for the beneficial use of that party (the user). A lessor may also be a dealer, owner, lessee, user, or operator.

9.2.1 Lessor as a Dealer. When a lessor uses the aerial platform as a dealer, the lessor shall have the responsibilities of dealers as specified in Section 5 of this standard.

9.2.2 Lessor as an Owner. When a lessor uses the aerial platform as an owner, the lessor shall have the responsibilities of owners as specified in Section 6 of this standard.

9.2.3 Lessor as a User. When a lessor uses the aerial platform as a user, the lessor shall have the responsibilities of users as specified in Section 7 of this standard.

9.2.4 Lessor as an Operator. When a lessor uses the aerial platform as an operator, he shall have the responsibilities of operators as specified in Section 8 of this standard.

Reprint from ANSI/SIA A92.6-1990 10. Responsibilities of Lessees 10.1 Basic Principles. Sound principles of safety, trammg, inspections, maintenance, application, and operation consistent with all data available regarding the parameters of intended use and expected environment shall be applied in the performance of responsibilities of lessees with due consideration of the knowledge that the aerial platform will be carrying personnel.

10.2 Lessee. A lessee is a person(s) or entity to whom an aerial platform is provided by lease, rental, loan, or other arrangement. A lessee may also be a dealer, owner, user or operator.

10.2.1 Lessee as a Dealer. When a lessee uses the aerial platform as a dealer, he shall have the responsibilities of dealers as specified in Section 5 of this standard.

10.2.2 Lessee as an Owner. When a lessee uses the aerial platform as an owner, he shall have the responsibilities of owners as specified in Section 6 of this standard.

10.2.3 Lessee as a User. When a lessee uses the aerial platform as a user, he shall have the responsibilities of users as specified in Section 7 of this standard.

10.2.4 Lessee as an Operator. When a lessee uses the aerial platform as an operator, he shall have the responsibilities of operators as specified in Section 8 of this standard.

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IRESPONSIBILITIES MANUAL

Reprint from ANSIISIA A92.6-1990

Figure 1 - Typical Examples of Equipment Covered

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IRESPONSmILITIES MANUAL

Reprint from ANSYSIA A92.6·1990

Figure 3

BUS BARS

~

•

-_

• . til>

...

.

M.S.A.D. = MINIMUM SAFE APPROACH DISTANCE (SEE TABLE BELOW)

~

DENOTES PROHIBITED ZONE

DANGER: • DO NOT ALLOW MACHINE, PERSONNEL OR CONDUCTIVE MATERIALS INSIDE PROHIBITED ZONE .

• MAINTAIN M..S.A.D. FROM ALL ENERGIZED LINES AND PARTS AS WELL AS THOSE SHOWN • • ASSUME ALL ELECTRICAL PARTS AND WIRES ARE ENERGIZED UNLESS KNOWN OTHERWISE. CA UTION: • DIAGRAMS SHOWN ARE ONLY FOR PURPOSES OF ILLUSTRATING M.S.A.D. WORK POSITIONS, NOT ALL WORK POSITIONS.

Table 1 MINIMUM SAFE APPROACH DISTANCE (M.S.A.D.) to energized (exposed or insulated) power lines and parts.

MINIMUM SAFE APPROACH DISTANCE

VOLTAGE RANGE (Phase to Phase)

(Feet)

o 10 300V Over 300V to SOKV Over SOKV to 200KV Over 200KV to 3S0KV Over 350KV to SOOKV Over 500KV to 7S0KV Over 750KV to 1000KV

(Meiers)

AVOID CONTACT 10 15 20 25 35 45

3.05 4.60 6.10 7.62 10.67 13.72

\,

j

PAGE 10

SELF-PROPELLED ELEVATING WORK PLATFORM

MODEL 3887G/4887G MAINTENANCE MANUAL

(')

3887G

4887G

SHIPPING ADDRESS

-MAILING ADDRESS

CALAVAR CORPORATION

CALAVAR CORPORATION P. O. Box 21447

8300 IMPERIAL DRIVE' WACO. TEXAS 76712 (817) 666-4545

WACO. TEXAS 76702-1447 (817) 666-4545

MANUAL 92328-002 SEPTEMBER 1995

INTRODUCTION

(i

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

THE OPERA TOR'S MANUAL MUST BE RETAINED ON THE CONDOR® AT ALL TIMES.

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

It is YOUR RESPONSIBILITY to follow procedures while operating the CONDOR®. The manufacturer of this CONDOR® cannot control the wide range of applications that may be used in carrying out a variety of jobs. Therefore, it is THE USER'S RESPONSIBILITY to consider all personnel when making decisions regarding the CONDOR®'s intended use.

c

It is also YOUR RESPONSIBILITY to understand and obey all federal, state, and local regulations regarding the operation and use of aerial work platforms. A copy of the ANSI/SIA Manual of Responsibilities is attached for your use: ANSI/SIA A92.5-1992 is provided for BoomSupported Elevating Work Platforms, and ANSI/SIA A92.6-1990 is provided for Self-Propelled Elevating Work Platforms.

Calavar Corporation reserves the right to modify, improve, add, andlor delete certain design features of its products without any obligation to incorporate new features into products previously sold. Our manuals are continually updated to reflect these changes.

DO NOT ALTER OR MODIFY THIS CONDOR® WITHOUT PRIOR WRITTEN APPROVAL FROM THE MANAGEMENT OF CALA VAR CORPORATION

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

NOTE:

Please refer to the Calavar Parts section of the Operation, Maintenance, & Parts Manual for information pertaining to your CONDOR®.

( CONDOR® SERVICE INFORMATION

1. If you need assistance or have any service or maintenance questions, Calavar service and parts personnd are always available by phone or fax. The tdephone numbers are: (817) 666-4545 Telephone (817) 666-5125 Voice Mail (800) 443-5803 FAX

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

( 3. Service and maintenance are not a substitute for trained, qualified service technicians.

Calavar conducts service schools on a continuing basis. Call any of our service or sales persons for a schedule. Remember, training of mechanics is the responsibility of their employer, but Calavar Service Schools hdp you provide this training.

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

CALAVAR CORPORATION

8300 IMPmuALDR1VE, P.O. Box 21447, WACO, TEXAS 76702-1447. 817-666-4545, 817-666-4544 FAX

Self - Propelled Booms and Scissors

WARRANTY Calavar Corporation ("Calavar") warrants to the purchaser that each new aerial work platform made by Calavar is free from defects in material and workmanship arising under normal use and service, in the case of major weldments (chassis, turret and booms), for a period of 5 years after the original shipment of the aerial work platform from Calavar's plant; and in the case of all other parts, for a period of 1 year after'the aerial work platform is first placed in service or two years after the original shipment of the aerial work platform from Calavar's plant, whichever occurs first.

c

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

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

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

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

Products or parts manufactured by others are covered only by such warranties as are extended to the purchaser by Calavar's suppliers.

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

8300 Imperial Drive, P.O. Box 21447, Waco, Texas 76702-1447 • 817-666-4545, 817-666-4544 FAX Fonn No. 513-1M-495

Printed in U.S.A.

Effective January 1, 1993 WARRANTY PROGRAM Warranty is a function of a manufacturing company to back up the product it manufactures.

It is a guarantee against defects in design and workmanship of components utilized in the product, and is offered for a fixed period of time following the purchase of the product by a customer.

(

Calavar Warranty states, in general, that Calavar will replace free of charge any components found to be defective within the time frame of the warranty period. There are exceptions to some components which are not the responsibility of Calavar. These will be outlined in subsequent paragraphs.

A.

NOTE:

WARRANTY PERIOD 1.

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

2.

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

3.

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

4.

Replacemeftt parts provided under the terms of the Warranty are for the Warranty Period applicable to the unit in which they were installed as if such parts were original components of the aerial work platform.

5.

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

(

·,N

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

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

( 2

MANUAL 82328-002

SEPTEMBER 1996

B.

PRE-DELIVERY INSPECTION SHEET (P.D.I.)

1.

Each Self-Propelled Boom or Scissor CONDOR® shipped from Calavar's facility will have a Pre-Delivery Inspection (P.D.I.) sheet enclosed in the Safety Manual holder tube.

2.

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

3.

Failure to complete the P.D.I. sheet and return it to Calavar within the time frame given will result in voiding the Warranty on the CONDOR® .

(

NOTE:

C.

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

ITEMS NOT COVERED UNDER WARRANTY Some components are used on the CONDOR® which are not warranted by Calavar.

However, these are warranted by the component manufacturer. Some of these are:

1.

Engine: Manufacturers used include Wisconsin, Ford, Deutz, Isuzu, Kubota, Onan, Cummins, John Deere, and others. To apply for warranty on the engine, contact should be made with the engine manufacturer's dealer in your area. Calavar can advise you who the dealer is if unknown to you.

2.

Tires and Batteries: These are normal wear items and are considered normal maintenance items. However, if they are found to be defective, contact can be made with the manufacturer's local dealer.

3.

Hydraulic Filters and Fluid: These are considered general maintenance and service items, and are not covered by warranty.

4.

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

5.

Freight and Charges: The warranty does not include any transportation, other charges, or the cost of installation or any liabi.lity for direct, indirect, or consequential damages or delay resulting from the defect.

6.

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

7.

Troubleshooting: Troubleshooting is not covered or reimbursable. However, Calavar Warranty will cover reasonable labor charges for the removal and replacement of defective components.

MANUAl 92328-002 SEPTEMBER 1885

3

D.

PROCESSING OF WARRANTY CLAIM During the Warranty Period, should a component failure be encountered within the guidelines of the Calavar Warranty Policy, the following procedure is to be followed: 1.

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

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

b.

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

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

2.

NOTE:

4

Although not recommended, you may purchase the part locally.

When this is done, a copy of the purchase order or receipt MUST accompany the claim. Calavar has the option to ship a replacement part at no charge if the local cost would be greater, in lieu of issuing credit for locally purchased parts.

d.

When parts are puchased from Calavar, part numbers with invoice numbers MUST be referenced in the appropriate section of the claim form.

Complete the Warranty Claim as noted in the ·Warranty Claim Procedure n section. Provide as much information as possible to enable Calavar to thoroughly evaluate the claim and process it in the shortest amount of time possible.

WARRANTY CLAIMS NOT RECEIVED BY CALAVAR WITHIN 45 DAYS OF FAILURE WILL BE DENIED

3.

E.

c.

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

RETURN AUTHORIZATION 1•

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

2.

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

MANUAL 92328-002 SEPTEMBER 1995

(

NOTE:

DO NOT SHIP ANY RETURN PARTS WITHOUT A RETURN AUTHORIZATION (RIA) NUMBER

(i

Doing so may result in parts getting lost in the system and may delay proce.ssing the claim, or may cause denial due to the time element of the claim.

3.

All RIA parts must be received at Calavar within 45 days from the date the RIA number was issued. Failure to do so will cause the claim to be denied.

4.

All parts claimed under Warrranty will be required to be shipped back to Calavar FREIGHT PREPAID. No freight collect shipments will be accepted.

MANUAl. 82328-002 SEPTEMBER 188&

5

CHECK-OUT INSTRUCTION The following instructions are a step-by step procedure for checking out the self-propelled CONDOR®, as well as for acquainting operating personnel with the CONDOR®'s operation.

This procedure will not take more than one hour and is time well-spent, as it will give both operating and maintenance personnel preliminary experience and a better understanding of the operation of the self-propelled CONDOR®.

(

Prior to placing the CONDOR® into service, a full check-out of the CONDOR® should be made and the Installation Inspection Report should be completed and returned to Calavar.

Each CONDOR® has undergone a thorough Quality Control Inspection, and each CONDOR® leaves Calavar in first-class condition. Unfortunately, some CONDOR®'s may be damaged in transportation; all such damage should be recorded on the consignee copy of the freight bill. Calavar Corporation is not responsible for damage to CONDOR's in transit.

1. Visually inspect all exposed components. Check for loose nuts and bolts, damaged hydraulic lines, broken wires, and structural damage.

2. IMPORTANT: Check tire pressure. Tires must be properly inflated before operating the CONDOR®. Do not over-inflate. Proper P.S.I. rating appears on decals applied to both sides of the carriage.

3. Check hydraulic oil level and add Shell Tellus T-32 hydraulic oil, if required.

4. Fill fuel tank using unleaded gasoline or diesel fuel.

5. Check battery with an hydrometer. Battery must have a full charge.

(

6. Inspect all hydraulic valves located in the front carriage compartment before putting the CONDOR® into service.

7. Turn on the key switch at the lower control station; IF DIESEL-POWERED, first activate glowplugs and allow 30 seconds before starting engine. Depress the start button and allow engine to warm up at idle. After the CONDOR® has warmed up, and with the UPPER/LOWER control station selector switch in the LOWER position, the CONDOR® may be operated by activating the control handles on the lower control valve. Activate each control lever to check operation and ensure that when released, the control levers return to center (neutral). While wheel drive is not available from the lower control station, the engine may be started and stopped from both control stations.

8. With the key switch ON, switch to the UPPER control station. Position the CONDOR® in an area that is free from any overhead obstruction. At the upper control station, engage the footswitch and activate a control lever while maintaining pressure on the footswitch. Ensure that when released, the control levers return to center (neutral).

Learn to operate the controller slowly to obtain the smoothest possible operation.

( 6

.MANUAL 92328-002 SEPTEMBER 1995

c

9.

The CONDOR® has been designed to drive with the counterweight over the drive wheels. This configuration will provide the best traction and a familiar driving position.

10.

A series/parallel drive valve is located in the front carriage compartment between the drive wheels. This valve performs the necessary functions of dividing the hydraulic oil for slow speed travel with adjustable differential action to round corners, and diverting the oil flow for high speed travel. The counterbalance valve softens the brake release and application efficiently without an accumulator.

11 •

The wheel drive has the following features: A.

There is a FAST/SLOW speed selector (toggle switch) on the upper control box.

B.

FAST speed is only available in stowed position.

c.

In FAST speed mode, no aerial functions may be operated, even if the controllers are activated.

12.

Gradually operate the unit up to its maximum elevation and extension.

13.

All CONDOR® models are equipped with a slope-sensing device which senses a 50 out-of-Ievel condition. This safety system is operational when the ignition circuit is on and the boom is above horizontal. When the unit is subjected to an out-of-plumb condition of 50 or more, the system will sound an audible alarm at both control stations. The operator should correct the condition by reversing the drive direction or by selecting an alternate path, observing normal safety precautions when operating the equipment. The slope-sensing device is a safety system and must not be disconnected. Should the system be found inoperable, the unit must be taken out of service and must not be used until the system has been repaired.

MANUAL 92328-002 SEPTEMBER 1995

7

PREVENTIVE MAINTENANCE

( GENERAL The finest equipment manufactured is only as good as it is maintained. Costly repairs and loss of revenue can often be avoided by planning ahead, setting a regular schedule and exercising preventative maintenance NOW or costly repairs LATER. A good preventative maintenance program will enhance a properly operating CONDORi!!I.

The preventative maintenance inspection is generally, but not exclusively, the responsibility of the operator. Since it directly affects him, it is in his best intrest that the inspection maintenance be carried out. The lubrication and service is the RESPONSIBILITY of the serviceman or mechanic since shop time will be required to perform the maintenance tasks in some instances.

Many of the suggestions for preventative maintenance described and noted herein may sound time consuming and expensive. THIS IS NOT THE CASE. The program has been carefully structured and, if followed closely, will result in an extended life expectancy of the unit, as well as a REDUCTION in down time and costly repairs.

NOTE The inspections and checks listed are not intended to replace any local or regional regulations which may pertain to this type of equipment, nor should the list and schedule be considered all-inclusive. Interval times may vary due to climate and/or conditions, depending on the location and use of the CONDORi!!I.

CAUTION Always ensure that applicable precautions are strictly observed when performing the maintenance inspections and checks. Make certain that damaged components, or those in need of adjustment, repair, or replacement are corrected before operation.

8

MANUAL 92328-002 SEPTEMBER 1995

c

LUBRICATION The CONDOR® Model 3887 and 4887 are equipped with bushings at the majority of pivots, tie-rod and cylinder areas that requres attention and service. CONDOR® that has been stored or exposed to environmental conditions of extreme low humidity and high dust level, elevated temperatures of heavy rainfall, lubrication of components may be required more frequently than under normal conditions. External, nonbearing surface shall be wiped clean of extruded or spilled surplus grease with a clean lint free cloth, to prevent damaging dust and abrasive accumulation on lubricant wet surfaces.

ENGINE OIL FILTER

(,

AIR CLEANER OIL BASE

CRANK CASE DRAIN AND REFILL EO

INTERVAL SYMBOL EO ENGINE OIL: SAE 30 WEIGHT

o

D

o

so

HOURS or SEMI - MONTHLY

100 HOURS or MONTHLY 500 HOURS or ANNUALLY MANUAL 92328-002 SEPTEMBER 1995

9

\

1.

SERVICE TOOLS To properly and efficiently service your CONDOR4D, several basic tols are required. The following list of tools should be available.

(

A. Volt/OHM meter.

B. Hydraulic pressure gauge (0-3,00 psi).

C. #16 JIC swivel run tee and proper hose connection to gauge and run tee.

D. Battery hydrometer.

E. Battery load tester.

F. Standard mechanics hand tools.

G. Electrical test light.

2.

HYDRAULIC SYSTEM The CONDOR4D SCISSORS hydraulics are used to power the various operational functions.

As with any operational system, it is only as good as it is maintained. This section is offered to alert you and guide you in maintaining the hydraulic system. CAUTION - One of the major contributors leading to malfunctions in a hydraulic system is CONTAMINATION. Care must be exercised to prevent dirt from entering the system. ALWAYS CAP or PLUG OPEN PORTS AND HYDRAULIC LINES.

(

A. FLUID LEVEL - Check level daily. Maintain fluid level at full mark on side gauge with the CONDOR® in fully retracted position.

B. OIL FILTER - Change return line filter located on hydraulic tank after the first 30 days or 50 hours of operation. Therafter, change the filter every 3 months or 300 hours of operation.

C. TANK BREATHER - Clean every 50 hours of operation. Remove from tank and clean with solvent. Air blow dry.

D. HYDRAULIC TANK - Drain oil from tank every 500 hours of operation or yearly, which ever comes first, and replace filter element. Add oil to tank to required level.

CAUTION

Use only Shell TELLUS T-32 or Mobil DTE - 13M. DO NOT MIX different brands of hydraulic oil or hydraulic oil with automatic transmission fluid. It may be necessary to lubricate or service the hydraulic system more frequently when operating CONDOR4D SCISSOR in severe environments, such as dusty conditions.

10

MANUAL 112328-002 SEPTEMBER 1996

(

3.

BATTERIES A. Check electrolyte level (water) in batteries once a week and fill to proper level using distilled water. CAUTION - Add water only when batteries are fully charged to reduce the possibility of over filling.

(

B. Check battery connections for corrosion and condition at least once a week.

C. Periodically wash batteries off with clean water to reduce current leakage across a dirty battery surface.

D. NEVER let the batteries stay completely DISCHARGED. Batteries should be charged at the end of each work day with the charger time set to accommodate overnight charging. A fully charged battery will have an electrolyte specific gravity of 1.265 to 1.285 at electrolyte temperature of 77.

CAUTION

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

c

4.

BATTERY CHARGING A. DO NOT charge batteries unless the electrolyte level has been checked.

B. Operate charger in accordance with the battery charging instructions.

C. Make sure the charger INPUT A. C. VOLTAGE is the same as the voltage rating of the battery charger.

D. Avoid arcing battery conditions. DO NOT smoke or INTRODUCE a FLAME or SPARK in the CHARGING AREA. E. Use protective face and eye equipment when checking the condition of charging batteries.

DANGER Lead acid batteries generate highly explosive hydrogen gas especially during the charging cycle.

To AVOID the possibility of an explosion, charge batteries ONLY in a well VENTILATED AREA. Keep fire, sparks, and burning material away from the charging area. Do Not smoke near a battery, and always shield the eyes when working near a battery.

( MANUAL 92328-002 SEPTEMBER 1995

11

5.

ENGINE Refer to engine manufacturers recommended maintenance and service procedure for lubricant and time interval.

ENGINE MAINTENANCE SCHEDULE

DAILY

WEEKLY OR 50 HRS.

100HRS

250HRS.

SEASONALLY OR 600HRS

• •

CHECK OIL LEVEL. Add to full mark • DO NOT overfill.

CHECK AIR CLEANER. Shake out eccumulated dirt from dry element cleaner· Maintain oil laval in oil bath type cleaner.

CLEAN AIR INTAKE SCREEN. Clean cooling fins if necessary.

•

CLEAN AIR FILTER aEMENT. Dry alement and oil bath types.

• •

CLEAN CRANKCASE BREATHER CAP.

•

GREASE CLUTCH HOUSING BEARING (VG4D.V46SDJ.

•

CHANGE CRANKCASE OIL.

REPLACE OIL FILTER. In adverse conditions replace evary oil change.

•

LUBRICATE DISTRIBUTOR SHAFT.

•

CHECK COMMPRESSION. Preasure should not vary mora than 10 p ••• i. between cylinders. Remove head· clean out cerbon deposits. Reseat valves if necessary.

•

INSPECT SRARK PLUGS. and BREAKER POINTS. Replace if necessary and regap to specification.

(

• • •

INSPECT FUEL FILTER. Clean filter acreen and glass bowl.

LUBRICATE DISTRIBUTOR CAM and breakar arm pivot.

INSPECT COOLING SYSTEM. Remove shrouding and scrape

•

off dirt from between fins. around cylinders and from shrouding.

INSPECT STARTING MOTOR. Chack for loose mounting and ceble connections.

CHANGE OIL IN CLUTCH and REDUCTION GEAR HOUSINGS.

• •

( 12

MANUAL 92328-002 SEPTEMBER 1995

FIGURE 27-Engine, Hatz Diesel (Option A502)

(

ITEM

PART NUMBER

Ref. 1

A502-38/4887 .......... Engine, Hatz Diesel ..................................................... Ref. 54470 ...................... Engine - Hatz Diesel 2M40 ............................................... 1 54604-004 ............... Pump, .854 Cipr JSB 900 Gear ........................................ 1 54470-001 ............... Pump Mnt, SAE 'A' 2-Bolt ............................................... 1 54470-002 ............... Coupling, Hyd. Pump Drv 9-Tooth ..................................... 1 54514 ...................... Tailpipe, Hatz Diesel ........................................................ 1 54956 ...................... Schematic, 4887 Hatz Elec .............................................. 1

2 3 4

5 6

DESCRIPTION

OTY

- Indicates Items Not Shown

c

MANUAL 92328-003 SEPTEMBER 1995

77

FIGURE 28-Generator, Hydraulic Driven (Option A411)

(' EXISTING PUMP ole FILTER INTERRUPT

- - - ExiSTiNG LiNe -

-

"p" PORT OF EXISTING MANIFOLD

3000 PSI

I

~

SEE NOTE 3.

EXISTING RETURN FILTER EXISTING RETURN LINE

NEW 3/4" TEE

NEW JUMPER

*'7~'/~IB6L~A~NFK=~TH~R~O~T~TL~E~_~~~~1 21

~~L~C~~N~o~gU~H;~RS

1

TERMINAL

1

~

1 " " , . . J.p..:2~1F , _ _ _ _-<I'

=_____

=E-",XI",S=TI,::N~G::,C",IR",C",U,:,:I:,:-T~ ':2,=:'

EXISTING CIRCUIT #'7/BLANK-REMOVE CONDUCTORS 17 ole BLANK FROM 11-115 CIRCUIT AND RE-LABEL THIS CIRCUIT 117A

EXISTING FOOT SWITCH

IN UPPER CONTROL BOX

NEWSWlTCH~

USE SPARE CONDUCTOR IN CON TROL CABLE

IN UPPER CONTROL BOX NEW D E C A L ,

'@ EXISTING CIRCUIT

5

IN LOWIER CONTROL BOX NEW DECAL 67989 , _

'C2;)

I, I'

-----<:D -----0 I

INCLUDED WITH GENERATOR

REF 13

REF

REF

FUSE

NEW 20A CIRCUIT BREAKER NEW GENERATOR

NEW. RELAY ~

78

I,

MANUAL 92328-003 SEPTEMBER 1995

PLUG

NOTES: HOLDING VALVE 37171 4 PL

OUTRIGGER CYL 2.00 DIA BORE 1.25 DIA ROD 15.00 SROKE 162-96449-00 4 PL

STEERING CYLINDER 2.00 DIA BORE .75 DIA ROD 10.00 STROKE 54548

1. KAWASAKI ENGINE 20HP03.600 RPM PUMP 54604-003 .61CIPR 2. FOR BATTERY POWERED CONDORS. SEE SCHEMATIC BELOW. .3. REPLACE RV.3 I< RV3. WITH PLUGS. PARKER Pl0-2.

OR. SET AT 3000 PSI. 4. THE DRIVE SPOOL IS PARKER 697604.

5. HYD HOSE DIA IS IDENTIFIED BY IMPERIAL-EASTMAN PART NUMBER. 6. THIS SCHEMA TIC SUPERCEDES 54522.

LIFT CYLINDERS FIRST STAGE-5.5 DIA X 20.56 STROKE SECOND STAGE-4.25 DIA X 21.69 STROKE 55085 2 PL

5708

0608

FRONT MOTORS .321-00010-00

0608

_.120

1.12

FOI

0808

1.14

SAHR BRAKES 126-10007-00 REAR AXLE

I

---'''----$703

ASSY 315-00025-00 I ---- MANIFOLD - ---- ------ --

S703

CHECK VALve: 50068

S703

FREE WHEEL 52661

5703

S703

BRAKE 58079

FILTER 250-00012-00

~ I-- l - - + - - I - - l . . _ tPROPRI[TAR1' l S . . . ." INFORMA"," . . . . . . . IIIf.MIIII_ ~4-_~L-_~--1~J::~:~~::~~T===~

FILTER JJ4JO

" .... -.mQlll5(Jn'.

(.U'fM~IOI.~..a

...... ":.!.~='::'w~ I--=+O:82:;;;09::;-!-;6"'/26:;"/9;;:5;-!::R:":A:;1K ........,,' ""

HYDRAULIC TANK 2.3.27 GALLONS

LlR. £.C.N. NO.

5393 LTR.

\

E.R.N. NO.

DA T£ " 12 DATE

~

_____W_A_C_O_._T_E_X_A_S_ _ _~

fltn.£

SCHEMATIC. MDA4887 HYDRAULIC

.:r.'i:'it '-::;::"

(2WO-SEE SHEET 2 FOR 4WO)

APPR. DRAWN RAK CHECI<tO A.PPR. API>R<MD

~EV.

55096 RAK

"1' IS SCALE FULL

SHEET

A IOF2

OUTRIGGER CYL 2.00 DIA BORE 1.25 DIA ROD 15.00 STROKE 162-96449-00 4 PL

HOLDING VALVE 37171 4 PL

STEERING CYLINDER 2.00 DIA BORE .75 DIA ROOD 10.00 STROKE 54548

LIFT CYLINDERS FIRST STAGE-5.5 DIAX20.56 STROKE SECOND STAGE-4.25 DIAX21.69 STROKE 55085 2 PL

BRAKES-4 PL 126-10007-00 MOTORS-4 PL 321-00011-00

1.13 1 1

SVI

SIP

_ _-'I>-...J FRONT PA

pCYI

I

I"

190G : PSI

I

'.120 •. 106

FOI

F02

1.14 1

SIP

1

L - - - ' 1 ' - _ _ _ _ ~E~

G

~'----

315-00027-00

____ ~ ____ ' -___ --.---l MANJE()LD 315-00025-00'

2 PL FREE WHEEL 52661

CHECK VALVE 50068

BRAKE 58079

FILTER 250-00012-00

NOTE: SEE SHEET 1 FOR HOSE PART NUMBERS.

PRtlf'ftIETAR"~"'lION

PUMP BALL VALVE 450-00052-00 HYDRAULIC TANK 23.27 GALLONS

FILTER 33430

~

.. - " ' - - - - ~4---~--+--~~~~==~~~==~ _ _ -.nlIICCIIPI'flWWlUIII'Cb _ _ -..s lin.£"

..... "=.~"w~ fOlDtAH((S ON: - S

LYR. E,C.N. NO,

"...

5J93 [JUt. NO.

DAl[ ~/12"S

0A1t

-

OftA ...

RAK O<£O<EO

...... ....

_lid

"'/I' '::ttto

......

--

WACO. TEXAS ____________ -1

SCHEMA TIC. MDA4887 HYDRAULIC (4WD- SEE SHEET 1 FOR 2WD)

55096 SHEET

2 Of 2

...A

~.

(

OUTRIGGER JACKS-SEE NOTE 1

FRONT MOTORS

REAR MOTORS

STEERING CYL

RIGHT

LEFT

@

@) @

LEFT

@

@

,RONT SIP MANIFOLD PLATFORM UFT CYLS

@O

@

MAIN VALVE MANIFOLD

@D®®

REAR BRAKES

FRONT MOTORS

@) @

@)

@

@ MAIN VALVE MANIFOLD

REAR SIP MANIFOLD

~

@@

RIGHT

@

~

@~------' @~-------'

@

@ @ @D

BRAKE VALVE

BRAKE VALVE BALL VALVE

4WO OPTION

2WD STANDARD

NOTES: 1. MODEL 3881 HAS NO OUTRIGGER JACKS. PLUG PORTS L1 AND L2.

.. -

PROPRI£TARY N"ORWA1'JOH

.. - - - - . .

~

WACO, TEXAS

~~---4L---~--4~J::~~~==~~ -H;,._roUIIDrCF tIlAWIIIQIf'OIlA.......... nn;;;ru:F=='-------------------1 .....

f--:-~=:-I---~--4 A 6805

~~!E.~

TO.DtANC(S ON: :-:::

.::tit

'Ill. E.e.N. NO. ~+---'1c....:.D.-'l[::._,I_.......:;.+___-.---'.;;;..HI"'T-"Tl=E.p2/2::.;.!.:.:jI'..

....UI

4475 'Ill.

E.R.N. NO.

02

4

DIAGRAM, 38/4887 HYDRAULIC

~

a,a:

ORAWING NO.

54523

R[v.

A

RAK Qt£(M:m

RAK 02

SCALE FULL

I

or

I

ScOOnatic3887GElec.

22/23

\.~ FAST

22/23

SLOPE ALARM OPTION

UMIT SWITCH SHOWN WITH PL TFRM ABOVE 7' - 6·

~

20

20

's ''/';,-....:'.:.SA:.:.---_+>--...:'-f

0

SPEED

'9

,

'9

CREEP

T

'9 J

"DS4" VALVE PUTS DCV4 VALVE IN SERIES "DS5" VALVE -CREEP

~-----~60~~,,;,~-6-0-A---~CR~--~'~

(

SIP VALVES RELAY

UMI T SWI TCH SHOWN WI TH PLATFORM ABOVE 11'-6" .~ __ ~

~~--~------------1~

,

28A

TRAVEL ALARM BRAKE VALVE

A

"DS3· VALVE -DUMP

60B

++++

VALVES PUT TWO SjP MANIFOLDS IN SERIES 12VDC BATTERY

,

THROTTLE SOLENOID

OPTIONAL CHARGE LAMP START LOCKOUT RELAY VOLTAGE REGULATOR ALTERNATOR

STARTER MOTOR STARTER SOLENOID START RELAY OiL SWITCH IGNITION COIL

.?,

7

~

25

l~

I I I -1-

START

7A

~4~2

___________________________________________________

~

'V:'ri/BLANK

~~

VOLT METER OPTION CHO<E

24

"DSI" VALVE -UFT UP

7B 64

2'A~

2'Al;t-

ri/BLANK

CHO<E

24

PLATFORM

17/BLANK

I

64

55/62

,

~

'7 64

29~

DRIVE

I

I i L. ....J

I

16 r~'-'

I

i

I

13

STEERING

15

I

DESCEND ALARM OPTION DUMP RELAY

I

'4,90-, UMIT SWITCH SHOWN WITH PLATFORM BELOW 25 FEET

17/BLANK

"DS2" VALVE-LOWER HOLDING VALVES ON LIFT CYLS

START 25

63

L ..--l

?NOTES:

-'--

1, THIS SCHEMATIC SUPERCEDES 54592.

2. ZS.27.3' " 65 ARE ISOLA TED SPARES 3. SPADE TERMINALS AT ENGINE ARE SHOWN AS:

16

CHO<E SOLENOID

63

7

2

(

-7)

MANuAL 82328-002 SEPlEMBER 1995

, 54671

BRAKE/SPEED RELAY FORWARD "DRIVE" VALVE REVERSE

RIGHT "STEER" LEFT

(.

2Z/Z3

~

ZZ/Z3

.

,B

r"'ST

20

SPEED

IS

20 CR6

"

or

60 RIo.NGE

LO

IS8

ZBA

""

\...:.'"

Z88

++++ ++++

"

ili

KEY

~ 58

UPPER

112-'23

LOVtt:R 7

ElAERGENCY SToP

lOA 5

5A

~ i~8

CB

I I

SA

~11111111111

:

L~~

I

7

(

Rt

"

L

I I

IIGNmON

I

I

I

I

I

I7/BL~NK ~ 7B~ ~OTTLE

.zr

.! J

I 4Z

0'['

7A

3/

60

~"zrs

71/BLANK

63

.63A

/:

t±

~rg !l1~

START 115

CHOKE

GIg ~I;

Jl4

::lIn.

63 PLATFOR..

Z8 0

0

I7/BLANK

ZB

v

Z8A

27

63

27-"

~

29-"

28

~

63A

~

C>'C:7

'4

I I

I 55/62

... v

~ :

29

" 052" VALVE -LOWER HOLDING VALVES ON un cns

DESCEND ALAR'" OPl1ON OUIAP RELAY J ACKS UP RELAY

,

UP 'OCVZ" VALVE -JACKS ooWN

, ,

r:,-:-1 , 'r

:

'3 '

BRAKEjSPEEO RELAY

I

FORWARD

,

r;,-"-'l

IS :

NOTES:

'

L_~.:.J

THIS SCHE.....nc SUPERCEDES S4509.

2. 3'" 65 ARE ISOLA TEO SP...RES SPADE TERlAtNALS AT ENGINE ARE SHOWN AS:

,

_

RIGHT "STEER" VALVE

LEFT

'--

54672

-7>

MANUAL 82328-002 SEPTEMBER

1

!

..--'

"DRIVE" VALVE REVERSE _'_ _

L:_.:.J

'6

3.

"051" VALVE -urT UP

,...".,._. _ _ .A

'4

STEERING 1.

:

29C>'C:7

UIIlT SVo1TCH SHO'MII Vo1TH JACK UP

I7/BLANK

CHOKE SOLENOID

L_~.:.J

29

13

ORIVE

'IOLT "ETER OPnON

,

r--:-1

i DUAL FUEL opnON

BE'"CON/STR08E OPnON

I

v

I

I

Z8AJ-

..k

OUll!tGGERS

I7/BLANK

28

v

I I

64

J-

63A

J

HIGH TEMP SHUTOFF

I

~

6.

~~ 21-,

I7/BLANK

G"'S LP

, ,

64

PUMP

HOUR lAtTER OPTION

,

I

JlfA~

fUEl

I

114

7B

Z'A~

IGNI TION COtL

-Q--!

.2

I rOOT

2JX F

,....

START

7

)!

OIL SWITCH

~

.2 115

START RELAY

~

I I

~CHOKE

I I I -L

...£..

ST AATER SOlENOID

-0---!-

C.7

7

STAA TER MOTOR

,

66 't-oVACUUW

AL TERNATOR

RED~

~I

I I

'IOLT...GE REGUL... TOR

.YEl/WH~

31

31A

STAA T LOCKOUT REt... Y

I

Bt.U/RED

~,

F~

THRO TTLE RELAY oPTIONAL CHARGE LAlAP

__ -.I,

'c;:;., :

J!SA

d

THROTTLE SOLENOtD

;,;,

CR2 , r,--~~ REO'

SA

~>42

lIOn

~ «

6

2'

12VDC B...TTERY

,

i~~

~,

SToP

HOLOING VALVES ON J'"CK cns

-H---!

86

~I.

/I

8

vALVES PUT TWO SIP .....

NlrDLDS IN SERIES

, ,

r";,BA

:

E.. ERGENCY

"D53" VALVE -DU..P

~

B

Z6

TR AVEL ALARIA OPl1ON

, ,

NEG.

S/P VALVES RELAY

BR AKE VALVE

t#-....!;

608

~8

58

"0 55" VALVE -CREEP

~,

20

1

"OS4" VALVE PUTS

DC V4 VALVE IN SERIES

-€)---! .

60A

CR7

, ,

,.;i"~'

UIIIT SWITCH SHOWN WITH ptA TFORIA ABOVE 11' -6"

~5

'SB

,

'9 '9J

HI

20 _ ' .

58

'BA

0/

CREEP

20

SLOPE AL ...R", OP110N

UI,UT SWITCH SHOWN WITH PllFRlA ABOVE 7'-6"

'''Ii

17

....

(I)

NOTES: LIFT CYLINDERS FIRST STAGE 5 DIA X 20.56 STROKE SECOND STAGE 3.75 DIA X 21.69 STROKE 162-96448-00 2 PL

STEERING CYLINDER 2.0 DIA BORE .75 DIA ROD 10.0 STROKE 54548

1. WISCONSIN ENGINE 30HP02,400 RPM PUMP 355-00014-00 .91CIPR 2. KAWASAKI ENGINE 20HP@3,600 RPM PUMP 54604-003 .61CIPR 3. FOR BATTERY POWERED CONDORS, SEE SCHEMA BELOW. 4. REPLACE CROSS-RElIEF VALVES 51616, 2 PL, WITH PLUGS, PARKER P10-2, OR SET AT 3000 PSI. 5. THE DRIVE SPOOL IS PARKER 697605.

6. HYD HOSE DIA IS IDENTIFIED BY IMPERIAL-EASTMAN PART NUMBER.

nc

A

FRONT MOTORS 321-00010-00 CHECK VALVES 450-00062-00 0608

•. 120 •. 106

F01

0608

F02

M4

F SAHR BRAKES 126-10007-00 REAR AXLE

G MANIFOLD

T N

n

§ 0

"

5703

5703

FREE WHEEL 52661

g•.

5703

S703

CHECK VALVE 50068 FILTER 250-00012-00

570J

BRAKE 58079 N

n

"

PUMP FILTER 33430

HYDRAULIC TANK 23.27 GALLONS

~TAR" W()IIN'ATJON

~~

~4---~~--~~~~;:~~~k:~~==~-_________W_A_C_O__'_T_E_X_A_S______--l

tt::~t6~/26:/9;:5tR~A~Kf~';:;":'~'::~~~"::~':"~':-~:-~~·.:~~~g'lf~~':"-':_=jnSCHEMATIC, B

8209

1-=-+-:'::':'~":'/:,,:,7'J/9:::5=-t::R""A:.,-lK TOL£RANC£S 0'" 75012

:::: .~ "'::;::"'

Lm. ~.C.N. NO. j..:.::.j..::::::,~~D:.:A1t!:.-!-=""""='~"'='="=_____A.:::.H",IT.:.:TLE=jp.:/2:::!3/94"'l

4935LIR. E.R.N. NO.

to

4

RAK CHECKm RAK 10

~

MDA3887 HYDRAULIC

(2WD-SEE SHEET 2 FOR 4WD)

B .......

SCAlE FULL

NO.

54806 SHm

REV.

B 1 Or: 2

LIFT CYliNDERS FIRST STAGE 5 DIA X 20.56 STROKE SECOND STAGE 3.75 DIA X 21.69 STROKE 162-96448-00 2 PL

STEERING CYliNDER 2.0 DIA BORE .75 DIA ROD 10.0 STROKE 54548

BRAKES-4 PL 126-10007-00 MOTORS-4 PL 321-00011-00

'.120

FOI

'.106

F02

1.14

S~

--'1'---- - - - - -

-

2 PL

--.I

- - - - - - __ MANIFOLD 315-00025-00

I

~~ 315-00027-00

'---:,...,-'l'-- - - -

I I

FREE WHEEL 52661

CHECK VALVE 50068 BRAKE 58079 NOTE: SEE SHEET 1 FOR HOSE PART NUMBERS. ALTER 33430

PROPRCTNtY 1--f---I---+--l .. _I11 ....."'INF'ORMA1KlN _____ _ ~ WACO, TEXAS I--f---I---+--l~~~.~~ ~~~~~~~~n~Mr===~-------------1

.... '==.:'.."="

HYDRAUUC TANK 23.27 GALLONS

....<0

I--f---I---+--l LTR. Lt.N. NO. L~

'93~ E.R.N. NO.

.A"

,.

DAtt:

"""'AN""" ::-:: .iii. "'="

APPR. tlltAWN 4

RAK ~PPR.

A.HITTlE

/23/14

OI[O(OJ

N'f"ItO\O

RAM: 10

SCHEMATIC, MDA3887 HYDRAULIC (4WD- SEE SHEET 1 FOR 2WD) ",v.

54806

.....,

B 2 OF 2

(

(

APPENDIX A

c

NOTES: 1. THIS CHART SHOWS RECOMMENDED BOLT TORQUES.

2. TORQUE = R X D X T R = .150 FOR LUB CONDITIONS R =.200 FOR DRY CONDITIONS TO ASSURE CONSISTENCY IN TORQUE, LUBRICATE FASTENERS WITH ENGINE OIL (MAY BE USED OIL) D = NOMINAL DIAMETER IN INCHES T =DESIRED CLAMP LOAD IN POUNDS = 75% PROOFLOAD X STRESS AREA

APPENDIXB

( BOLT TORQUE CHART FOR METRIC HEX HEAD CAP SCREWS • RECOMMENDED ASSEMBLY TORQUES IN FOOT-POUNDS (*VALUES IN LB-IN. OTHERS ARE LB-FT.)

-THE TORQUE VALUES FOR EACH DIAMETER ARE ACCEPTABLE FOR ANY THREAD PITCH IN THAT DIAMETER.

DIAMETER

DRY LUBRICATED THREADS THREADS

DRY THREADS

LUBRICATED THREADS

DRY THREADS

LUBRICATED THREADS

DRY THREADS

LUBRICATED THREADS

M4

27.5*

17*

30*

18*

38.5*

24*

53*

32.5*

M5

56.5*

33.5*

61*

37*

78*

47*

107*

65*

M6

95*

57.5*

103*

61*

132*

79*

180*

109*

M8

19

12

21

13

27

16

37

22

M10

39

23

42

25

53

32

73

44

M12

67

40

73

44

92

55

127

76

M14

107

64

116

69

146

89

203

122

M16

167

100

181

108

230

138

316

190

M20

325

195

352

211

449

269

617

370

M24

562

337

609

386

775

465

1066

640

M30

1117

670

1210

726

1540

924

2188

1271

(

(

SELF-PROPELLED ELEVATING WORK PLATFORM

MODELS 3887G/4887G ILLUSTRATED PARTS MANUAL

3887G

4887G

SHIPPING ADDRESS

MAILING ADDRESS

CALAVAR CORPORATION

8300

CALAVAR CORPORATION

P. O. Box 21447 76702-1447 . (817) 666-4545

IMPERIAL DRIVE

76712 (817) 666-4545

WACO, TEXAS

WACO, TEXAS

MANUAL 82328-003 SEPTEMBER 1885

(l

(

,

INTRODUCTION

(

The primary purpose of this manual is to provide the user with a thorough understand ing of the proper operating procedures necessary to comply with the intended use of the CONDOR®, and to provide the information necessary to maintain and service the CONDOR®.

THE OPERATOR'S MANUAL MUST BE RETAINED ON THE UNIT AT ALL TIMES.

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

It is YOUR RESPONSIBILITY to folfow procedures while operating the CONDOR®. The manufacturer of this CONDOR® cannot control the wide range of applications that may be used in carrying out a variety of jobs. Therefore, it is THE USER'S RESPONSIBILITY to consider all personnel when making decisions regarding the CONDOR®'s intended use.

()

It is also YOUR RESPONSIBILITY to understand and obey all federal, state, and local regulations regarding the operation and use of aerial work platforms. A copy of the ANSI/SIA Manual of Responsibilities is attached for your use: ANSI/SIA A92.5-1992 is provided for Boom-Supported Elevating Work Platforms, and ANSI/SIA A92.6-1990 is provided for SelfPropelled Elevating Work Platforms.

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

DO NOT ALTER OR MODIFY THIS CONDOR® WITHOUT PRIOR WRITTEN APPROVAL FROM THE MANAGEMENT OF CALA VAR CORPORATION

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

NOTE:

Please refer to the Calavar Parts section of the Operation, Maintenance, & Parts Manual for information pertaining to your CONDOR®.

MANUAL 92328-003 SEPTEMBER 1995

c."

( CALAVAR CORPORATION

Self - Propelled Booms and Scissors

WARRANTY Calavar Corporation ("Calavar") warrants to the purchaser that each new aerial work platform made by Calavar is free from defects in material and workmanship arising under normal use and service, in the case of major weldments (chassis, turret and booms), for a period of 5 years after the original shipment of the aerial work platform from Calavar's plant; and in the case of all other parts, for a period of 1 year after the aerial work platform is first placed in service or two years after the Original shipment of the aerial work . platform from Calavar's plant, whichever occurs first.

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

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

Any operation of the equipment beyond rated capacity, improper use or application of the equipment, substitution upon it of parts not approved by Calavar or alteration or repair of the equipment by any person not authorized by Calavar shall, at Calavar's option, void this Warranty. Calavar shall have nQ liability or responsibility for damages resulting from accident or the malfunction of equipment and components not supplied by Calavar.

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

Products or parts manufactured by others are covered only by such warranties as are extended to the purchaser by Calavar's suppliers.

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

(

8300 Imperial Drive, P.O. Box 21447, Waco, Texas 76702-1447 • 817-666-4545, 817-666-4544 FAX Form No. 513·11.1-495

ii

Printed in U.S.A.

MANUAL 12328-003

SEPTEMBER 11196

( CONDOR~

SERVICE INFORMATION

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

(817) 666-4545 Telephone (817) 666-5125 Voice Mail (800) 443-5803 FAX 2.:>:. There

are numerous written Maintenance Procedures available for this machine. These , procedures are available through the Calavar Service Department to anyone who requests them.

3. Service and maintenance are not a substitute for trained, qualified service technicians.

Calavar conducts service schools on a continuing basis. Call any of our service or sales persons for a schedule. Remember, training of mechanics is the responsibility of their employer, but Calavar Service Schools help you provide this training.

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

CALAV AR CORPORATION

(.i 8300 IMPERIAL DRIVE. P.o. Box 21447. WACO. TEXAS 76702-1447.817-666-4545.817-666-4544 FAX

iii

(

(

CONDOR® MODEL 3887G/4887G ILLUSTRATED PARTS MANUAL

TABLE OF CONTENTS

INTRODUCTION ............................................................................................................ i WARRANTY ................................................................................................................ ii SERVICE INFORMATION ............................................................................................... iii

FIGURE

DESCRIPTION

PAGE

A B C

............................... Serial Number Location .................................................... 2 ............................... Recommended Spare Parts List ......................................... 3 ............................... How To Order Parts ........................................................ 4

1

............................... Final Installation .............................................................. 6 ............................... Decals Installation ......................................................... 10 ............................... Chassis Installa~ion ....................................................... 14 ............................... Outrigger Installation ..................................................... 18 ............................... Cover Installation ........................................................... 20 ............................... Steer Installation .......................................................... 22 ............................... Steer Cylinder Assembly ................................................ 24 ............................... Hydraulic Installation ..................................................... 26 ............................... Brake/Hub Assembly ..................................................... 28 ............................... Brake Assembly ............................................................ 30 ............................... Lift Cylinder Assembly ................................................... 32 ............................... Hydraulic Tank Assembly ............................................... 36 ............................... Engine Assembly .......................................................... 38 ............................... Lower Control Assembly ................................................ 40 ............................... Limit Switch Assembly .................................................. 54 ............................... Arm Stack .Assembly ..................................................... 56 ............................... Platform Assembly ........................................................ 60 ............................... Upper Control Box Assembly .......................................... 64

2 3 4 5 6 7

8 8A

9 10 11 12 13 14 15 16 17

OPTIONS 18 19 20 21

22 23 24 25 26 27 28

............................... 110 Volt Line to Platform .............................................. 68 ............................... 4-Wheel Drive .............................................................. 69 ............................... Spark Arrestor .............................................................. 70 ............................... Slope Alarm 5-Degree Multi-Axis .................................... 71 ............................... Dual Fuel Carb-Vapor Kit ............................................... 72 ............................... LP/Gas Dual Fuel (Liquid) ............................................... 73 ............................... Tires, Foam Filled ......................................................... 74 ............................... Hour Meter .................................................................. 75 ............................... Decend Alarm .............................................................. 76 ............................... Engine, Hatz Diesel ....................................................... 77 ............................... Generator, Hydraulic Driven ........................................... 78

MANUAL 12328-003

SEPTEMBER 1196

FIGURE A-Serial Number Location

) 3887G

4887G

2 2

The CONDORG» Model 3887G/4887G Serial Number is stamped in two locations on the machine.

1.

The first place to find the serial number is on the data plate affixed to the chassis, below ground controls.

2.

The second serial number is located at the left rear (drive) axle.

) 2 ,-----

MANUAL 92328-003 SEPTEMBER 1995

FIGURE B-Recommended Spare Parts List Models 3887G & 4887G (1 Unit-1 Year Operation)

PART NO.

DESCRIPTION

QTY

34354 ..................................... Holder, Saftey Manual ••••.••.••••••••••••••••••••••••••...••..•..•..... 1 92328-001 .............................. Manual, Operator's 3887G/4887G ................................. 1

•

67821-002 .............................. Rod End, 5/8 Male ....................................................... 1 355-00014-00 .......................... Pump, Hydraulic .......................................................... 1 52671 ..................................... Operator, 3Pos. Rot. Key .............................................. 1 206-00001-00.......................... Diode ...................•...•.•..•...•.....•..••.•.••.•.....•...•............. 9 51913 ..................................... Operator, Red Push-Pull ......................................... ; ...... 1 50077 ..................................... Switch ....................................................................... 1 50075 ..................................... Switch ....................................................................... 2 67758 ..................................... Switch, Toggle ............................................................ 1

)

36083 ..................................... Switch, Foot ............................................................... 1 40808 ..................................... Solenoid, Throttle ........................................................ 1 32111 ..................................... Solenoid, Choke .......................................................... 1 394-00006-00 .......................... Solenoid, Essex ........................................................... 1 67408 ...................................... Element Hyd. Filter - PIN 33430 ..................................... 5 50316 ..................................... Breather Filler .............................................................. 1 250-00012-00 .......................... Filter, High Pressure ..................................................... 2 030-G7oo0-00 ......................... Decal Installation 3887G .................: ............................... ·1 030-G9000-00 ......................... Decal Installation 4887G ............................................... 1 392-00011-00 .......................... Switch, Limit ............................... (4887 Only) ............. 1 52773 ..................................... Lever, Actuating Arm 5- ............... (4887 Only) ............. 1 105-00003-00.......................... Actuator Arm .............................. (4887 Only) ............. 1 392-00010-00 .......................... Switch, High Speed ...................... (4887 Only) ............. 1

MANUAL 92328-003

SEPTEMBER 1996

3

FIGURE C - How to Order Parts

1.

When ordering parts for your CONDOR®, ensure that you are able to give the model and serial numbers of all units for which parts are needed. The serial number(s) will assist the Calavar Parts Department in providing the correct parts for your machine(s). Please refer to FIGURE A for Serial Number Location on this model.

2.

If known, please specify the Calavar part number(s) for the partes} you require, and always provide a complete description of all parts.

3.

Fax orders are preferable, though parts may also be ordered by mail and telephone.

A sample parts order (with fax number) follows this page.

4.

Parts needed for a warranty repair must be purchased through the Calavar Parts Department. Credit will be authorized through the Service Department after a Warranty Claim has been submitted to Calavar. A Warranty Claim is to be filed for any part received as • defective" •

5.

Calavar will ship parts as per our customers' request at the time of the order-Le., UPS, Federal Express, or preferred truck line. When shipping Federal Express, your customer account must be given at the time of the order.

6.

Calavar classifies its orders in the following ways: Emergency

(unit out of service) - Top priority. Shipping deadline for emergency orders to ship same day is 2:00 p.m. Central Standard Time. Any emergency order received after 2:00 p.m. will be shipped the following day.

Order to be shipped within one (1) week.

7.

Calavar has a $25.00 Net Minimum Billing charge per order.

8.

All price quotations will be valid for 90 days.

9.

Parts shown as shipped on the Calavar packing list and subsequent invoice but not received by the dealer/customer MUST be reported within 10 days after the date of shipment. If the parts are still required, a NEW parts order must be submitted.

Shortages and discrepancies will be reviewed on an individual basis by the Parts staff and adjustments will be made accordingly.

10.

Invoice discrepancies regarding incorrect prices or discounts should be reported immediately to the Parts Department. Report the Sales Order number, Purchase Order number, and Invoice number. Your request will be reviewed and adjustments will be made accordingly.

) 4

MANUAL 92328'()()3 SEPTEMBER 1995

FIGURE C - How to Order Parts

CALAVAR PARTS DEPARTMENT FAX ORDER FORM FAX NO. 800-443-5803

r)

I

ACCOUNT # C U S T 0 M

I N

PURCHASER

SALES ORDER # NAME

NAME

F 0

ADDRESS R M CITY A T E I R PHONE 0 ( ) N CUST. PURCHASE ORDER NO.

STATE

S iADDRESS H T I 0 ~ITY P

ZIP

FAX ( )

STATE

!PHONE

(

I ORDERDATE

I

I

I

FAX ( )

)

lU QUEST DATE

ZIP

SPECIAL MARKS" NUMBERS

SHIPPING INSTRUCTIONS

PART NUMBER

QTY.

DESCRIPTION

NOTES

FOR ORDER STATUS PLEASE CHECK APPROPRIATE BOX BELOW EMERGENCY

STOCK MANUAL 82328-003

SEPTEMBER 189&

5

FIGURE 1 -Final Installation (3887G)

1

3

) 6

MANUAL 82328-003

SEPTEMBER 1895

FIGURE 1-Final Installation (3887G)

ITEM

PART NUMBER

Ref. 1 2 3

MDA3887G •.•••......... Model 3887G Scissor .................................................. Ref. 001-G7000-1 A ....•..... Deck/Rails Weldment .•.••...•.•••............•.•.••..•...•.•..•....•...... 1 55081 ..•.••.•.•........•.•. Armstack Weldment, MDA3887 ....................................... 1 55079 •...•.•.•..•..•....... Chassis Installation, 3887G .............................................. 1 54741 ...................... Wiring Assembly 3887G Electrical .................................... 1 54507 ...................... Hydraulic Installation - 3887 ............................................ 1 030-G7000-00 .......... Decal Installation - 3887G ............................................... 1 54671 ...................... Schematic, 3887G Electrical ............................................ 1 54806 ...................... Schematic, MDA3887 Hydraulic ....................................... 1 53259 ...................... Tape, Non-Skid 6 wW Black ....................................... 5.91lF 55179 ...................... Hose Kit - 3887G 2WD Kawasaki ..................................... 1

-4 -5 -6 -7 -8· -9 -10

DESCRIPTION

QTY

- Indicates Items Not Shown

)

) MANUAL 112328-003 SEPTEMBER 111115

7

FIGURE 1 -Final Installation (4887G)

1

)

3 6

) 8

MANUAL 92328-003 SEPTEMBER 1995

FIGURE 1-Finallnstallation (4887G)

ITEM

PART NUMBER

Ref. 1 2 3 -4 -5 6 -7 -8 -9 -10 -11 -12

MDA4887G .....•....•..• Model 4887G Scissor .................................................. Ref. 001-G9000-1A .......... Deck/Raiis Weldment MDL4887 ....................................... 1 55117 ...................... Armstack Weldment, 4887 .............................................. 1 55080 ...................... Chassis Installation, 4887G .............................................. 1 54670 ...................... Wiring Assembly 4887G Electrical .................................... 1 55104 ...................... Hydraulic Installation - 4887 ............................................ 1 020-G903Q-OO .......... Assembly - Outrigger ...................................................... 4 53259 ...................... Tape, Non-Skid 6 R W Black ....................................... 7.58LF 030-G9000-00 .......... DecallnstaUation - 4887G ............................................... 1 55096 ...................... Schematic, MDA4887 Hydraulic ....................................... 1 54523 ...................... Diagram, 38/4887 Hydraulic ............................................ 1 54672 ...................... Schematic, 4887G Electrical ............................................ 1 55180 ...................... Hose Kit - 4887G 2WD Kawasaki ..................................... 1

DESCRIPTION

QTY

- Indicates Items Not Shown

,) MANUAL 82328-003 SEPTEMBER 1995

9

FIGURE 2-Decallnstallation (3887G)

3

16

) 18

6 -----F~---i~-e:~

17

2

7

) 10

MANUAl 92328-003 SEPTEMBER 1995

FIGURE 2-Decallnstallation (3887G) 10

IS 4

QTY

ITEM

PART NUMBER

Ref.

030-G7000-00 .......... Decal Installation - 3887G .......•...........................•....... Ref. 54186 .•••.•.............•.• Decal, Caution Guard Rail Use .......................................... 1 54183 ...••.........••..•.•. Decal, Danger Arm Stand ..•...•.•.................••...••.•.•........•.• 2 54190 ...................... Decal, Stop ..............................................................<...... 1 52735 ...................... Decal, 110 Volts ............................................................ 2 21882-002 ............... Decal, Danger Not Insulated ......................... ; ................... 2 21850 ......< ................ Decal, Hydraulic Fluid ...................................................... 1 54125< ...................... Decal, Free Wheel Valve .................................................. 1< 276-R 1046-00 .......... Latch, Rubber Hold Down ................................................ 4 50070 ...................... Decal, Battery Service ..................................................... 1 54749 ...................... Decal, Operator Warning ................................................. 2 52964 ...................... Decal, Platform Capacity 2,000 Ibs ................................... 2 55007 ...................... Decal, Emergency Lowering ............................................. 2 54293 ..• Decal, Tie "Down ..••••••••• 2 310-00 191-00 .......... D~cal, Gasoline .............................................................. 1 54710 ...................... 4887G Operating Instructions .......................................... 1 58419 ...................... Tape Orn/Red 5" ....................................................... 39LF 55008 ...................... Decal, Caution Emergency Lowering .................................. 2 37515-002 ............... Decal, Model 3887 ......................................................... 2

1 2 3 4 5 6 7 -8 -9 10

11 12 13 14 15 16

17 18

DESCRIPTION

1 ••••••••••••••••••

I I . I • • • • • • • • • I • • • • • • • • • • • 11 • • 1 I • • • • • • • • • • • • I • • • • • •

- Indicates Items Not Shown

) MANUAL 92328-003 SEPTEMBER 1995

11

FIGURE 2-Decal Installation (4887G)

3

19

7

--------------~~a~

17

) 2

10 --------~~~--~--~

)

18

12

MANUAL 92328-<>03 SEPTEMBER 1995

FIGURE 2-Qecallnstallation (4887G)

16

5

ITEM

PART NUMBER

Ref. 1 2

030-G9000-00 .......... Decal Installation - 4887G ........................................... Ref.· 54183 ...................... Decal, Danger Arm Stand ................................................ 2 54186 ...................... Decal, Caution Guard Rail Use .......................................... 1 54190 ...................... Decal, Stop .................................................................... 1 21882-001 ............... Decal, Keep Clear ........................................................... 4 52735 .............. ; ....... Decal 110 Volts ............................................................. 2 55007 ...................... Decal, Emergency lowering ............................................. 1 69473-002 ............... Decal, Die-Cut, CONDOR® 3.45 x 23 ................................. 4 50070 ...................... Decal, Battery Service ..................................................... 1 52759 ...................... Decal, Stand Clear .......................................................... 4 21850 ...................... Decal, Hydraulic Fluid ...................................................... 1 55008 ...................... Decal, Caution Emergency lowering .................................. 2 54088 ...................... Decal, Tie Down ............................................................. 2 310-00 191-00 .......... Decal, Gasoline .............................................................. 1 54749 ...................... Decal, Operator Warning ................................................. 2 276-R1046-00 .......... latch - Rubber Hold Down ............................................... 4 54710 ...................... 4887G Operating Instructions .......................................... 1 37515-001 ............... Decal, Model 4887 ......................................................... 1 54291 ...................... Decal, Free-Wheel Instruction ........................................... 1 58419 ...................... Tape Orn/Red 5" ....................................................... 39lF 52963 ...................... Decal Platform Cap 1,500 Ibs ........................................... 2

3 4 5 -6 7 -8 9 10 11 12 13 14 -15 16 17 18 19 20

DESCRIPTION

QTY

- Indicates Items Not Shown

) MANUAL 82328-003 SEPTEMBER 1885

13

FIGURE 3-Chassis Installation

2

17

7

()

1

6

11

14

MANUAL 92328-003 SEPTEMBER 1996

FIGURE 3-Chassis Installation

c)

ITEM

PART NUMBER

Ref. 1 2

55079 ............................ Chassis Installation, 38/4887G ................................................. Ref. 54643 •..•.••..•.•.•••..•••...••.• Chassis Weldment, 38/4887 .••...•••....••.•.•.••......•••••....••...••.•...•.......• 1 55074 ............................ Engine Installation, 38/4887 Kawasaki .......................................... 1 51306 .....••••.••....•........•.. Tank, Fuel, 12 Gallons ....•..•••..•.••..•.•.••••••..••...•...••••..•.•••.••....••.•.•.... 1 51307 ............................ Bracket Set, Fuel Tank Mtg ........................................................... 1 54551 •...•.••.•••.•.••..••••.••.. Tie Rod - 38/4887 Steering ............................................................ 1 020-G9001-00 .••..•.•.•••••. Assembly, Rim & Tire, Right .......................................................... 2 476-00025-00 ••••.•••..••••• -Tire ............................................................................................... 1 4n-OOOO2-oo •...•.......... -Rim ••.....••....•..•.•••...•........•.••..••...•...•.••••.•..••••.••••....••......•••....•••••...• 1 020-G9001-10 .•••••.••.••••• Assembly, Rim & Tire, Left ............................................................ 2 46-00025-00 ................. -Tire ............................................................................................... 1 4n-00002-00 ............... -Rim ............................................................................................... 1 67821-002 ..................... Rod End, 5/8 Male ......................................................................... 2 BOW34287 ................... Nut, Hex Lock .63 - 18UNF............................................................ 2 54567 ............................ Weldment, 4887 LH Yoke .............................................................. 1 54568 ........................,.... Weldment, 4887 RH Yoke ............................................................. 1 01 0-G5062-00 ............... Weldment, King Pin ....................................................................... 4 54074 ............................ Bushing Flange ..............................................................................4 55197 ............................ Cover Installation - 4887G ............................................................. 1 55123 ............................ Step Weldment, 4887 .................................................................... 1 54793 ............................ Mnt. Kaw. Lower Elec. Box ........................................................... 2 55162 ............................ Mnt. Lower Elec. Box .................................................................... 2 55224 ............................ Fuel Line, 38/4887G ...................................................................... 1 55225 ............................ Fuel Line, 38/4887G Tank ............................................................. 1

3 -4 -5

6 7

-8 -9

/)

10 11 -12 -13 -14 15 16 17 -18 -19

DESCRIPTION

QTY

- Indicates Items Not Shown

) MANUAL 112328-003 SEPTEMBeR'1I115

15

FIGURE 3-Chassis Installation

2

17

7

-)

1 15

6

11

) 16

.\

MANUAL 82328-003

SEPTEMBER 1885

FIGURE 3-Chassis Installation

ITEM

PART NUMBER

Ref. 1 2 3 -4 -5 6

55080 ...................... Chassis Installation, 38/4887G ..................................... Ref. 54643 ...................... Chassis Weldment, 38/4887 ............................................ 1 55074 ...................... Engine Installation, 38/4887 Kawasaki .............................. 1 51306 ..................... ; Tank, Fuel, 12 Gallons .................................................... 1 51307 ...................... Bracket Set, Fuel Tank Mtg .............................................. 1 54551 ...................... Tie Rod - 38/4887 Steering .............................................. 1 020-G9OO1-OO .......... Assembly, Rim & Tire, Right .. ~ .......................................... 2 476-00025-00 .......... -Tire ............................................................................. 1.

477-00002-00 .......... -Rim ............................................................................. 1 020-G9001-10 .......... Assembly, Rim & Tire, Left .............................................. 2 476-00025-00 .......... -Tire ................................."............................................. 1 477-00002-00 .......... -Rim ............................................................................. 1 67821-002 ............... Rod End, 5/8 Male ...............................................,........... 2 BOW34287 .............. Nut, Hex Lock .63 - 18UNF ............................................. 2 54567 ...................... Weldment, 4887 LH Yoke ................................................ 1 54568 ...................... Weldment, 4887 RH Yoke .............. :-................................ 1 010-G5062-00 .......... Weldment, King Pin ........................................................ 4 54074 ...................... Bushing Flange ............................................................... 4 55197 ...................... Cover Installation - 4887G ............................................... 1 55123 ...................... Step Weldment, 4887 ..................................................... 1 54793 ...................... Mnt. Kaw. Lower Elee. Box .............................................. 2 55162 ...................... Mnt. Lower Elee. Box ...................................................... 2 55224 ...................... Fuel Line, 38/4887G ....................................................... 1 55225 ...................... Fuel Line, 38/4887G Tank ............................................... 1

7

-8 -9 10 11 -12 -13 14 15 16 17 -18 -19

DESCRIPTION

QTY

- Indicates Items Not Shown

MANUAL 82328'()()3 SEPTEMBER 1895

17

FIGURE 4-0utrigger Installation

8

I I

7

4

0

6

9

3

o

o

5

2

) 18

MANUAL 92328'()o3 SEPTEMSER 1995

.f

\

1.25 ROD

1-

1 1/2

Ima----I : D

IT'1I:

'$1------------

40.75 EXTENDED 25.75 RETRACTED 15.OD STROKE

1--------- 17 9/16

1 3/4DIA

--------1 1 R

' - - - DIA THRU 2 PL

1/2" SAE BOSS PORT 2 PL

MAXIMUM OPERATING PRESSURE IS 2500 PSI

VENDOR: BEST METAL PRODUCTS CO. VENDOR P /N: C33094

WACO, TEXAS

162-96449-0

c

FIGURE 4-0utrigger Installation (4887G Only)

)

ITEM

PART NUMBER

Ref. 1 2 3 4 5 6 7

020-G9030-00 .......... Assembly, Outrigger ................................................... Ref. 010-G903S-00 .......... Outrigger Weldment, 4887 .............................................. 1 010-G913S-00 .......... Foot Weldment, 4887 Outrigger ....................................... 1 010-G9140-00 .......... Weldment, Inner Tube ..................................................... 1 24S-00008-00 .......... Pin, 3/4 x 4-1/4 Hitch ..................................................... 1 3S0-000 19-00 .......... Pin, Pivot ....................................................................... 1 164-00014-00 .......... Chain #4 Straight Link ................................................ 18LF 621-G9113-00 .......... Pin - Cylinder ................................................................. 1 54490 ...................... Cover Weldment, Outrigger .............................................. 1 162-96449-00 .......... Cylinder MDL4887 Outrigger ............................................ 1 020-G90S0-00 '''''''''' Assembly, Limit Switch Outrigger ..................................... 1 392-00011-00 .......... -Switch, Limit ................................................................ 1 67114-003 ............... -Strain Relief 1/2NPT .37/.S ............................................. 1 52773 ...................... -Lever, Actuating Arm-S· ................................................. 1

8 9 10

DESCRIPTION

QTY

- Indicates Items Not Shown

i)

) MANUAL 92328-003 SEPTEMBER 1996

19

FIGURE 5 -Cover Installation (3BB7G/4BB7G)

5 4

7

8

)

) 20

MANUAL 112328-003 SEPTEMBER 11195

FIGURE 5 -Cover Installation (3887G/4887G)

c)

ITEM

PART NUMBER

Ref. 1 2

55197 .....................• Cover Installation ........................................................ Ref. 55238 ...................... Cover Weldment - RH ...................................................... 1 55195 ...................... Cover Weldment - LH ...................................................... 1 529-G9085 ............... Cover, Inside Angle .......................................................... 2 020-G9401-00 .......... Assy, Deck Floor ............................................................ 1 34354 ...................... Holder Safety Manual - Black Caps .................................... 1 67793 ...................... Clamp Cable 2 3/4 ........................................................... 1 55198 ...................... Cover - MDA38/4887G Engine ......................................... 1 55014 ...................... Cover, Kawasaki Front ................................................... 1

-3 4 5 -6 7 8

DESCRIPTION

OTY

- Indicates Items Not Shown

~) MANUAL 82328'()()3 SEPTEMBER 1995

21

FIGURE 6-5t eenng . Installation

2 6

3 4 5

8

23

1 18

15

25

25

22

~UAl 92328-003

PTEMBER 1995

}

ATTENTION PARTS DEPARTMENT: • IF SERVICING MODEL 3172 SCISSORS (ELECTRIC OR GAS), REPLACE 010-G5062-00 WITH 55964, PIN WELDMENT. THESE PARTS ARE FULLY INTERCHANGEABLE. • IF SERVICING MODEL 3887 OR 4887 SCISSORS (ELECTRIC OR GAS), REPLACE 010-G5062-00 WITH 55273, KINGPIN FIELD KIT. THIS KIT WILL REQUIRE SOME FIELD REWORK (SEE DRAWING 55273).

I---I~--I---+--~

UNLESS OtHERWISE N01ED: ttURANCES:

I---I~--I---+--~ FRAC1IONS:I:

'(1'

ANGI.ES :I: 1 ~I----+--+--I SUllF'ACE PINISH

1---i1------+--4---I A

10018

1ttf

PRO.EC'IIDN OF VIEWS

DEQMALS

DAlE

APPR. APPROVED

~~IIE~ co. _____I

INSTRUCTION DWG, KINGPIN

@c::J

ALL DIMENSIONS ARE IN INCHES

~L'IR.-+-D.c.N...-.-NO-+ • ..-.-DAlE..-.-+-A.....

PPR-I ...... ~ ..... ...,_-=C=OL=EM;.;;..;AN-+-':.-/18:..:.;/I7--1 L1ft. D.R.N. NO.

@ 0 [] tIj.o P.J

.X :1:.1 L ...,.."._ _ _ _ ~___.,;;:::.___WACO_._1ElCAS_7'_712_ .)()( :I: M r= .xxx :I: .010 llU

AI

CRAVING

SCALE NONE

"01 0- G506 2 _ 00 IREVA ISHEET

1 OF 1

(

(

c'

GRIND 1/32-1/111 X ~. CHAMF 4PL

EXlSllNG UPPER S'IEER YOKE PLATE ON CHASSIS 'M..DMNT 4 REPLACE EXlSllNG BUSHINGS

EXlSllNG S'lEERING KNUCKLE WLOMNT

EXlSllNO STEER AXLE PLATE

STEER AXlE KINGpiN ASSEMBLY

WACO. TEXAS

.437 DIA C'SK X 82' x .75 4 PL

Ir-.. - - 1.75 ----1""1 .030 R

.03 X 45' CHAMF 16- 3

V

t 1.750

.1....QQQ 0.998 DIA

2.50 DIA REF

,

l r

+ /

--I

00.13 THRU

J-

.750

1.980

14----1.500 ----1'"'l 125

DRILL 00.13 X 1.81 DP TAP 1/8 NPT

RMH00213

LF'

BAR.RND 2.500DIA C1144 TG&P

ITEM PART NUMBER

1--+---+----+----1

UNLESS OTHERWISE NOlED, TllLERANCES:

ANGLES

*

~ '~

DECIMALS

t---I----if----+----I FRACllCNS * 1('1$

.X

1

t---I----if----+----I SURFACE FINISH 1'V'

.XX

.XXX :I: .010 11nE

I---i--.....,-il---:--:--+-:----I PRO.ECllON OF VIEWS @ c::::J A 12516 10/12/98 SEC AU.. DIMENSIONS ARE IN INCHES LlR. D.C.N. NO. DATE APPR. DRAYfi SLK 9/30/98

KINGPIN, 38/4887 SIZE

~~-+--~~~------+---~A 5676 9/26/95 RAK CHEa<ED LlR. D.R.N. NO.

DATE

APPR. APPROVED

RAK

lllAE CONDOR CORPORAl10N 8JOO IMPERIAL ORIVE WACO, TEXAS 78712

*.OJ 1=:-::-------------------1 *.1

0/25/95

DRAWING NO.

SCALE 1/1

REV.

55272 SHEET

A 1 OF 1

FIGURE 6-Steering Installation

)

ITEM

PART NUMBER

Ref.

.. ............................. Steering Installation .................................................... Ref. 020-G9042-00 .......... Assembly, Motor/Hub #3 ................................................. 1 289-00006-00 .......... -Hub-Drive ................................................................... 1 321-00010-00 .......... -Motor, Hydraulic Wheel (Ref 54751) .............................. 1 BOW36111 .............. -Bolt, Hex .50"-13UNC x 2.75" ..................................... 4 BOW36729 .............. -Washer, Split Lock .50" ............................................... 4 396-00003-00 .......... -Stud Wheel .50"-20 x 1.75" ......................................... 5 54551-001 ............... Tie Rod, Steer ................................................................ 1 BOW32278 .............. Nut, Jam .75"-10 .......~J ................................................ 2 67821-002 ............... Rod End, .625" Male .... ~.~.............................................. 2 ............................... Assembly, Steer Clyinder ................................................. 1 54548 ...................... - Cylinder, Steer 2 x 6 .................................................... 1 253-96590-00 .......... -Fitting, Adapter ........................................................... 2 54548-100 ............... -Seal Kit ...................................................................... 1 67821-003 ............... -Rod End, .75" Female .................................................. 1 01Q-G5062-00 .......... Weldment, King Pin ........................................................ 4 124-00033-00 .......... Bushing, 1.25" x 1.00" x 1.25"-.125"FL ........................... 4

1 2 3 4 5 6 7 8 9 10

11 12 13 -14

~: .

17

i.)

18 -19 -20 -21 -22 23 24 25 26 27

DESCRIPTION

QTY

~"..-

................................ Not Used ........................................................................... .

020-G9041-00 .......... Assembly, Brake/Hut;> ...................................................... 1 126-10007-00 .......... -Brake, Eskridge ........................................................... 1 289-00006-00 .......... -Hub-Drive .................................................................... 1 396-00003-00 .......... -Stud, Wheel .50"-20 x 1.75" ........................................ 5 529-G5060-00 ........... -Plate, Brake Cover ....................................................... 1 BOW30160-350 ........ Bolt, Hex .75"-10UNC x 3.50" .............. : .......................... 3 BOW34278 .............. Nut, Stop Elastic .75"-10 ................................................ 3 .

BOW36834 .............. Bolt, Socket Flat Head .38 "-16UNC x 1.00" ....................... 8 54568 ...................... Weldment, Right Hand Yoke ........................................... 1 54567 ...................... Weldment, Left Hand Yoke ............................................. 1

- Indicates Items Not Shown

MANUAL 92328-003 SEPTEMBER 1996

23

FIGURE 7 -Steer Cylinder Assembly

D

) ...

) 24

MANUAL 92328-003 SEPTEMBER 1995

(

( ..

(

19.00 RETRAClED 1.06 10.00 STROKE 1.06 29.00 EXlENDID

1 - - - - - - - 3.19

----~__i

.75

1 - - - - - - - - - - 4.88 - - - - - - - - - - i

11. lENSlLE LOADING SAFETY FACTOR= 1.39:1 02.500 PSI. (Kg-pist=I.7) 10. COLUMN LOADING SAFETY FACTOR= 1.2:1 02,500 PSI. BASE ON LOAD 9. CYL BURST SAFETY FACTOR~ 4.0: 1 MIN. 0 2.500 PSI. 8. MAX. OPERATING PRESSURE2.500 PSI. 7.

6.

5.

4.

3.

ALL MArL STEEL UNLESS OlHERWlSE NOTED HARD CHROME PLATED ROD PAINT-RED PRIMER TEST2,500 P.5.I. TORQUE- lHMS 10 2. LUBE ALL SEALS BEFORE ASS'Y. 1. ALL DIMENSIONS REFERENCE

WACO, TEXAS

CYL, 4887 STEERING

'-110

FIGURE 7-Steer Cylinder Assembly

')

ITEM Ref.

1

2 3 4

5 6 7 8

PART NUMBER

DESCRIPTION

OTY

54548 .•..•....•..•..•...... Steer Cylinder ASSe~IY~ ............................................... Ref. 54548-100 .............. : Seal Kit ........................................................................ 1 ............................... O-Ring ......................................................................... 1 ............................... Crown Seal .................................................................... 1 ............................... Back-Up ........................................................................ 2 ............................... O-Ring .......................................................................... 1 ............................... Back-Up ........................................................................ 1 ............................... U-Cup (Dual Lip) ............................................................. 1 ............................... Wiper ............................................................................ 1 ............................... Lock-Nut ....................................................................... 1

- Indicates Items Not Shown

)

) MANUAL 92328-003 SEPTEMBER 1996

25

FIGURE a-Hydraulic Installation

3

12

17

~~::---+--- 20

18 19

10

26

MANUAL 92328-003 SEPTEMBER 1995

FIGURE 8-Hydraulic Installation ITEM

'\ )

Ref.

.,...,

2

3 -4 -4A

5 6 7 8 9 10 11 12 13

t.~.··)·.····· .,

14 15 16 17 18 19 20 21

22

PART NUMBER

DESCRIPTION

QTY

54507 ...................... Hydraulic Installation .~ ................................................. Ref . .......... Assembly - Brake/Hub #3 ................................................ 2 126-1 OOQ7..00-.......... -Brake, Eskridge ............................................................. 1 396-o0003~00 .......... -Stud Wheel ................................................................... 5 529-G5060-06 ........... -Plate, Brake Cover ......................................................... 1 289-00006-00 .......... -Hub, ............................................................................ 1 020-G9042-00 ...... ; ... Assembly - Motor/Hub #3 ................................................ 2 289-00006-00 .......... -Hub ............................................................................. 1 321-00003-00 .......... -Motor, Hyd. Wheel (Ref. 54751) ..................................... 1 396-00003-00 .......... -Stud Wheel ................................................................... 5 020-G9049-00 .......... Assembly - Hydraulic Tank 4887 ...................................... 1 54506 ........... ·........... Cylinder Assembly, 3887 lift ........................................... 2 55092 ...................... Cylinder Assembly, 4887 lift ........................................... 2 54548 ...................... Cylinder, Steer .............................................................. 1 250-00012-00 .. : ....... Filter, High Pressure ........................................................ 1 51921 ...................... Valve, Solenoid ....: ....)-1 .................................................... 2 315-00025.-00 ........... Valve, Lift Con~ro.t,· ......................................................... 1 392-00025-00 ......'.... Switch' - limit Pressure ..................................................... 1 51,616 ...................... Valve Relief Cart 1500-3000 ............................................

2 , 450-00061-00 .......... Valve, Flow Control (Ref. 66418) ..................................... 3 54574 ...................... Tube Assembly; Lift on Man/Blkhd .................................... 1 020-G9003-00 .......... ~ssembly - Dump Valve ................................................... 1 450-00054-00 .......... -Valve-Dump .... :-............................................................. 1 450-00056-00 .......... -Valve-Body Dump .......................................................... 1 54579 ...................... Tube Assembly, HP Filter/P Prt Man .................................. 1 54580 ...................... Tube Assembly, T to Return Filter ..................................... 1 54577 ....................... Tube Assembly, S1 Man/Strg. Blkhd ................................. 1 54578 ................ ~ ..... Tube Assembly, S2 Man/Strg. Blkhd ................................. 1 54575 ...................... Tube Assembly, l T ManITp Tee Blkhd ............................... 1 54576 ...................... Tube Assembly, L2 Man/Bm Tee Blkhd .............................. 1 67821-003 ............... Rod End, 3/4 Female ....................................................... 1 BOW32288 .............. Nut Jam .75-16UNF ........................................................ 1 50068 ...................... Check Valve ................................................................. ~ 1

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MANUAL 82328-003 SEPTEMBER 1886

27

FIGURE 8A-Brake/Hub Assembly

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28

MANUAL 112328-003 SEPTEMBER 11195

FIGURE 8A-Brake/Hub Assembly

ITEM

PART NUMBER

Ref. 1 -2

02Q-G9041-00 .....•••.. Brake/Hub Assembly #3 ......•.........•....••••.•••••••.•••.......•. Ref. 126-10007-00 .......... Brake, Eskridge ................................... :3....'1 ................... 1 396-00003-00 .......... Stud Wheel 1/2 - 20 x 1 3/4 ........... ~ ::£~L ......... 5 529-G5060-00 .......... Plate, Brake Cover ............................................... ; .......... 1 289-00006-00 .......... Hub, 1.5 Taper 38/4887 Wheel ........................................ 1

3 4

DESCRIPTION

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MANUAL 92328-003 SEPTEMBER 1995

(;~

29

FIGURE 9-Brake Assembly

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30

MANUAl 92328-003 SEPTEMBER 1995

FIGURE 74 ESKRIDGE BRAKE ASSEMBLY I

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

CALAVAR PART NUMBER DRJOI034 DRJOI035 DRJOI036 DRJOI037 DRJOI038 DRJOI039 DRJOI040 DRJOI041 DRJOI042 DRJOI043 DRJOI044 DRJOI045 DRJOI046 DRJOI047 DRJOI048 DRJOI049 DRJOI050 DRJOI051

QUANTITY

DESCRIPTION 1 23 45

Nut, Slotted Jam Screw, Socket Head Cap Plug, Hollow Hex Case, Brake Bearing, Output Key'· Shaft q~ -~ _ -a('S J Spacer Plate, Seperate Plate, Bronze Friction Piston Spring, Blue Spring, Green Cover, Brake Bearing, Input Ring, Snap Ring, Snap Kit, Seal -Ring, Piston Backup -a-Ring, Piston -a-Ring, Piston -Ring, Piston Backup -a-Ring, Case Seal -Gaske~, Mounting

111 444 1

4

1

111 111 111 111 111 999 888

1 4 11 1 '

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111 111 111 111 111 111

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FIGURE 9-Brake Assembly

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ITEM

PART NUMBER

Ref. -1 2 3 4 5

126-10007-00 .......•.. Assembly, Brake •..•••.•.....................•..•••••••••..•......••..... Ref. . ....••....•.......•.......•... Nut, Slotted Jam ............................................................ 1 .•••.•..•.•....•.....•••.•.•.•. Screw, Socket Head Cap •.•........•.......•••..•.•.•....•...•.•..•...•.• 4 ....••..•..•..•.......•..•..... Plug, Hollow Hex •.•.•........••.••.•••...•.•..•.••••••.•...••••••••••...••.• 1 ......•.••.........•.•..•••.••. Case, Brake ........•••••.•........•.•.............•••......•••••••.••.....•.•. 1 •.•••.•.•.......••.....••••.••. Bearing, Output •••••...•.•.•.•.•.••..•..•••••.•..•.....•.•••...•.••..•...•... 1 .. . .•. ~ ..•.•...•..•.••.. Key •....• ).) ..........J.....•......•••.....•....(jtsLj .......................... 1 ........................ Shaft ....... f.I:.T..t>.. !?~Q .... P.f. .. ~f.:: ........7'.y..$.;.,............... 1 ~ Spacer ....

1 ..... :.-) ................... ; Plate, Sera rate ...................... : ........................................ 9 .~t Plate, Bronze Friction ...................................................... 8

--6

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-7 8 9 10 11 12 13 14 15 16 -17 -18 -19 -20 -21 -22 -23

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••••••••• I I I I I I •• I I .

DESCRIPTION

OTY

I I ••••••• I I •••••••••• I I ••• I I . I I •• I I •• I I •••••••••••••••••••••••••• I I I I .

.........................

. .. ............................ Spring, Blue ................................................................. 12 ~ ............................. Cover, Brake .................................................................. 1

..•......................... Piston .•...................•.....•.........•...•.....•..................•.•...... 1

............................... Bearing, Input ................................................................. 1 Ring, Snap .. .....

1 ............................... Ring, Snap ..................................................................... 1 ............................... Kit, Seal (includes items 18-23) ........................................ 1 ............................... Ring, Piston Backup ........................................................ 1 ............................... O-Ring, Piston ................................................................ 1 ............................... O-Ring Piston ................................................................. 1 ............................... Ring, Piston Backup ........................................................ 1 ....... ~nlt)' ............ O-Ring, Case Seal ........................................................... 1 .l)g.... I<. .....5.~ ...... Gasket, Mounting ........................................................... 1 •••••••• II •••••••••••••••• II •••

1. I I •••••• I I •••••••••• I I • • • • • • • • • • • • • • • • I I ••• I I ••••••• I I ••••• I

- Indicates Items Not Shown

I) MANUAL 92328-003

SEPTEMBER 11195

31

FIGURE 10-Lift Cylinder Assembly 3887G x

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MANUAL 92328'()()3 SEPTEM8ER 1995