Condor 60N Industrial Self-Propelled Parts Manual - PDF DOWNLOAD

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ILLusTRATED PARTS INDEX INDUSTRIAL SELF-PROPELLED CONDORS MODEL 60N Description

.' Figure No. 1

Final Assembly

2

Safety Decal & Placard Location

3

Carriage Assembly, Gasoline Engine

3A

Carriage Assembly, Diesel Engine (Option)

4

Torque Drive Assembly

4A

Wheel Drive Valve Assembly

5

Front Hub Assembly

7

Steering Assembly

9

Rotary Coupl ing

9B

Electric Slip-Ring

10

Turret Assembl y

13

Pump Installation

14

Fuel Tank Assembly ""Hydraul i c Oi 1 Tank Assembly

15

:,",:'-

16

:

17

Hi

'\

'

. Ground Control Box Assembly . Turret-Rotation Speed-Reducer Installation ~

Muffler Installation, Gasoline Engine

18A

Muffler Installation, Diesel Engine

19

Air Cleaner Installation

'20

Electric Motor Pump Assembly for Emergency Power

.~

.

ILLUSTRATED PARTS INDEX (Continued) INDUSTRIAL SELF-PROPELLED CONDORS MODEL 60N

Figure No.

Description

21

Boom Assembly, 60N

23

Slave Leveling Cylinder Assembly

25

Boom Extension Cylinder Assembly, 60N

28

Topping Cylinder Parts Breakdown

31

Platform Control Console Assembly

32

Platform Assembly

33

Skirt Weldment, Non-Rotation

34

180 0 Platform Rotation Assembly (Option)

35A

180 0 Rotary Actuator

39

Diesel Engine-Pump Assembly (Option)

40

LP Tank (Option)

41

Spark Arrestor, Muffler (Option)

l

FIGURE 1

FINAL ASSEMBLY

f)

<1 ~--------------

3/83

FIGURE 1

1\ REF

FINAL ASSEMBLY

(60N)

DESCRIPTION

PART NUMBER

QTY

./

Strobe Light Cover, Turret (Fiberglass, 5 pieces) ~ 3 Latch 4 Tie-Down Ring 5 Bracket, Latch Pin,· Boom to Ski rt 6 7 Grease Fitting (Zerk), 1/4" 8 - t-- Pin, Leveling Cylinder 9 Capscrew, Hex Hd. 1/4" - 28 UNF x 3/4" Lg. 10 Lockwasher, 1/4" 11 Pin, Topping Cylinder 12 Pin, Main Boom Pivot 13 Truss Hd. Machine Screw I 5/16" - 18 UNC x 1" Lg. Fender Washer, 5/16" 14 15 Nut, Hex (Nylon) 5/16" - 18 UNC Capscrew, Hex Hd. 3/8" x 3/4" Self-Tapping 16 1

).

','"

68459 30310· LBL 00200 32536 LBL 00256 30390 21126

68241 68177

1 1 2 7 2 1 2 1 1 1 1 2 6 6 6 15

FIGURE 1A SAFElY DECALS AND PlACARDS

1

2

CONDOR 58 LOAD CAPACIlY

1250LBS.

DO NOT UFT WHEELS WITH BOOM

CAPACIlY INCLUDES PERSONNEL 8< BQUIPMENT

21971-002

58021

3

4

110 VOLTS 15376-024

5

TRAVEL SPEED HIGH SPEED WORKS ONLY WITH

67846

• SELECTOR SWITCH IN "HI" • BOOM BELOW HORIZONTAL • BOOM FUlLY RETRACTED

NOTE:

AERIAL FUNCTIONS DO NOT OPERATE IN HIGH SPEED

40130

)

6 WAI¥.IQI 1. BEFORE ONMI'ING CCNDOIII. READ AND UNDEfI8TAND ALLINPOfIMATION liTHE 0PERA1I0NI SAFITY MANUAL AND ON ALL DECALSII'I.ACAA DlSl'l.AVED ON THIS UNIT. z. IE FAMIUAA WITH THE CQNTJIQ. FUNCTIONS ON THE OPERATOR CONSOLES. a. IE lURE ,""T CONDOR II PAOPERLY MAINTAINED It ACCORDANCE WITH CALAVM'S l'IEQUIREMENT8 ASIPECIF1ED It THE ~ IWAML 4. DO NOr OPEMTElMII MAQINE • rr DOES NOr JIUNC110N PROPERLY. &. DO NOr OPEMTI THE CONDOR WHEN"WIND VELOCIYY ElIC&D8 • .. DO NOT REIoO/E ",., WEIGHT FROM UNIf.ITAIIIlnY WILL E AFFECTED. 7. DO NOr MAIlE ",., MCXIFICATIONI 10 CONDOR WI1HOUT WAfTTEN CONSENr OF CALAv"..

DALY _ _ _ CIIICICLIIT..aM _ _ CIDIIIIOR-

"'.H.

1. CHECI( FWD LEVfiU It HYIlMLIC AND FUEL TANICB AND MnIRY. 2. CHI!CK . . . . . Cfl'.HICA8E CIL. AND COOLANT !'Oft WA11iRQXlLB) ENGINEI ONLY. So VllUALLY IB'EICf CONDOR RIR UXIIE OR . . . . fWIT8, WEN!, WELD CIW:ICI. DENTI, OR OTHER 8IGN8 OF DAMAGE. 4. CHECIlTIIBI'Oft WEAR, CUTS, AND MATION . . . . . . . f'NIUMATIC TIAE8 ONLY). &. CHI!CK ALL - . . ICI.TI. NUTS. ..... AND FASlENEM I'Oft I'fICfIER _N.LATION. .. CHECK HVDAAUUC COMPONIN1I. FLUI) UNU AND I'ITT1NGI OR LEAICS. 7. IN8PECT IELICTRICAL IWINI.... COHNI!C1OFII, CIACUfTI. AND IIOQM MIiCHANICAL CAlLES CNICTION IOQIIl8 ONLY) I'Oft IWUoQE AND PfIOPIR IN8TALLATlCN. .. Ct£CK .. acPE 8ENIOR AND INDICATOR UOHTIIIOUND AI.NIIot !'Oft PROPER OPEMTION. .. CHECI( ROTATION ClEAR lOX. . . . GEAR ICI.TI. LQCK.81"fUP8 !'Oft PfIOPER INSTALLATlCN. 10. ",., DB'm1W I'IIUND DUNG . . ECTION AND F\ItCTIONAL TIlT MUST IE COI'R!CTED EPa. THE CONDOR. (REFER 10 OPEM~ IIoUIUM.I'Oft

=_ ...

..

FN:rf:IIf't MOe It..".TION8J.

-.

-~

1. CHICK 1NlT ,.,..,. LOCIC.fIII .. REMOVED CAPPUCAILE ONLY 10 CONDOR MODIUI WI'IM 'rUMrI'.-e1.OCDlG Fl!ATUAE!'Oft ~ a. 1\JM 1I'OWI!R..-c:H "ON" AT GROUND CONnQ. CONICU.ITNn" ~ IMO ItUDit UNIT 10 WNW 10 OPERATING 1EM'ERATUfII. a. ..... ~ _ _ IMTCH TO "QAOUND" ClONIROL AND lUrOPlMli AU. AERIM. FUICl10NI ". _ 0ClN1'R0L CON8OLI. 4. I'08rTlON IIEUiCI"OR 8WIJCH 10 ''PLATFOAIoI''CCINTROL THEN ENTEJII THE WQfI( PlATRlIW IMO ATTACH THE WETY aaTA.ANYARD.

s.

LMI'I_"""

7.

FOR 1MN8PCIRrIIG, UIE EXJNMI CMITIOtI wtIILI ~ THE CONDOR UNDEJ! rrJ OWN fIOMifI: o lRA't'IL It LOW 8PEED MODE ONLY. o IWCE SUAE PlATFORM IS LOWERED IIIOOM FULLY IElRACrED I BELOW HORIZDffTAL., o ROTATE TURRET It LINE WITH CHA8SI8.

ALL . . II I IL IlIUnI'ONot MUST WEAR API'ACMiD HoW) HATI. , IIODY lB..,. WI'IM 10 DUlClNAT!D POIHT8I1 THE 1'lA"n'ONII A88Ef8.Y. .. fIII!P!III TO MlM PI.A'n'OMI ''CAUT1UI'" DECALlI'OR ALL OI'tIMoTlONl It ntI! PLICY'I'IOMI.

)

o

DO NOr DCEED .w. ANQLE OF 140 (2.1 FEET III8E 1110 FEEll.

...

5366 REV. 08-92

FIGURE 1A SAFETY DECALS AND PLACARDS

7

WARNING THIS UNIT IS NOT INSULATED AND MUST NOT BE OPERATED WITHIN 10 FEET OF ENERGIZED POWER UNES.

32200

32200

8· 1. INSPECT VEHIClE AND AERIAL DEVICE. INCLUDING OPERAJlON. PRIOR TO USE. DAILY 2. FOR STAnONARY OPERATION VlHIClE MUST BE SECURELY PARKED AND STABILIZED FOR THE WORII TO BE PERFORMED BEFORE AERIAL DEVICE IS OPERATED. 3. OUTRIGGERS WHUI REQUIRED MUST BE 011 SOLID FOOTING. 4. OPERATORS SHAll WEAR A 80DY BElT. AID AnACH WITH A LANYARD TO 800M OR PLATFORM. 5. OPERATE AU CONTROLS SLOWLY FOR SMOOTH PLATFORM MOTION. 5. DO NOT LOAD 8EYOND RATED CAPACITY.

,..

CAUTION

DO NOr USE CONDOR AS A WELDING GROUND DO NOT WELD ON CONDOR WITHOUT DISCONNECTING BOTH POSITIVE AND NEGATIVE BATTERY LEADS REFER TO MAINTENANCE MANUAL FOR ALL WELDING PROCEDURES

DO NOT JUMP START OTHER VEHICLES WITH BATTERY CONNECTED TO CONDOR

.-

~

21854

91 TIRE PRESSURE 70 PSI 1

21882-004

21971-006

1°1 PLATFORM CAPACITY

)

I

36884

11

12

CAUTION

POWER TAKEoOF' OPERATION MECIofAJlOlCAl; TRANSI\oIISSION

TIlis vehicle is equipped

1"

1M .~Id ~. oowet. . . . . . . I"'.",.. ItWI 01 tft. "'_'"

1. A DOWW , ......'

with a POWER TAI(E·OFF. CONSULT OPERATING INSTRUCTIONS BEFORE uSlr~G. (SEE SUN VISOR)

2.

.....-

..

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~

tw out of..., ... •• dl • ."..... ,,,. cfuteft . . .

".r.O.......

AUTOMATIC TII_ISSION 0.. WI........ tr.......n ..... th. . . . .

Ie

"............... """......,...,... ".......,........ "'," Mlt~

........................ et.............. oecurl. tfte ......., ,....,. ,. """_ . . . . . . . ., , ....

I-Located on Dash at left of Red" Caution PTO Control" Knob 13

a.,... tlttfttft9 ,h_ .,....... ,.....n I"to

. . . . '''' ,,,............. Ott

I Shut

tr.,._................. .,.., 01 ,. .

rlrWe ......... J'N .......... t~

Ir~ ......

~. . '""" few.....,..

2. ShtIt ~''''''''- .... 0--.

3. Shift ,'....................... (T . . . . . .

.

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

..,_ .,.,......-. ' _n.o. ___ 'lore: Toe·"...... oor....,., ..IW'ic.......

~.T.O:.

,....,.

Ii .....

2-Located at left of Windshield Wiper

CAUTION

THIS SElf-PRtlPEl.l.Ell CONDOR IS EOIJIPPED WITH SLOPE SENSORS AlII a.A. LIIIT. IllEllBOOIts AIIfIVE HORIZONTAL AND THE IlACllINE IS BEING IIRIVEJJ up, 0011, III ON ASlOE GRADE AT 5° OUT Of LEVEL. THE IIIDICATOR LIGHT WILL COME ON AND ALl BOOM FUNCTIONS WILL BE INOPEIIAIILE. TO CORRECT CONDITION-iDO NOT LOWER BOOM WITH EMERGENCY LOIBIS),IIEVEaIIlllECTJON Of GROUND TRAVB. UNTIL UGHT GOES OUT .an.11I_ts AGAIN LESS T11A15° OUT Of LEVEl AND THE IIOIIM FIIICTaS ARE AGAIN OPERABLE. 21880

21880

14

21849

REV. 08-92

FIGURE 1A SAFE1Y DECALS AND PlACARDS

)

15

0

FACTOR'\' RECat.lNENDED TRANSPORTING DIAGRAM

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---,

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-

II I

"

/ --r---. r""

. '. . a:

IY

. - 7·-" . - - ,

16l f

~0

f-----

r--~

I

CAIITIOII ) ~------~~--------------------------1. DO NOT OPERATE THIS MACHINE UNLESS YOU ARE ATRAINED AND

21658

Also located opposite side and on rear of carriage~

17

)

Lh.

T1-115 MACHINE IS NOT INSULATED

AUTHORIZED OPERATOR FOR THIS CONDOR MODEL BE FAMILIAR WITH UNIVERSAL SYMBOLS USED ON CONSOLES. 2. CHECK ALL MACHINE FUNCTIONS. INCLUDING BRAKES. PRIOR TO EACH DAY'S USE. 3. ALL PERSONNEL IN PLATFORM MUST WEAR APPROVED HARD HATS AND BODY BELTS WITH LANYARDS ATTACHED TO DESIGNATED POINTS ON THE PLATFORM ASSEMBLY. 4. OPERATE ALL CONTROLS SLOWLY FOR SMOOTH PLATFORM MOVEMENT. WATCH FOR OBSTRUCTIONS WHICH MAY STRIKE PLATFORM. PERSONNEL. CONTROLS OR MACHINE. 5. DO NOT OPERATE THE CONDOR ON SOFT OR UNEVEN SURFACES OR ON SLOPES IN EXCESS OF 5° (10.5" RISE IN 10 FEET).

6. DO NOT OPERATE THE CONDOR WHEN WIND VELOCITY EXCEEDS 2S MPH. 7. NORMAL TRAVEL POSITION IS WITH THE BOOM FULLY RETRACTED AND "TUIIIET COUNTERWEIGHT" POSITIONED OVER THE DRIVING (FRONT) AXLE. THE BOOM MUST BE ELEVATED TO PROVIOE ADEQUATE IIIDUNO CLEARANCE FOR THE PLATFORM ASSEMBLY. DIRECTION OF PLATFORM TRAVEL REVERSES IN RELATION TO CONTIICLLEIMOTION WHEN THE BOOM IS OYER THE FRONT AXLE. DO NOT DRIVE 1HE CONDOR WITH THE BOOM ELEVATED IF Aff'( PART OF THE lilia_IS WITHIN. FEET OF AN OBSTRUCTION. 8. THIS CONDOR IS EQUIPPED WITH ASLOPE SENSOR AND AN INDICATOR LIGHT 011 MIIAL CONTROL. CONSOLE TO INDICATE A 5° OUT-OFL£VEL QlIlIIfIDN. ALL IGOII FUNCT10NS AlE IIJPERA8lE WHEN CONDOR • MORE THAN 5- OUT-OF-LEVEL NOTE: TO CORRECT THIS CONDITION. REVERSE/CHANGE DIRECTION OF GRfUIt TRAVEL UNTIL INDICATOR LIGHTS GOES OFF. 9. HIGH SPEED MODE FOR TRAVEL WORKS ONLY WHEN SELECTOR SWITCH IS IN "HIGH" AND BOOM IS BELOW HORIZONTAL AERIAL FUIIIC11IIB DO NOT OPERATE WITH UNIT IN HIGH SPEED. 10. IN CASE OF EMERGENCY. DEPRESS EMERGENCY "STOP" BUTTON. 35365

ELECTRoCunON HAZARD

35365

_ _ :Wl CllM*tSfaltlallClllllSAPI'IIIIIUS IOU IIISf M1OII" . . . . . . . .

"'U" __

SAG ... lllCTIICM llll lHlSAl_ . . Mlf. . . . .S ... . PtIOIfCIIIII f a CIIIIIC1_III01 . - . .• • [UCTIIICMU CIIMGlD a.ICIIII IOU IIISf ....... AQUIMC( 01 AltUSI IIfUI

18

8ETWUIIAIIIY"" 0I1Mf WOIII PlAIIOIIIIIOI U.....

M' melRICAI. llll( 01 .......US CAIIIhIIIi "" 10 ~ OlIO GIS 0IIl fOOl AOOIIICNIIlUIUIG IS R[QUII(D fDR ('It'" AIIOIIIOIUl lO OlIO GIS 01 tlSS DUI" 01 SlRiIllI$ iIWIIY Will It)llli fllCll c.ua 01 NIIlDUAIl ClUIAIIICl lilli'

s;9n21882-002 warns of pot.ntial hazard when operating a noninsulated .erial deYlCe on or ne., charged cond"ctors. Application ....ould be in lineo'.sight YiSibility of upper and tow.r controt operators.

21882-002

EUCTIOCUTIOI HAZAID KEEP CLEAR

.,we

DU. . . _ _ • IISUlr fIOII (01110 WIll IllS E " ' " .. YmCII If n s.-. • BKBAIlI CUMa.

J_.

sitn2188a-OO Iel...,." .......8tton.. lymbattar.I. . . icily .... w..... of danI8t'rCHlt . . .lectIiCatly ct'Ia'9" vehicle _ equipmML

)

TwoolU-. . . . . ' ..uis ...... eor .................... ....

No. 7771aG1on,.., ........ if ............... 1111 . : _ .... No. 7711011 on,... of ...... if . . . . . . . . . . .

I 'III'

not.

21882-001 REV. 08-92

FIGURE lA SAFETY DECALS AND PlACARDS

19 i

I I

CAUTION. CAUTION. CAUTION

REMOVE TURRET LOCK-PIN BEFORE ROTATING TURRET

I

41091 * SEE FIG. 1B, DECAL LOCATION CHART, ITEM # 9 TWO PLACES, FRONT SIDE OF BOTH CONTROL BOXES

)

) :iliV. U8-92

FIGURE 1A SAFElY DECALS AND PlACARDS

-) 15

0

FACTOfN RECOMMENDED TiANSPORTING DIAGRAM

16~f====~====CA=m=ON========~)~

o

o

21658 Also located opposite side and on rear of carriage~

) THIS MACHINE IS NOT INSULATED

ELECTROCUTION HAZARD MAIIIIAlil SAf( ClUIIMCts 1lI0II mCllIICAI. llllS ...

Al'l'MAIUS IOU MUSI AUOIIII 101100II_ lOCI. SAG MIG mCTRIeN. UN( AND lOAll SlllUIMi THIS AlRIAlIlllbl PIA/IOIII 00(5 IIOII'IIOIIIDt PROIEe/1ON 1lI0II COII1M:1 WlIH 01 PICIUIIY ....

El£C1I11CAllI CIWIGlD CIlIIIIIICICII lOU IIISI ..... IAII ACWIIMCE Of AllEASI 10 lEU 8ETWUN All, PIlI, Of THE WOIIR 1'1 AIIOIIII OR lOAll AND All, lllCIRICAlIINE OR Al'l'MAIUS CAIII'1Mi UP /0 ~o 000 WIllS ON( 1001 AOOI/IOIW IllAlUM:lIS R(QUII(O 1011 ('I(IY ADDlIIOIW 10 OlIO '415 OILE5S. DEAl" OR SlRIOUS "'JURY'MU RI ,UII IROII COIIIM:I 01 IlUII(flIIA/E CIUIINICl

1. DO NOT OPERATE THIS MACHINE UNLESS YOU ARE A TRAINED AND AUTHORIZED OPERATOR FOR THIS CONDOR MODEL. BE FAMILIAR WITH UNIVERSAL SYMBOLS USED ON CONSOLES. 2. CHECK AlL MACHINE FUNCTIONS, INCLUDING BRAKES, PRIOR TO EACH DAY'S USE. 3. ALL PERSONNEL IN PLATFORM MUST WEAR APPROVED HARD HATS AND BODY BELTS WITH LANYARDS ATTACHED TO DESIGNATED POINTS ON THE PLATFORM ASSEMBLY. 4. OPERATE ALL CONTROLS SLOWLY FOR SMDOTH PLATFORM MOVEMENT. WATCH FOR OBSTRUCTIONS WHICH MAY STRIKE PLATFORM, PERSONNEL, CONTROLS OR MACHINE. 5. DO NOT OPERATE THE CONDOR ON SOFT OR UNEVEN SURFACES OR ON SLOPES IN EXCESS OF 5" (10.5" RISE IN 10 FEET).

6. OD NOT OPERATE THE CONDOR WHEN WIND VELOCITY EXCEEDS 2S MPH. 7. NORMAL TRAVEL POSITION IS WITH THE BOOM FULLY RETRACTED AND "TURRET COUNTERWEIGHT" POSITIONED OVER THE DRIVING (FRONT) AXLE. THE BOOM MUST BE ELEVATED TO PROVIDE ADEQUATE &ROUND CLEARANCE FOR THE PLATFORM ASSEMBLY. DIRECTION OF PLATFORM TRAVEL REVERSES IN RELATION TO CONTROlLER MOTION WHEN THE BOOM IS OVER THE FRONT AXLE. DO NOT DRIVE THE CONDOR WITH THE BOOM ELEVATED IF ANY PART OF THE ~ IS WITHIN 6 FEET OF AN OBSTRUCTION. 8. THIS CONDOR IS EQUIPPED WITH A SLOPE SENSOR AND AN INDICATOR LIGHT ON ASIAl CONTROl CONSOLE TO INDICATE A 5" OUT-OF· LEVEL coremDN. ALL 100M FUNCTIONS ARE IfIJIIERA8lE WHEN CONDOR IS MORE THAN 5- OUT-OF·LEVEL. NOTE: TO CORRECT THIS CONDITION, REVERSE/CHANGE DIRECTION OF GROUND TRAVEL UNTIL INDICATOR LIGHTS GOES OFF. 9. HIGH SPEED MODE FOR TRAVEL WORKS ONLY WHEN SELECTOR SWITCH IS IN "HIGH" AND BOOM IS BELOW HORIZONTAL. AERIAL FUNCTIONS DO NOT OPERATE WITH UNIT IN HIGH SPEED. 10. IN CASE OF EMERGENCY, DEPRESS EMERGENCY "STOP" BUTTON. 35365

35365

18

IIUlI

Si9n21882-002 warnl of po.entlal hazard when operating a noninsula.ed aerial deVIce on or near charged conductors. Application should be in lineof"ight visibility ot upper and lower control operators.

21882-002

EuaROCUTION HAZARD KEEP CLEAR DlIIII . . sn.s .N.'UN IISUlJ FlO. (OIII(J WIT. rIllS EQUIPMIIIf 01 YEIIQE

IF R 51l0III • II.K1'IKAllY OIAIIII..

lila ..

Si9lt"2188~OOld""'tNifttemation"aymDotforel.otricity.nd

0'

)

warns danger from an electriCally Charged vehicle or equipment.

Two . . . . . . . . . . . , ..uir_ on. tor e8Cttatdaofvahild. u.. ...

No. 7771001 on,.., of ...... if • .,.. dewica. iNIIl ••••;-1ion No. 7711011 on ,...01 . . . . . if . . . . d . . . . . Muir....... -

21882-001 REV. 08-92

- - -\~ -----------------------------------~\~~~-----------------------------------------VIEW A

11 19

29

20 18

8 3

16 17

15

23

25 om

9 r""'0

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9 ;;:0

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'§ 9

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--z

FIGURE 2

i)

REF

SAFEiY DECAL & PLACARD LOCATION

DESCRIPTION

QTY

.

1-r- Decal - 60 2--rDecal - Condor (Trade Mark) 3--LDecal - Turret Lock - Pin 4±Decal - Caution & Warning 5 Decal - Warning 6 Decal - Danger Decal - Danger 8 -rDecal - Travel Speed 9 I Decal - Do Not Uft Wheel. with Boom 10 Decal - Forward-Direction Arrow 11 Decal - Calavar (Logo) 12 Placard - Transporting Diagram 13 Decal - Caution (No Welding Ground) 14+Decal - Danger (Electrocution Hazard) 15 Decal - No Step 16 . Decal - Danger 17±Placard - Dual Fuel* 18±Placard - Platform Cap. 19 Decal - Lube Fitting 20 Decal - N 21 $Placard - Caution 22 Placard - Gas 23 Placard - Serial No. Deca! - Danger 24 25~ Placard - Operating Instructions 26 Decal - Operation & Safety Manual 27 Placard - 110 Volts * 28 Placard - Battery (Disccntinued) 29 Placard - Hydraulic Fluid 30 Decal - Posi-Traction

7+ I

I

31 32

PART NUMBER

--------------!-I

I

)

(60N)

Decal, Tie Down Ring Decal, Tire Replacement

40103-006 2 . 21834 2 40191--------+-2 I 35365 1 . 32200 1 21882-004 1 I 21882-003 1 I 40130 1 i 21971-002 1 35042 and 35043'( FORWARD }f--1 ea . 15430 1 30349 3 21854 I 1 21882-001 2 32156 I 2 21882-002 1 32189 1 1 80283 1 21079 I 2 32563 .

2 21880 1 21849 1 15843 1 21882-003 1 35366 1 21384 1 15376-024 1 21399 1 21850 1 21971-004 1

t I

I

67846 58398

2 2

* Used with options

) REV. 08-92 1/83

FIGURE 2A

SAFETY DECALS

o~____________________________________~ 0

I CAUTION I

CAUTION 00 NOT USE CONDOR AS A WELDING GROOND 00 NOT WELD ON CONDOR WITHOUT DISCONNECTING 80TH POSITIVE AND NEGATIVE BATTERY LEADS REFER TO MAINTANCE MANUAL FOR ALL WELDING PROCEDURES

1.

INSPECT VEHICLE AND AEllIAL DEVICE, INCLUDING OPERATION, PllIOll TO USE, DAILY.

2.

FOil STATIONARY OPERATION VEHICLE MUST BE SECURELY PARKED AND STABILIZED FOR THE WORK TO BE PERFORMED BEFORE AERIAL DEVICE IS OPERATED.

3.

OUTRIGGERS WHEN REQUIRED MUST BE ON SOLID FOOTING.

4.

OPERATOllS SHALL WEAR A BODY BELT, AND ATTACH WITH It. lJ\NYARO TO BOOM Oil PLATFORK.

S.

OPERATE ALL CONTROLS SLOWLY FOil SMOOTH PLATFORK HOTIOll.

6.

DO NOT LOAD BEYOND RATED CAPACITY.

00 NOT JUMP START OTHER VEHICLES WITH BATTERY CONNECTED TO CONDOR

0'--------------------------------------' 0 21854

32999-4

O~I___C~A~U~T~I~Q~N______

Q

THIS seLF-PIIOPELLeD CONDOIIIS EQUIPPED WITH SLOPE SENSORS AND INDICATOR LIGHT. WHEN 100M IS ABOVE HORIZONTAL AND THE MACHINE IS BEING DRIVEN UP, DOWN, 011 ON A SIDE GRADE AT.5- OUT OF LEVEL, THE INDICATOR LIGHT WILL COME ON AND ALL BOOM FUNCTIONS WILL BE INOPERABLE.

Q

TO CORRECT CONDITION--(DO NOT LOW!II 800M WITH EMERGENCY I.OWERING). ItEVERSE DIRECTION OF GROUND TRAVEL UNTIL LIGHT GOES OUT INDICATING THE CONDOR IS AGAIN I.ESS THAN ,- OUT OF LEV!LAND THE BOOM FUNCTIONS ARE AGAIN OPERABLE. 0

21880

DO NOT LIFT WHEELS WITH BOOM £

DANGER EXPLOSIVE GASES

£

POISON CAUSES SEVERE BURNS

Clglrett.., IIlme. or IPlrb could CIUle blttery to e.plode. AI.I,. "'Ield e,.e end flee from blttery. Do not cherg. or UN boo.ter Clble, or .dlult Jlo. connectlonl wltllOUt proper Instruction Ind trllnlng.

KEEP VENT CAPS TIGHT AND" LEVEL Contlln, ,ulfurlc leld. AvOid contece with skin, e,el or clothlnl. In event 0' Iccldent flul" with wlter Ind cIIi phYllclln Immedl"ely.

KEEP OUT OF REACH OF CHILDREN 35785

FIGURE 2A

SAFETY DECALS

TRAVEL SPEED HIGH SPEED WORKS ONLY WITH • SELECTOR SWITCH IN -HI• BOOM BELOW HORIZONTAL • BOOM FULLY RETRACTED

NOTE: AERIAL FUNCTIONS DO NOT OPERATE IN HIGH SPEED

32996

YOU MUST NOT OPERATE THIS MACHINE UNLESS YOU AlE QUALIfiED IY T.. INIIIIAND UPEIIENCE IN THE SAfE OPEIATlDN OF THIS MACHIIIL

)

rU'NIIIIINCLUOES COMPlETE KNOWLEDSE OF YOUI EMPLOYErS won IULES, ALL GOVERNMENTAL REGULATIONS, AND MANUFACTUIER'S O'IUTOI AND SAfETY MANUALS RlU TIVE TO THIS MACHIN£S SAFE USL AN UNTUINED aPPAlOI 5U.,leTS HIMSELF AHa OTHEIS TO

CAUTION I DO NOT OPERATE THIS MACHINE UNLESS YOU ARE A TRAINED AND AUTHORIZED OPERATOR FOR THIS CONDOR MODEL BE FAMILIAR WITH UNIVERSAL SYMBOLS USED ON CONSOLES 2. CHECK ALL MACHINE FUNCTIONS, INCLUDING BRAKES. PRIOR fa EACH DAY'S USE 3 ALL PERSONNEL IN PLATFORM MUST WEAR APPROVED HARD HA fS AND BODY BELTS WITH LANYARDS ATTACHED TO DESIGNATED POINTS ON THE PLATFORM ASSEMBLY 4. OPERATE ALL CONTROLS SLOWLY FOR SMOOTH PLATFORM MOVEMENT WATCH FOR OBSTRUCTIONS WHICH MAY STRIKE PLATFORM, PERSONNEl. CONTROLS OR MACHINE, 5. DO NOT OPERATE THE CONDOR ON SOFT OR UNEVEN SURFACES OR ON SLOPES IN EXCESS OF 5 1105" RISE IN 10 FEET) 6 DO NOT OPERATE THE CONDOR WHEN WIND VELOCITY EXCEEDS 25 MPH. 7 NORMAL TRAVEL POSITION IS WITH THE BOOM FULLY RETRACTED AND "TURRET COUNTERWEIGHT' POSITIONED OVER THE DRIVING IFRONTl AXLE. THE BOOM MUST BE ELEVATED TO PROVIDE ADEQUA TE GROUND CLEARANCE FOR THE PLATFORM ASSEMBLY DIRECTION OF PLATFORM TRAVEL REVERSES IN RELATION TO CONTROLLER MOTION WHEN THE BOOM IS OVER THE FRONT AXLE DO NOT DRIVE THE CONDOR WITH THE BOOM ELEVATED IF ANY PAHT OF THE MACHINE IS WITHIN 6 FEET OF AN OBSTRUCTION 8. THIS CONDOR IS EQUIPPED WITH A SLOPE SENSOR AND AN INDICA TOR LIGHT ON AERIAL CONTROL CONSOLE TO INDICATE A 5 OUT-OFLEVEL CONDITION. ALL BOOM FUNCTIONS ARE INOPERABLE WHEN CONDOR IS MORE THAN 5" OUT -OF-LEVEL NOTE TO CORRECT THIS CONDITION, REVERSE/CHANGE DIRECTION OF GROUND TRAVEL UNTIL INDICATOR LIGHTS GOES OFF 9 HIGH SPEED MODE FOR TRAVEL WORKS ONLY WHEN SELECTOR SWITCH IS IN 'HIGH" AND BOOM IS BELOW HORIZONTAl. AERIAL FUNCTIONS DO NOT OPERA TE WITH UNIT IN HIGH SPEED 10. IN CASE OF EMERGENCY. DEPRESS EMERGENCY STOP' BUTTON 35365

DEATH OR SERIOUS INJURY, SICHMAIIP I

32999-3

NO STEP 32991 THIS MACHINE IS NOT INSULATED

ELECTROCunON HAZARD \lAlNTAIN SAfE CLEARNICES FIIOM ELECTRICAL LINES AND AmRAruS. YOU 'lUST ALLOW FOR 800M .y, ROell OR SAG AND ELECTRICAL lift( AND LOAD ."NIl THIS AERial iIOfIII PlATFORM DOES NOT PROVIDE PROTECTION FROM CONTACT WITH OR I'IIOXIIliTY 10 AN ElECTRICALLY CHARGED CONQUCTOR 'IOU MUST MAlNTAI" ACLEARNICE OF AT LEAST :0 fEET BETWEEN AllY FIIJIT OF !ME WORK PlATFORM OR LOAO AIID AllY ELECTRICAL LINE OR AmRAruS CARRYlfII) ~p 10 50,000 VOLTS, ONE fOOT ADDITIONAl CLEARANCE IS REQUIRED FOR EVERY ADDITIONAl 30000 VOLTS OR LESS :EATH 'J. iER!OUS ·NIURY WILL ~ESW ,~c'" :J~fAC; JR 'NAOEaUATE CLEARANCE

)

32999- 2

EualOCUTIOIHAZAID KEEP CLEAR DUll. SIIIOUS "JUI' CAl IESUlI FIOM (OIIIACI WIll IllS E. . . . 01 WINKlE IF II SIIOIU • DKIIJWl' atAIQI.

32999-1

.--------------------------------~

WARNING

THIS UNIT IS NOT INSULATED AND MUST NOT BE OPERATED WITHIN 10 FEET OF ENERGIZED POWER LINES. 32994

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

)

)

DAILY INIPEmDN CHECKUIT IEFDRE UIINI CONDOR (REFER TO OPERATION/MAINTENANCE MANUAL FOR FACTORY RECOMMENDATIONS) 1. CHECK FLUID LEVELS IN HYDRAULIC AND FUEL TANKS AND BATIERY. 2. CHECK ENGINE CRANKCASE OIL, AND COOLANT FOR WATER-COOLED ENGINES ONLY. 3. VISUALLY INSPECT CONDOR FOR LOOSE OR MISSING PARTS, WEAR, WELD CRACKS, DENTS OR . OTHER SIGNS OF DAMAGE. 4. CHECK TIRES FOR WEAR, CUTS, AND INFLATION PRESSURE (PNEUMATIC TIRES ONLy).

5. CHECK ALL VISIBLE BOLTS, NUTS, PINS AND FASTENERS FOR PROPER INSTALLATION. 6. CHECK HYDRAULIC COMPONENTS, FLUID LINES AND FITIINGS FOR LEAKS. 7. INSPECT ELECTRICAL HARNESSES, CONNECTORS, CIRCUITS, AND BOOM MECHANICAL CABLES (3-SECTION BOOMS ONLY) FOR DAMAGE AND PROPER INSTALLATION. 8. CHECK 5° SLOPE SENSOR AND INDICATOR LIGHT FOR PROPER OPERATION. 9. CHECK TURRET ROTATION GEAR BOX, RING GEAR BOLTS AND LOCK-STRIPS FOR PROPER INSTALLATION. GENERAL DPERAnNI INmuenDNS 1. CHECK THAT TURRET LOCK-PIN IS REMOVED (APPLICABLE ONLY TO CONDOR MODELS WITH TURRET ROTATION LOCKING FEATURE FOR TRANSPORTING).

2. TURN MASTER SWITCH "ON" AT GROUND CONTROL CONSOLE. START ENGINE/MOTOR AND ALLOW UNIT TO WARM TO OPERATING TEMPERATURE. 3. POSITION SELECTOR SWITCH TO "GROUND CONTROL" AND TEST OPERATE ALL AERIAL FUNCTIONS FROM THE GROUND CONTROL CONSOLE. 4. POSITION SELECTOR SWITCH TO "AERIAL CONTROL", THEN ENTER THE WORK PLATFORM AND ATIACH THE SAFETY BELT/LANYARD. 5. REFER TO WORK PLATFORM "CAmDN" DECAL FOR ALL OPERATIONS IN THE PLATFORM. 6. FOR TRANSPORTING, USE EXTREME CAUTION WHILE LOADING/UNLOADING THE CONDOR UNDER ITS OWN POWER: • TRAVEL IN LOW SPEED MODE ONLY. • MAKE SURE BOOM IS FULLY RETRACTED AND BELOW HORIZONTAL. • ROTATE TURRET IN LINE WITH CHASSIS. • DO NOT EXCEED RAMP ANGLE OF 14° (2.5 FEET RISE IN 10 FEET).

35366 ...J

FIGURE 2A

SAFETY DECALS

CALAVAR SELF-PROPELLED CONDOR WARNINGBEFORE OPERATING UNIT, READ AND UNDERSTAND ALL OPERATING AND SAFETY INFORMATION IN THE MANUAL AND ON ALL PLACARDS. REFER TO INDIVIDUAL PLACARDS FOR SPECIFIC INSTRUCTIONS AT EACH CONTROL STATION. GENERAL INSPECTIONDAILYCHECK HYDRAULIC FLUID LEVEL CHECK BATTERY WATER LEVEL. ROUTINE INSPECTION FOR STRUCTURAL DEFECTS. INSPECT FOR DETERIORATION (A) FLUID LINES, (B)- ELECTRICAL CIRCUITS, (C) BOOM EXTENSION CABLES. CHECK ENGINE OIL AND FUEL LEVEL. 5MAXIMUM INTERVALS OF SO HOUR51-

234-

1-

)

23456-

CHECK GEAR BOX LUBE LEVELS. GREASE ALL PRESSURE GUN FITTINGS. INSPECT WHEEL DRIVE COMPONENTS. INSPECT STEERING COMPONENTS, AND WHEEL NUTS. INSPECT BRAKE COMPONENTS, AND FLUID LEVEL. VISUALLY INSPECT ALL MECHANICAL BOOM CABLES FOR ANY SIGNS OF DAMAGE. REPLACE IMMEDIATELY ANY DAMAGED CABLE. CONTINUED USE OF CONDOR WILL RESULT IN A DANGEROUS CONDITION TO OPERATOR AND EQUIPMENT.

GENERAL OPERATING INSTRUCTIONS1TURN MASTER SWITCH ON AT GROUND CONTROL STATION. 2POSITION SELECTOR SWITCH TO GROUND CONTROL, AND TEST OPERATE ALL AERIAL FUNCTIONS FROM THE GROUND CONTROL STATION. 3POSITION SELECTOR SWITCH TO AERIAL POSITION. 4REFER TO WORK PLATFORM INSTRUCTION PLACARDS FOR ALL OPERATIONS IN THE PLATFORM. 5REFER TO THE PLACARD ON THE REMOTE CONTROL BOX FOR OPERATIONS FROM THE REMOTE STATION. 21415

)

)

(

60N LOAD CAPACITY 500 LBS. CAPACITY INCLUDES PERSONNEL & ·EOUIPMENT 30348

)

CAUTION. CAUTION. CAlITlON

REMOVE TURRET LOCK-PIN BEFORE ROTATING TURRET 32998

-

FIGURE 2A

)

SAFETY DECALS

9200 S. Sorenson Ave. Santa Fe Springs, CA. 90670 CONDOR MODEL-

-------- SERIAL

ND-

--------

ASSEM Bl Y NO - _______________________ PART NO-__________ DATE OF MFG-_ _ ___ MAXIMUM PLATFORM HEIGHTMAXIMUM HORIZONTAL

-------------REACH---------

RATED WORK LOAD -

LBS.

HYDRAULIC OPERATING PRESSURE U.S. PATENT 4,506,480 THIS UNIT IS NOT ELECTRICALLY INSULATED THIS MOBILE UNIT CONFORMS TO ALL APPLICABLE REQUIREMENTS OF ANSI A92.5-1980

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OPERATION AND:; SAFETY MANUAL ~

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CARRIAGE ASSEMBLY

DESCRIPTION

1 Carriage Weldment 2- -Air Cleaner Modification 3 Cover, Rear 4 Engine & Pump Assembly 5 Ring Gear 6 Cover, Eng i ne 7 Muffler 8 Tire & Wheel Assembly - Steering 9 Tire & Wheel Assembly - Drive 10 Steering Assembly 11 Cover, Lower Rear 12 Drive Motor Assembly 13 Torque Hub 14 Cover Plate 15 Battery 16 Hydraulic Tank Assembly 17 Fuel Tank Assembly 18 Capscrew, Hex Hd. 3/8" - 16 UN C X 1" 19.

19 Battery Hold-Down 20 J-Bolt , 5/16" -18UNCx 12-1/2 11 19.

21 Battery Cable, PBL-19 22 Cover, Side Vent-LH 23· Cover, Side Vent -RH 24 Lockwasher, 3/8 11 25 Capscrew, Hex Hd. 1/2 11 - 13 UNC x 2" 19.

26 Lockstrip Nut, Lock 1/4 11 -20UNC 27 28 Lockwasher, 1/4" 29· Capscrew, Hex Hd. 1/4" - 20 UNC X 5/8 11 Lg. 30 Lockwasher, 1/4 11 31 Nut, Hex 5/16" - 18 UNC 32 Battery Cable, 55 11 Lg. 33 Capscrew, Hex Hd. 5/8" - 11 UNC x 411 Lg. 34 Lockwasher, 5/8" 35 Lug Nut, 3/4" - 16 UNF 36 Lug Nut, 5/8" - 18 UNF 37 Hub Assembly 38- - Battery Coble 39 Flexible Hose 40 Solenoid, Choke 41 Solenoid, Throttle 42 Engine Shroud Assembly 43- I--Electric Motor and Pump Assembly 44- r--Filter, In Line 45- r-Battery Cable 46- t-- Battery Cable

(60N)

PART NUMBER

QTY

30203 Ref. Figure 30338 68392 21922 30337 Ref. Figure -303lJ 30312 Ref. Figure 30339 Ref. Fig. 4 Ref. Figure 68223 32614 Ref. Figure Ref. Figure

1 1 1 1 1 1 1 2 2 1 1 2 2 2 1 1 1 16 1 2 1 1 1 16 26 9 4 4 8 8 2 1 9 9 20 20 2

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18

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80299

30320-1 30320-2

68226 BOW34272 BOW31373

Grade 8

Ref. Fig. 5 Ref. Figure 5 67246-001 Ref. Figure 19 32111 ...

32111· 30345· Ref. Fig. 20 50148 67296-022 67296-025

1 1 1

1 1 1 1 1 1

3/83

FIGURE 3A

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I

M N

CARRIAGE ASSEMBLY

(60N)

DIESEL ENGINE OPTION

FIGURE 3A

REF

CARRIAG E ASSEMBLY

DESCRIPTION

(60N) DIESEL ENG INE OPTION

PART NUMBER

QTY

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7

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8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29· 30 31 32 33 34 35 36 37 38 39 40 41 42

Carriage Weldment

30203

Cover, Rear Diesel Engine & Pump Assembly Ring Gear Cover, Engine Muffler Tire & Wheel Assembly - Steering Tire & Wheel Assembly - Drive Steering Assembly Cover, Lower Rear Drive Motor Assembly Torque Hub Cover Plate Battery Hydraulic Tank Assembly Fuel Tank Assembly Capscrew, Hex Hd. 3/8 II - 16 UN C X 111 Lg. Battery Hold-Down J-Bol t, 5/16" - 18 UNC x 12-1/2" Lg. Battery Cable, PBL-19 Cover, Side Vent-LH Cover, Side Vent -RH Lockwasher, 3/8" Capscrew, Hex Hd. 1/2" - 13 UNC x 2" 19.

Lockstrip

30338 See FiQ;~-~_9 21922 30337 Ref. Figure 18A 30311 30312 Ref. Figure 7 30339 Ref. Fig. 4 Ref. Figure 4 68223 32614 Ref. Figure 15 Ref. Figure 14

Capscrew, Hex Hd. 1/4" - 20 UNC Lockwasher, 1/4" Nut, Hex 5/16 11 - 18 UNC

80299

30320-1 30320-2

68226

1 1 1 1 1 2 2 1 1 2 2 2 1 1 1 16 1 2 1 1 1 16 26 9

8 8 2

5/8" Lg.

...

Capscrew, Hex Hd. 5/8" - 11 UNC x 4" Lg. Lockwasher ,. 5/8" Lug Nut, 3/4" - 16 UNF Lug Nut, 5/8" - 18 UNF Hub Assembly Battery Cabl e

43- r-Electric Motor and Pump Assembly

44- r--Filter, In Line 45- I--Battery Cable 46

X

1

Battery Cabl e

Grade 8

Ref. Fig. 5 Ref. Figure 5 67246-001

Ref. Fig. 20 50148 67296-022 67296-025

9 9 20 20 2 1

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FIGURE 4

TORQUE DRIVE ASSEMBLY

(60N)

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FIGURE 4

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

11

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12 13 14 15 16 17 18 1920 21 22 23 24 25

TORQUE DRIVE ASSEMBLY

DESCRIPTION

(60N)

PART NUMBER

30363 Hose Assembly 30365 Tube Assemb I y 30356 Tube Assembly 30355 Tube Assembly 30357 Tube Assembly 30358 Tube Assembly 30361 Tube Assembly 30360 Tube Assembly 30359 Tube Assembly 30362 Tube Assembly 2662 Elbow, 90° 2215 Elbow, 90° 4007 Elbow, 90° LLWasher Flat 5/8" 2448 Connector, STR 266 Connector, STR 32799Drive Block 11 r-G rad~_8 Capscrew, Hex Hd. 5/8 - 11 UNC x 2-:-.1/21' Lg.30381 Torque Drive Hub Lockwasher, 1/2 11 21568 Hydraulic Motor Capscrew, Hex Hd. 1/2 11 - 13 UNC x 1-1/411 Lg. 2662 Elbow, 90° 30364 Tube Assembly Nut, Hex (Bowma-Grip) 5/8 11 - 11 UNC

QTY 1 1 1 1 1 1 1 1 1 1 4 2 4 16 4 4 1 16 2 4 2 4 1 1 16"~

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