CONDOR Scissor Lift 3172 Parts Manual - PDF DOWNLOAD

A dive of TIME Manufacturing Company

January 1, 1996

O'Flaherty Holdings Limited has announced that two of their U.S.A. holdings will merge into one company. Time Manufacturing and Calavar Corporation, both Waco, TX companies, will merge their operations on 1 January 1996.

Our newly formed company is twice the size with over 600 employees. The company will be called: TIME MANUFACTURING COMPANY. Since Calavar is better known by the CONDOR® product name, the following name change will evolve.

SHIPPING ADDRESS

MAILING ADDRESS

CONDOR®

CONDOR®

A DIV. OF TIME MFG. co.

A DIV. OF TIME MFG. co.

8300 IMPERIAL DRIVE VVAco,TExAs76712 (817) 666-4545

P.O. Box 21447 VVAco,TExAs76702-1447 (817) 666-4545

(817.) 666-4545 Telephone, (817) 666-5125 Voice Mail, (800) 443-5803 Fax

Our address and phone numbers remain the same as do the names of the people you deal with. We thank you for your business and we thank you for your support.

PARTS MANUAL SELF-PROPELLED AERIAL WORK PLATFORM

3172 SCISS

CALAVAR CORPORATXOB provides this manual

for the guidance of all owners, operators and servicing personnel in order to obtain the longest possible trouble-free service. It contains general data, operating instructions, lubrication procedures, mantenance procedures, illustrated parts breakdown, vendor's information and safety rules. Additional copies of this parts book (PIN 92275) may be obtained through the Parts Department at CALAVAR.

ial No • . te Del i vered customer ________________________

~

SHOWN MODEL 3172G

CORPORATION

MANUAL 92275 -00\ 8300 IMPERIAL DRIVE. WACO. TEXAS 76712 (817 )666-4545 FAX (817 )666-4544

2'••

FROM SDI~ ...

ISSUBD _ _ _ _ 11'1

INTRODUCTION

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 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 and safety. The various decals attached to this machine also contain vital safety and operational instructions. Read the decals before operating this machine.

It is YOUR RESPONSIBILITY to follow safe procedures while operating the CONDOR®.

The manufacturer of this unit 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 the safety of all personnel when making decisions regarding the unit's intended use.

It is also YOUR RESPONSIBILITY to understand and obey all federal, state, and local regulations regarding the safe operation and use of aerial work platforms. A copy of the ANSI/SIA 92.6-1990 Manual of Responsibilities is attached for your use.

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 UNIT WITHOUT PRIOR WRITTEN APPROVAL FROM THE MANAGEMENT OF CALA VAR CORPORA TION

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 machine.

TABLE OF CONTENTS GBDOL SEeTIO. Specifications· •••••.••.••.•..••..••.••....•••.•.••.•.••. 1 Introduction 1. Description of Scissor ••••••••••••••••••••••••••• 2 2. operator's Qualifications •••••••••••••••••••••••• 2 3. Danger, caution and Warning Decals ••••••••••••••• 3 Warranty •••••••••••••••••••••••••••••••••••••••••••••••• 5 Warranty. Claim •••••••••••••••••••••••••••••••••••••••••• 6 How to F1ll Out - Procedure ••••••••••••••••••••••••••••• 7 Loading Transporting and Unloading .

1. Loading and Unloading •••••••••••••••••••••••••••• 8 2 • Ramp Method •••••••••••••••••••••••••••••••••••••• 8 3. Forklift Loading/Unloading Method •••••••••••••••• 8 4 • Transportinq ••••••••••••••••••••••••••••••••••••• 9 Conversion Table Degrees to Percentage •••••••••••••••••• 9 Pre-Operation Inspection 1. Overall Machine Condition ••••••••••••••••••••••• 10 2• 3.

Platform •••••••••••••••••••••••••••••••••••••••• 10

2•

Travel •••••••••••••••••••••••••••••••••••••••••• 12

Batteries/Charger ••••••••••••••••••••••••••••••• 11 4. Hydraulic System •••••••••••••••••••••••••••••••• 11 5. Engi~e •• : ••• 6'••••••••••••••••••••••••••••••••••• 11 6. Mult1-Ax1S 5 Slope Sensor •••••••••••••••••••••• 11 Control Familiarization and Limitations 1. Platform Capacity ••••••••••••••••••••••••••••••• 12 3.

Ground Controls •••• ~ •••••••••••.•.•••••••••••••• 13

4 • Platform Controls ••••••••••••••••••••••••••••••• 14 Operational Procedure 1. Operation from Ground Controls •••••••••••••••••• 15 2. Ope~atio~ from Platform Controls •••••••••••••••• 16 3.

4•

L1m1t Sw1tch •••••••••••••••••••••••••••••••••••• 17 Shut Down ••••••••••••••••••••••••••••••••••••••• 17

5. EmergencI Lowering •••••••••••••••••••••••••••••• 17 6. Brake Re eased/Free Wheeling •••••••••••••••••••• 17 Preventative Maintenance 1. Serv-i'c:e Tools •••••••.•••••••••.••••••••••••.•••• 18 2. Hydrautic System Care and Maintenance ••••••••••• 18 3. Batter1es .•.•........•.......................... 19 4. Battery Charging •••••••••••••••••••••••••••••••• 20 5. Engine •••••••••••••••••••••••••••••••••••••••••• 20 How to Order Parts ••••••••••••••••••••••••••••••••••••• 21 Warranty Return Authorization Form ••••••••••••••••••••• 23 Do Not Rules ••••••••••••••••••••••••••••••••••••••••••• 24

VBNDOR SBCTIO.

Kohler M 18S Gasoline Engine Eskridge 95W Multiple Disc Brake Parker Hydraulic PUmp TRW MAE Wheel Motor TRW ME Brake Whe.el Motor PARTS SBCTIO. Illustrated Parts Breakdown SAFETY SBCTIO.

SPECIFICATIONS SPECI FICATIONS

MODEL 3172 ELECTRIC

MODEL 3172 GAS

Maximum Working Height Extended Platform Height Stowed Platform Height Overa 11 Length Overa 11 Wi dth Removable Safety Rails Inside Platform Size Platform Capacity Gross Weight Power System Stabilizers Battery Capacity Number of Batteries Battery Voltage Battery Charger Toe Plate Wheel Base Wheel Track Tires Inside Turning Radius

31 ft.

25 ft.

4 ft. 3.5 in.

12 ft.

6 ft.

3 ft. 6 in.

140 x 68.5 in.

1,500 lbs.

5,520 lbs.

24 volt Optional 375 amp

31 ft.

25 ft.

4 ft. 3.5 in.

12 ft.

6 ft.

3 ft. 6 in.

140 x 68.5 in.

1,500 lbs.

5,120 lbs.

18 hp Optional 95 amp

8

1

6 volt 40 amp 7 ft. 6 in.

5 ft. 1 in.

26 x 12.00 x 12 9 ft. 3.5 in.

12 volt N/A 6 in.

7 ft. 6 in.

5 ft. 1 in.

26 x 12.00 x 12 9 ft. 3.5 in.

19 sec.

22 sec.

19 sec.

22 sec.

3.2 mph 2.5 mph 0.75 mph 8 ft.

11 ft. 6 in.

2.5 mph 1 mph 0.75 mph 8 ft.

11 ft. 6 in.

OPERATIONAL FUNCTION TIMES

6 in.

(+ 10%)

Lift Up Lower Down DRIVE SYSTEM TIMES

High Speed Low Speed Creep Speed High Speed Cut Out Creep Speed Cut Out

The CONDOR Model 3172 is designed and built to conform to CALAVAR'S understanding and interpretation of all applicable OSHA rules and regulations as well as ANSI standards: •

OSHA Title 29, Paragraph 1910.67 - - - - -

Vehicle Mounted Elevating and Rotating Work Platforms - Labor

•

OSHA Title 29, Paragraph 1926.556

Aerial Lifts - Construction Self-Propelled Elevating Work Platforms

• ANSI Standard A92.6-1979 - -

CAUTION' It is imperative that all owners and operators of the CONDOR read, understand and conform to these regulations.

Ultimate compliance to prevailing OSHA regulations is the RESPONSIBILITY of the employer utilizing the equipment.

1

INTRODUCTION The primary purpose of this manual is to assist the operator and maintenance personnel to better understand L operate, and maintain the self-propelled CONDOR SCISSOR aerial work pla~form in a safe and proficient manner.

This manual has been produced as a valuable tool for our customers. It consists of a General section, Vendor section~ Illustrated Parts Section, and Safety Section. It is in the best interest or everyone involved with the operati9~~ maintenance, and repair of the machine to READ and thoroughly UNDERSTAMU all sections of this manual.

In general, this manual covers the servicing of the machine and associated standard egvipment. In some cases CONDORS are supplied with various options and speciaIized equipment. If service information is not found in this manual and information is re~ired it is suggested that CALAVAR customer Service Department be contacted. The proper 1nformation will then be forwarded if available at time of request.

All product descriptions, illustrations and specifications were in effect at the time the manual was released for printing. CALAVAR CORPORATION reserves the right to make changes in design or to maRe additions to or improvements in its products with9ut imposing any obligations upon itself to install them on its products prev10usly manufactured.

1. DESCRIPTION OP SCISSOR The CONDOR SCISSOR is a vertical Scissor arm aerial work platform and is rugged, maneuverable and safe. It is designed for work on firm level surfaces with normal operation controlled by an operator using a control box in the platform. All operational modes can be accomplished from the platform 1ncluding drive and steer. The CONDOR provides industrial, construction and ma~ntenance workers the ability to safely elevate and perform installation, ma1ntenance, and replacement tasks.

The Model 3172 is powered by a Kohler Model MI8 air-cooled gasoline engine rated, at 18 horsepower, at 3,000 RPM. Electrical unit is powered by six volt D.C. L eight batter1es producing a 24 volt D.C. system. Each battery is rated at 3/5 ampere hours. A 24 volt, 40 amp batte~ charger with 110V input is used to recharge the batteries after each day's use. Hydraulic system is 8.5 GPM @ 3,000 RPM at operating pressure of 2,400 psi.

2.

OPERATORS QUALIPICATIONS Each CONDOR SCISSOR has undergone a thorough Quality Control inspection at CALAVAR. The design incorporates built-in safety features. A person of average skill can readily become proficient and safe in the operation of the CONDOR. It is a personnel lifting device and can be potentially DANGEROUS in the hands of UNTRAINED or CARELESS OPERATORS. Knowing the characteristics of the machine and function of the controls is important to SAFE, PROPER OPERATION AND USE. Become familiar with the controls and prac~ices will result in smooth,L accurate positioning. It is the responsibility of all users to READ and COHP~Y with the following RULES and information designed to promote SAFETY and UNDERSTANDING of the CONDOR. • A thorough understanding of the operating characteristics and limitations of the CONDOR is always the first req¥irement for any use~, regardless of his prior experience with similar types of equ1pment.

• Only QUALIPIED/TRAINED and AUTHORIZED personnel must be allowed to opera~e the CONDOR. A QUALIFIED/TRAINED operator is one who has READ ana UNDERSTOOD the instructions in this manual and is thoroughly fa1piliar with the operating characteristics and limitations of the un1t.

• KNOW and POLLOW all cautions, warnings and operating instructions on the CONDOR.

2

•

Repairs and adjustments should be made only by QUALIFIED/TRAINED personnel.

•

No MODIFICATION is to be made to the unit without prior written consent of the CALAVAR Engineering Department.

•

UNDERSTAND and OBEY all Federal, State and local statutes and regulations applying to safe operation and use of aerial work platform.

YOUR SAFETY IS OUR UTMOST CONCERN AND YOUR RESPONSIBILITY

3. DANGER, CAUTION and WARNING DECALS are designed for your protection. and adhere to the information they provide.

STOP

CAUTION GUARD RAILS AND SAFETY CHAINS MUST BE SECURED AND USED AT ALL TIMES

READ OPERATING INSTRUCTIONS BEFORE OPERATING MACHINE

- WARNINGDO NOT WORK UNDERNEATH THIS LIFT UNLESS ARM STAND IS LOCKED IN PLACE See Service Manual for Location

UNLAWFUL TO OPERATE THIS EQUIPMENT CAUTION CAUTION CAUTION CAUTION WITHIN 10 FEET OF HIGH VOLTAGE LINES

LOAD CAPACITY (EVENL Y DISTRIBUTED LOAD)

MODEL 3172 ------- 1,500 LBS.

3

Know

CHECK BATTERY WATER LEVEL ONCE A WEEK.

BATTERY CHARGER PLUG 115 VOLT ONLY

This machine has been designed and tested to meet these standards:

FREE WHEELING· VALVE )

ANSI A92.2 1969 ANSI A92.3 1973 OSHA GISO 1910.67

OPERRTION SHEET WRRNING: Mochine is to be used on leuel ground only.

WRRN ING: Don't eHceed lood limit on specfic models.

1. STRRTING:

3. LIFT:

A. Tum Master Disconnect Switch On

A. When raising and Io'(t'ering the platform from the

B. Pull out the power switch on the lower control panel.

C. Push selector switch to UP on the lower control panel.

D. pun out the emergency ONtOFF button in the center of the upper control box.

lower control panel. make sure that the selector switch, in the lower control panel. is in the down position. Push the toggle switch for lift to either the up or down position.

B. Raising and lowering the platform from the upper control box, first make sure that the selector switch in the lower control panel is in the up position. Push in the dead man switch on the lett side of the upper control box. ftJ. the same time push the lift switch to the up position.

C. Both rift switches are of the momentary type; when the switch is released It will automatically return to the off position.

2. STEER I NG:

A. The steering is done by pushing in on the dead man switch on the left side of the upper control box and. by pushing the toggle switch for steering.

B. Pushing the steering switch to the left, the front wheels will go lett and remain to the left until the toggle switch is pushed to the right.

C. The steering switch is a momentary type switch. When the operator releases the switch It will automatically return to the off position.

4. DRIUE: A. Forward and reverse travel is done from the upper control box only.

B. The machine has two speeds, high and low. Select either high or low speed with toggle switch marked high or low speed.

C. Push the dead man switch in and then push the toggle switch marked drive forward or reverse.

S. FREE WHEELING:

A. For loading, Unloading and free wheeling at low speed without damage to any of the components or structure.

B. Free wheeling valve Is on cross member at rear of machine.

4

WARRANTY

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 orworkstoppage, 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 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· 817-666-4545,800-877-5544,817-666-4544 FAX Form No. 513-3M-392

Effective Date 911190

5

WARRANTY ClAIM FORM

WARRANTY CLAIM

OJ

P.o. BOX 21447, WACO, TEXAS 76702-1447 817-666-4545 800-877-5544 FAX 817~66-4996

NAME ADDRESS

OWNER

0

DEALER

0

MAIL TO

CALAVAR CORPORATION

CITY

STATE

ZIP

NAME SUBMITTED BY ADDRESS CITY

0

STATE

0

ZIP

DEALER CLAIM NO. UNIT SERIAL NO.

MODEL

CALAVAR WARRANTY NO.

DELIVERY DATE

RETURN AUTHORIZATION NO.

IN SERVICE DATE

DATE PARTS RET.

DATE OF CLAIM

DATE OF FAILURE

DATE OF PARTSREPL

CONDOR

0

QTY.

FIREBIRD

0

SCISSORS 0

[!]

PART NUMBER

[£]

REPLACEMENT PART 0

INVOICE NUMBER

DESCRIPTION

LABOR HOURS

LABOR DESCRIPTION

LIST EACH

AMOUNT CLAIMED

LABOR

NET AMOUNT

TOTAL PARTS TOTAL LABOR

r

TOTAL LABOR .. PARTS

DATE:

APPROVED BY:

[!] CALAVAR THIS SPACE TO BE USED FOR APPROVAL ONLY

APPROVED AMOUNT

REMARKS: PARTS LABOR TOTAL

APPROVED

0

WHITE - CALAVAR

DENIED

0

GREEN - CALAVAR

DATE:

SIGNED YELLOW - DEALER FILE COPY

PINK - CALAVAR

6

GOLDENROD - CALAVAR

USA Prin_ FORII392

2'92

WARRANlY CLAIM PROCEDURE WARRANTY CLAIM This procedure ;s offered to assist you in properly filling out the Warranty Claim Form.

The more information supplied on this form, the better CALAVAR can evaluate the problem and expedite processing.

The form should be typed or filled out legibly in ink. Several copies are utilized, thus ensure sufficient pressure is applied to make all copies legible.

HOW TO FILL OUT - PROCEDURE 1.

Where to mail claim - CALAVAR'S address, phone number.

2.

Dealer information: Name of company, address, name of person submitting claim. This will be the name used on all correspondence.

3.

Owner information: "SAME

Name of company, address.

If same as No.2, write

II •

4.

Claim information: A.

Dealer's claim number: This is necessary as there may be more than one claim for this unit.

B.

CALAVAR warranty number: This will be completed by the Warranty personnel at CALAVAR CORPORATION.

C.

Return Authorization number: If CALAVAR deems that the defective material be returned, a return authorization number will be assigned and appropriate paperwork will be mailed to the dealer/owner. Upon receipt of the paperwork, the dealer is to ship the parts freight prepaid to CALAVAR for evaluation and further disposition.

All dates pertinent to the claim are to be registered.

5.

This area is provided to identify the unit: It is important to furnish serial number, date of delivery (date received by you), inservice date (date unit is sold by you or put into operation), model number.

6.

This area is for part number(s) and description(s). The CALAVAR invoice number and amounts are necessary in order to properly process the claim. All dollar amounts are to be in U.S. currency.

7.

A detailed labor description is required in order to fully evaluate the hours of your claim and the amount CALAVAR will approve.

8.

This area is filled in by CALAVAR personnel and is for approval or denial of the claim and a brief explanation of steps taken.

9.

Upon completion of form, remove light yellow copy titled "Dealer Copy," retain, and send remaining copies to CALAVAR. 7

LOADING .. TRANSPORTING .. UNLOADING 1.

LOADING AND UNLOADING The CONDOR SCISSOR, although somewhat small in stature compared to larger type construction equipment, still requires the same care and attention in LOADING, TRANSPORTING, and UNLOADING, as does the larger, heavier type equipment. At no time should sight of this be OVERLOOKED. Before loading/ unloading the CONDOR, inspect for any physical damage or defects. DO NOT OPERATE A DEFECTIVE OR MALFUNCTIONING UNIT. The CONDOR SCISSOR Model 3172 electrical unit weighs approximately 5,520 lbs., and gas unit is approximately 5,120 lbs. Whatever means is used to load/unload the unit, should be of sufficient strength to withstand the weight of the CONDOR. DO NOT attempt to OPERATE the unit UNTIL you have READ and thoroughly UNDERSTOOD all INFORMATION provided on the operation of the CONDOR. FAMILIARIZE yourself with the CONTROLS, their FUNCTION and OPERATION.

2.

3.

RAMP METHOD A.

Ensure that ramp being used is sufficiently strong to handle the weight of the unit.

B.

Ramp should be set at an angle no steeper than 18° or 32%. rise in 10 feet.

C.

Before driving the unit on the ramp, test all the controls and the brake system. Then move the CONDOR slowly back and forth.

D.

Move the unit on the truck or trailer, up or down the ramp approximately a foot at a time allowing the steering corrections to be made. Keep unit in alignment with the carrier and ramp during loading or unloading procedure.

39 inches

FORKLIFT LOADING/UNLOADING METHOD A.

Ensure that forklift has sufficient capacity to handle the weight of the CONDOR.

B.

The forks should be long enough to completely go across the width of the frame and should be positioned as close to the inside of the tires as possible. When lifting unit, center the forklift between the CONDOR tires.

C.

Unit should be picked up from side of unit and should only be raised to a height to clear any obstructions.

D.

Keep forklift travel with CONDOR load to a minimum and set gently down to ground level.

8

4.

TRANSPORTING The CONDOR can be easily and safely transported from job site to if a few simple rules and procedures are followed:

job site

A.

Block all wheels to prevent forward and reverse motion.

B.

Tie down the CONDOR with chains or cables, running them through the tie-down brackets only. DO NOT chain or strap OVER the platform or GUARD RAILS. Severe damage to the scissor arms may result from excess pressure due to securing the unit over the top of the platform.

CONVERSION TABLE (DEGREE TO PERCENTAGE) Since the conversion of gradeabiLity is often referred to in percentages and then on the other hand often referred to in degrees, this chart is being provided for your convienlence to quickL~ convert percents to degrees.

100795790785% 80775770765% 60755% 50745740735% 30725720715%

8300 IMPERIAL DRIVE, WACO, TEXAS 76712 {817}666-4545 FAX {817}666-4544

lOr.

5%

----- 700 ft. -----

9

PRE - OPERATION INSPECTION The CONDITION of the unit prior to start-up is a very IMPORTANT FACTOR as it directly affects the operator's SAFETY. It should be a common practice that the operator perform a general inspection before each day's operation of the work platform.

The purpose of the operator's inspection is to keep the CONDOR in PROPER working condition and to DETECT any sign of malfunction during normal operations between scheduled maintenance checks.

DOWNTIME is COSTLY and can be prevented by taking a few minutes prior to start-up. A thorough walk-around inspection must be performed each day before the CONDOR is operated. Report damage of faulty operation immediately. Attach a sign at the ground control area stating liDO NOT OPERATE. Repair any discrepancies before use. Some of the major items to check are: II

1. OVERAll CONDOR CONDITION A.

Ground/platform controls - all controls are to function properly.

B.

Hydraulic leaks.

C.

Electrical system for frayed or broken wires or loose connections.

D.

Missing, broken, or damaged parts, pin retainers, bolts and nuts.

E.

External structural damage, or cracked welds.

F.

Condition of tires - pits, tears, cracks, or cuts.

G.

Steering connections, tie rod, cylinder.

H.

Wheel lug nuts - missing or loose.

I.

Decals, placards, and warning signs.

J.

Proper tire pressure.

K.

Scissor arms - pivots, connections, and lift cylinders.

2. PLATFORM A.

Pivot pOints, connections.

B.

Structural condition - damaged railings, flooring.

C.

Control box - electrical wiring for frayed or broken wires, damaged components, hoses, loose connections.

D. Access opening, chain, fasteners.

10

3.

4.

5.

6.

BATTERIES/CHARGER A.

Electrolyte level - all caps present.

B.

Cables and connections - ground connection.

C.

Battery hold down.

D.

Charger condition, meter, electrical plug.

HYDRAULIC SYSTEM

A.

Hydraulic leaks.

B.

Loose or damaged hoses, tubing.

C.

Fluid level hydraulic tank breather cap. Refill only with shell Tellus T-32'or Mobil DTE - 13M. DO NOT MIX different brands of hydraul i c oil.

D.

Hydraulic valves and control levers.

E.

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

ENGINE (ENGINE POWERED UNIT) A.

Mounts and mounting bolts.

B.

Fuel tank level and connections

C.

Fuel leaks

D.

Condition of belts

E.

Oil condition, level and leaks

MULTI-AXIS 5°SLOPE SENSOR (OPTIONAL) A.

General condition

B.

Loose or damaged wires

C.

Push to test.

D.

Warning buzzer in platform ;s operable

Moveable on mounting

KNOW THE UNIT AND ITS CAPABILITIES. Report any unusual operation. sway or motion of arms or platform while being operated. Excessive, noise, abnormally slow or fast operation.

I

Erratic unusual

CAUTION'

Defective components, structural damage, missing parts or equipment malfunctions jeopardize the SAFETY of the operator and other personnel and can cause extensive damage to the CONDOR. A POORLY MAINTAINED machine could become the greatest OPERATIONAL HAZARD you may encounter.

11

CONTROL FAMIUARIZATON AND LIMITATIONS It is important from a SAFE operational standpoint that you, the operator, know the function of each control, its limitations, as well as that of the unit. A good understanding of the controls, limitations and capabilities will enhance operation and assure maximum operating efficiency and safety.

1.

PLATFORM CAPACITY The platform capacity of the CONDOR SCISSOR is unrestricted and is applicable within the operational envelop/positions when operated on a firm level surface and slope not exceeding 5°. The capacity includes the required OSHA and ANSI safety margin. DO NOT lessen the SAFETY MARGIN by overloading the platform beyond RATED CAPACITY. PLATFORM CAPACITY - - - - - - 1,500 lbs.

The platform capacity noted above is the COMBINED WEIGHT of all personnel, their tools, and any other equipment or materials carried by the platform.

Larger platforms require de-rating capacity.

I

WARNING'

Proper stability of the CONDOR is based and tested on the standard unit and all of its components as supplied by CALAVAR. Any modifications of the unit, either by the addition or removal of parts and/or weight can greatly affect the unit1s STABILITY and SAFETY. 2.

TRAVEL Travel can be accomplished from both the stowed position or with platform elevated. Although the gradability of the unit is 18° or 32%, this should only be negotiated with the platform in stowed position. The CONDOR is designed to travel with platform elevated on FIRM LEVEL surfaces and slopes not exceeding 5°. The parking brake is spring applied and hydraulically released. This brake releases when the drive circuit is energized.

Maximum travel speed is 2.5 MPH for gas unit and 3.2 MPH for electrical unit.

This is high speed travel and is available when platform is in the stowed position (fully lowered). Low speed mode is available by moving high/low SPEED toggle switch to II LOW. II Creep speed mode is automatically shifted when scissor is elevated 1116" high.

Steering is accomplished through a tie rod and hydraulic cylinder arrangement. Although the STEERING toggle switch is momentary, return to center position, the steering system itself is not self-centering. Therefore, the toggle switch direction must be reversed when turn is completed in order to return to straight line travel. DEPRESS and HOLD appropriate side of switch for desired steering direction. II FORWARD " motion is determined with STEERING wheels leading the way. DRIVE toggle switch AWAY from the operator for FORWARD motion; TOWARD the operator for REVERSE motion.

12

Prior to making any attempt to operate the CONDOR SCISSOR, it is essential that the operator be thoroughly familiar with the location and function of each control. The following will assist in accomplishing this required understanding.

3.

GROUND CONTROLS The ground controls are primarily emergency type controls. The panel is located on the left-hand compartment facing forward. Driving and steering is not possible from this location.

• KEY SWITCH The ground control has a MASTER DISCONNECT SWITCH. The key straight up center position is IIOFF" and disconnects power. With switch in IION II position, the electrical circuit is energized. Gasoline engine unit, actuate switch II START II to start engine. Switch must be IION II to energize ground or platform controls.

• CHOKE SWITCH Pump switch to activate engine choke. May be used in conjunction with engine START key switch. Purpose to assist starting of engine first time in morning or after long periods of non-use. Actuate CHOKE switch npUSH INII for operation.

• POWER BUTTON The control panel has a 2 position POWER switch: npUSH OFF n position disconnects all power from the batteries; the IIPULL ON n position energizes the power circuit.

• SELECT SWITCH Two-positioned toggle switch for selection of operation from ground control or platform controls. The IIDOWN II position directs the power to the ground control panel. The "UP" position directs the power to the aerial platform controls.

• LIFT SWITCH Momentarily, return to center, toggle switch to raise or lower scissors.

Actuate switch to IIUP" position RAISES scissors; nDOWN" position LOWERS scissors.

• CIRCUIT BREAKER A 20 amp circuit breaker is used to protect the electrical system. Should it pop out, it is due to overload or short-circuit; and cause should be investigated before further operation .

.13

4.

PLATFORM CONTROLS The platform controls are located on a movable console and can be slid over the top railing of the platform which gives the best control advantage for the operator. The platform control box contains controls for complete operation of the units. The controls are energized only when the FOOT SWITCH is depressed and held. The platform control box contains the following controls:

• EMERGENCY ON/OFF BUTTON "PULL" to turn ON and "PUSH H to turn OFF. NOTE - This is also an emergency switch. PUSH TO STOP ALL FUNCTIONS. • DRIVE FORWARD/REVERSE "FORWARD" motion is determined with STEERING wheels leading the way.

REVERSE motion is determined with DRIVE wheels leading the way.

II

II

• HIGH/LOW SPEED Toggle switch for selection of travel speed. Actuate switch "AWAY" from operator for HIGH speed; "TOWARD" operator for LOW speed.

NOTE - High speed can only be obtained with stowed position. CONDOR has three speeds; at 8 ft., the LOW speed, and at 11 ft. 6 in., the LOW speed will automatically be activated. This will occur even if HIGH/LOW switch is in HIGH position.

• STEER - LEFT/RIGHT Toggle switch for control of steering wheels. Switch is momentary, meaning it returns to center position when released. Actuate switch to "LEFT" to turn wheel s for LEFT turn; "RIGHT" for RIGHT turn.

• LIFT - UP/DOWN Toggle switch for raising or lowering scissor. Move switch HAWAY" from operator to UP scissor; "TOWARD" operator to DOWN scissor.

STEER LEFT

RIGHT

(Q)

LIFT

EMERGENCY

SPEED

DRIVE

UP

PULL ON

HIGH

FORWARD

(Q)

@

(Q)

(Q)

PUSH OFF

LOW

REVERSE

DOWN

14

OPERATION PROCEDURE Prior to operation of the CONDOR for your OWN SAFETY, it is your RESPONSIBILITY to ensure that the unit is in proper working condition and that the PRE-OPERATION INSPECTION has been performed.

I

CAUTION

I

Located on the inside cover of Safety ManualP/N: 92271 are a few DO NOTS relative to proper operation and maintenance. ACQUAINT yourself with these simple RULES and be ALERT to their signs.

I

WARNING'

OBSERVE ALL SAFETY PRECAUTIONS WHILE OPERATING THE CONDOR. Before starting, on battery power units, disconnect the external power source from the machine1s battery charger. On engine powered units, check fuel level for any leaks in fuel system.

1.

OPERATION FROM GROUND CONTROLS

•

Pull out the POWER switch to IION II position.

•

Gas unit, turn KEY switch IION II to position. Engine power unit required IISTART. It may be necessary to choke engine. Actuate CHOKE switch, IIPUSH INII for operation.

II

•

The propane-gas fuel SELECTOR switch is used. for engaging the propane or gas fuel solenoid. When the selector is in the II GAS II position, the gas solenoid in the engine has been energized so as to allow fuel to flow through.

Conversely, when the selector switch is in the IIPROPANE II position, the propane solenoid has been energized. When the gas solenoid is energized, fuel will not flow through the propane solenoid, as it has not been energized; and when the propane solenoid has been energized, fuel will not flow through the gas solenoid.

• As the fuel in the propane tank is under pressure, the propane fuel will flow toward the solenoid at all times. (Fuel will not flow through the solenoid unless the solenoid is energized.) The primer button located in the upper control box and on the lower control panel energizes the propane solenoid only if the propane selector switch is on position and only as long as the button is depressed, to allow propane to flow to the carburetor, which facilitates easier starting.

•

•

Raise platform by actuating the LIFT toggle switch to IIUpll position.

WARNING - Check for overhead obstructions as well as at each end before raising platform. For lowering platform, actuate toggle switch to IIDOWN position.

I•

At the end of the operation, push in POWER switch to IIOFF II position at both control panels. If the machine will not be used for a period of time, reconnect power source to battery charger on electric units.

15

2.

•

OPERATION FROM PLATFORM CONTROLS Disconnect external power from battery charger on electric powered units.

• At the ground controls, pull out POWER switch to "ON" position, and turn KEY switch to "ON" position.

NOTE - Engine can be started from

•

Start engine on engine powered units. either the ground panel or platform.

•

Move SELECTOR switch to "UP" position, then enter the platform of the CONDOR with the access provided. Close the platform entrance with the chains provided.

•

On the control console, pull POWER switch to "ON position. For units equipped with engines, START button must be activated to START engine.

•

Depress the FOOT SWITCH and HOLD. This will energize the control circuit as long as the foot switch is depressed.

•

DRIVE

II

To operate DRIVE toggle switch in desired direction of travel, make SURE area around the machine is CLEAR before traveling. FORWARDoREVERSE directions indicated on control panel refer to control with the platform control console mounted on the guard rail at the end of the platform farthest from the entry.

All directions are relative to FACING the control console while in the platform. CONDOR has three speeds: high, low and creep. Select either high or low speed. Maximum high travel speed is 3.2 MPH (Elec.) or 2.5 MPH (Gas). Maximum gradability 18° or 32%.

•

STEERING Controlled by actuation of the toggle switch. Move switch in desired direction and hold until turn is complete. Switch will return to center position; however, steering wheels will remain in last activated position. To center wheels, move switch in appropriate direction until travel is straight.

•

LIFT UP/DOWN PLATFORM To LIFT platform, move the UP/DOWN switch to "UP" position, holding until desired height is obtained. To LOWER platform, move the UpoDOWN switch to "DOWN" position.

I

WARNING

I

You are head and shoulders above the platform railings. Be sure sufficient OVERHEAD clearance exists before raising platform. When lowering platform, make sure area is clear of personnel and obstructions in path of platform.

16

3.

LIMIT SWITCH Raising the platform to 8 ft. will cut out the high speed drive and will automatically put the CONDOR into LOW speed drive. Raising the platform to 11 ft. 6 in. will cut out the low speed drive and automatically put the CONDOR into CREEP speed drive.

4.

SHUT DOWN Turn KEY switch at ground controls to "OFF position, then "PUSH OFF" POWER switch. Electrical power unit must recharge batteries after each work shift.

When the CONDOR is not being used, batteries should be charged at least once a week.

H

5.

EMERGENCY LOWERING For emergency use when no power exists, the platform can be lowered by a manual means. This can only be accomplished at ground level. The emergency lowering valve is located inside the compartment where ground control is located.

To operate, turn valve handle COUNTERCLOCKWISE. allowing platform to descent under gravity.

To stop descent, turn valve handle CLOCKWISE. stopping descent.

This will open the line This will close the line

Be sure valve is closed before performing normal operation, otherwise platform cannot be raised.

6.

BRAKE RELEASED/FREE WHEELING The brakes are a multiple disc brake, liquid cooled (hydraulic oil). The brake(s) is released by hydraulic pressure (400 to 500 psi), applied to the piston to compress the springs. The brake is self-applying with zero pressure, producing maximum brake torque.

Since the incorporation of an open center spool, the need for a freewheeling valve has been eliminated.

To set the CONDOR in freewheel mode - Energize drive circuit, with SCISSOR in low speed, while simultaneously closing the needle valve (black handle) on the pressure reducing valve. This lock opens the piston inside the brake.

To reinstate braking, open the freewheeling needle valve.

A CAREFUL, TRAINED, AND OBSERVANT OPERATOR IS THE GREATEST SAFETY DEVICE AVAILABLE

17

PREVENTIVE MAINTENANCE

In conjunction with the PRE-OPERATION INSPECTION, a good preventative maintenance program will enhance a properly operating machine and the SAFETY of those operating and using the equipment. AN OUNCE OF PREVENTION IS A POUND OF CURE. This section of the manual is directed to those items of maintenance of which the operator should be aware and which can be accomplished by or for him prior to operation of the equipment. Refer to SERVICE MANUAL for a more detailed breakdown and recommended time interval of PREVENTIVE MAINTENANCE.

I

CAUTION

I

DO NOT perform any maintenance or repair on the CONDOR, several basic tools are required. The following list of tools should be available.

1.

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

2.

A.

Volt/OHM meter.

B.

Hydraulic pressure gauge (0-3,000 psi).

C.

#6 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.

HYDRAULIC SYSTEM The CONDOR 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 in 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 unit in fully retracted position.

18

B.

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

C.

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

D.

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

CAUTION

Remove from tank

I

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 CONDOR SCISSOR in severe environments, such as dusty conditions.

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.

I

CAUTION

a

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 unit with a battery DISCHARGED or that has a specific gravity of 1.130 or LESS.

19

IMPORTANT CHECK BATTERY

WATER LEVEL AT LEAST ONCE AWEEK.

4.

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

8.

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. spark in the CHARGING AREA. E.

DO NOT smoke or INTRODUCE a FLAME or

Use protective face and eye equipment when checking the condition of charging batteries.

,I

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.

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

20

HOW TO ORDER PARTS 1.

Always give serial number and model of COBDOR SCXSSOR. each unit name plate shown right).

HOTB: This manual is being released to cover COJ1DOR SCXSSOR units starting wi th serial numbers (SIN) 2698 to current production.

Some components used on earlier units differ from current productions. Where this occurs, the part is identified by a serial number.

(Refer to

~ ~300 Imperial Drive ~

Waco, Texas

76712

CONOOR MOOEL-_ _ _ SERIAL NO-_ __ ASSEMBLY NO- _ _ _ _ _ _ _ __ PART NO-· _ _ _ _ OATE OF MFG-_ __ MAXIMUM PLATFORM HEIGHT-_ _ _ _ __ MAXIMUM HORIZONTAL REACH-. _ _ _ _ __ RATEO WORK LOAD -

LBS.

HYORAULIC OPERATING PRESSURE US. PATENT 4.506.480 THIS UNIT IS NOT ELECTRICALLY INSULAUO THIS MOBILE UNIT CONFORMS TO ALL APPLICABLE REQUIREMENTS OF ANSI A92.5-1980

PSI

151"'3

2.

Always specify part number and complete name of parts ordered.

A.

Check your required part and its attaching parts and match with the illustration page.

B.

Refer to corresponding item number in the parts listing page.

C.

Part numbers are located in the part number column.

D.

When ordering variable or optional miscellaneous parts which are not found in this parts section, follow the above outlined procedure of how to order parts.

(1) When applicable, give model and serial component for which parts are desired.

(2)

number

of

the

In a specific, difficult to describe situation, a marked-up photograph or detailed sketch would be helpful.

3.

Do not designate quantity by "sets". parts are wanted.

4.

Always give complete address and full shipping instructions.

Specify parcel post, express, motor freight, air express, air freight, etc. united Parcel Service, Emery, DHL, and Federal Express are available in designated areas.

s.

TO ORDBR A.

state specifically how many

BY KAl:L

Attention: Parts Department CALAVAR CORPORATXOH 8300 Imperial Drive Waco, Texas 76712 B.

BY FAX

(800) 443-5803 (817) 666-4996 (817) 666-4544

• Parts Department • General Office • Sales Department

21

C.

BY PHOn

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

6.

(817) 666-4545 (800) 877-5544

Parts and Service

RETURH AUTBORIZATIOB

Parts returned without authorization will not be accepted.

If it is necessary to return parts for any reason, written authorization may be obtained from CALAVAR CORPORATIOB, Parts Department, Waco, TX 76712.

A Parts Return Authorization form is provided when CALAVAR deems it necessary to have the parts returned for evaluation. The form is issued by the Warranty or Parts Department of CALAVAR. A.

A Parts Return Authorization form (Refer to Next Page) will be filled out by CALAVAR unless requesting necessary information and you will receive a blue copy and white copy as well as a green shipping tag.

B.

Attach green shipping tag to part and insert return packing slip (blue copy).

C.

Ship part to CALAVAR PREPAID.

D.

Parts must be returned to CALAVAR within 45 days from date of authorization.

@

@

•

c

09 ... o~ ~ ...

..

.

C 0

~

«c

.. ~

~

a:

0;;

•

t:

tf

~

Os

t

...

0;; c

~

~

0

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22

WARRANTY RETURN AUTHORIZATION FORM WARRANTY RETURN AUTHORIZATION

CORPORATION

8300 IMPERIAL DRIVE, WACO, TEXAS 76712 (817)666-4545 FAX (817)666-4544

NO. SHOW THIS NUMBER ON ALL CORRESPONDENCE, TAGS, DEBIT OR CREDIT MEMOS.

DATE:

TO:

ATTN: REF. YOUR CLAIM # CALAVAR CLAIM # _ _ _ _ _ __

Sub Dealer'

The items listed below are authorized for return to our factory. We are enclosing shipping tags for attachment to and/or enclosure with the items being returned. The BLUE copy of Calavar's Return Authorization must accompany the material you are returning. Return only those items authorized. If a discrepancy in quantity or description developes at the time of shipment, please contact this office.

-

Tag No.

ALL ITEMS SUBJECT TO CALAVAR INSPECTION. ALL FREIGHT SHIPMENTS MUST BE "PREPAID" F.O.B. SANTA FE SPRINGS, CALIFORNIA. UNAUTHORIZED MATERIALS RECEIVED BY CALAVAR MAY BE REFUSED ANDIOR RETURNED FREIGHT COLLECT. THIS AUTHORIZATION EXPIRES AFTER FORTY-FIVE (45) DAYS FROM THE ABOVE DATE. INFORMATION REQUESTED ON THIS FORM MUST BE COMPLETED FOR EACH ITEM RETURNED. RETURNED MATERIAL DOES NOT GUARANTEE CLAIM APPROVAL.

Quan.

Calavar's Part Number

Part Description

Calavar Invoice Number

For additional items please attach a separate sheet.

If you need further advice or information regarding the items on this Return Authorization, please contact our Warranty Representative in Santa Fe Springs, CA.

SIGNED

REMARKS:

FORM 390A 1M 8/116

CALAVAR

23

DO NOT RULES Everyday application of product knowledge and common sense will help make your CONDOR the safest tool you operate.

1.

DO NOT operate the CONDOR unless you are qualified by training and experience in its safe operation.

2.

DO NOT overload the platform; know the rated capacity.

3.

DO NOT operate the CONDOR on soft or uneven surfaces. DO NOT elevate the CONDOR platform when machine is on a slope. (The CONDOR is designed to be used on firm and level surfaces only.)

4.

DO NOT elevate the CONDOR platform unless the guard rails access opening (entrance) is closed with the chains provided.

5.

DO NOT operate the CONDOR when the wind velocity exceeds 25 mph.

6.

DO NOT tow the CONDOR unless equipped with option for in-plant towing (5 mph max).

7.

DO NOT jerk controls. movements.

8.

DO NOT force the platform or its railing against any adjacent structure to brace the CONDOR unit.

9.

DO NOT sit or climb on platform railing. floor at all times.

Operate smoothly and deliberately into and out of

Keep both feet on the platform

10.

DO NOT allow overhanging loads on the work platform.

11.

DO NOT use ladders, planks, or other devices on the aerial platform for achieving additional height or reach.

12.

DO NOT operate a CONDOR that is malfunctioning.

13.

DO NOT perform maintenance with platform in an elevated position without the safety bar in place.

14.

DO NOT make any modifications to the CONDOR without prior written consent of the CALAVAR CORPORATION Engineering Department. DO NOT alter or disable any interlocks or other safety devices on the CONDOR.

15.

DO NOT operate near energized electrical conductors. This is a NONINSULATED aerial work platform. You must maintain a clearance of AT LEAST 10 FEET between any part of the machine or its load and any electrical power line.

16.

DO NOT use the CONDOR for any other purpose than to position personnel and their tools or equipment. The CONDOR is not designed for use as a crane.

17.

DO NOT recharge batteries near sparks or open flame. being charged emit highly explosive hydrogen gas.

Batteries that are

WHEN PROPERLY MAINTAINED AND OPERATED CONDORS ARE SAFETY AERIAL WORK PLATFORMS!

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.

CONDOR® SERVICE INFORMATION

1. If 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.

CALAVAR CORPORATION

8300 IMPERIAL DRIVE, P.O. Box 21447, WACO, TEXAS 76702-1447.817-6664545,817-666-4544 FAX

Condor® Self-Propelled Aerial Work Platforms 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 five (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 one (1) year after the aerial work platform is placed in service or two (2) years after the original shipment of the aerial work platform from Calavar's plant, whichever comes 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 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 damage 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 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 the 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 merchantibility 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. FAX 817-666-4544 Printed in U.S.A.

( CALAVAR CORPORATION

BOLT TORQUE CHART

c

NOTES: 1.

THIS CHART SHOWS STANDARD BOLT TORQUES TO BE A.PPLIED UNLESS OTHERWISE SPECIFIED"

z.

CLAMP ~OAD

3.

TORQUE (PL 1 = R D T R = . ZOO FOR DRY CONDITIONS R = . 150 FOR LUB CONDITIONS "LU8 CONDITiONS - !NClUDES LUBRICANTS, PLA TING AND HARDENED WASHERS. D = NOMINAL JIAMETER iN INCHES T .: DESIRED CLAMP LOAD IN POUNDS

= 75%

X PROOF X STRESS AREA.

LU8RIZING,

APPENDIX B

( CALAVAR CORPORATION

BOLT TORQUE CHART METRIC HEX HEAD CAP SCREWS (REGULAR PITCH) • Suggested assembly torques in Foot-Pounds (* Values in Inch-Pounds) • The torque values for each diameter are acceptable for any thread pitch in that diameter

Propeny Class 8.8 DIAMETER

Dry Thretlde

Property Class 9.B

TIntId8

Dry Thret1d8

Lubricated

Lubricated TIntId8

Propeny Clas. 10.9

Property C.... 12.9

Dry Thretlde

Dry Threllda

Lubricated Thrnda

LubrIcetIId ~

M4

27.5*

17-

30-

18-

38.5*

24-

53*

32.5-

M5

56.5*

33.5*

61*

37-

78-

47-

107-

65-

M8

95*

57.5*

103-

61-

132-

79-

180-

109-

MB

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

78

M14

107

64

116

69

146

89

203

122

M18

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

APPENDIX A

( SAEGRADE8 NOMINAL THREADS

DIA INCH

c

NOTES: l.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 CAPSCREWS • RECOMMENDED ASSEMBLY TORQUES IN FOOT-POUNDS (*VALUES IN LB-IN. OTHERS ARE LB-Fr.)

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

DRY THREADS THREADS

THREADS

THREADS

THREADS

THREADS

THREADS

M4

27.5*

17*

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

(-

(

TABLE OF CONTENTS

3172 FIGURB

~I~LB

lO .................................. Final Installation 21 .................................. Electrical Diagram

22 ....... '.......................... . Hydraulic Schematic

30 •••••••••••••••••••••••••••••••••• Platform Installation 31 •••••••••••••••••••••••••••••••••• Platform Control Box Assembly 50 .................................. List Installation

51 •.•••••••••••••••••••••••••••••••• Lift Cylinder Assembly 52 •••••••••••••••••••••••••••••••••• Safety Arm Stand Assembly

)

70 .....................•............ Chassis Installation

71 •.•••••••••••••••••••••••••••••••• Hydraulic Pump Assembly

I

72 .................................. Limit switch Assembly 73 ••.•......••••....•.•••..••....••• Fuel Tank Assembly

74 ••••••.••••••••••••••••••••••••••• Eskridqe Brake Assembly 75 •••••••••••••••••••••••••••••••••• Ground Control Box Assembly 76 ••••••.••••••••••••••••.••••••••••• Hydraulic Installation 77 •••••••••••••••••••••••••••••••••• Hydraulic Manifold Assembly 78 •••••••••••••••••••••••••••••••••• Hydraulic Tank Assembly 79 •••••••••••••••••••••••••••••••••• Steering Installation

INTRODUCTION

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 TALL 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 u,pdated to reflect these changes.

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

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 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.

CALAVAR CORPORATION

8300 IMPERIAL DRIVE, P.O. Box 21447, WACO, TEXAS 76702-1447. 817-6664545, 817-6664544 FAX

How to Order Parts

c

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 part(s) you require, and always provide a complete description of all parts.

3.

Fax orders are preferable, though parts may also be ordered by mail and telephone. A sample parts order (with fax number) follows this page.

4.

Parts needed for a warranty repair must be purchased through the 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-i.e., UPS, Federal Express, or preferred truck line. When shipping Federal Express, your customer account must be given at the time of the order.

6.

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.

Stock

Order to be shipped within (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.

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

IPURCHASER

ACCOUNT # C U S T

0 M E R

I N F

NAME

NAME

0

ADDRESS

R M A T I

CITY

0

SALES ORDER #

ZIP

STATE

PHONE

( ) N CUST. PURCHASE ORDER NO.

S H I P

J

iADDRESS

0 CITY

STATE

IPHONE

FAX

(

T

(

)

ORDER DATE

I

I

I

FAX

)

RE QUEST DATE

ZIP

(

)

SPECIAL MARKS & NUMBERS

SHIPPING INSTRUCTIONS

PART NUMBER

QTY.

DESCRIPTION

FOR ORDER STATUS PLEASE CHECK APPROPRIATE BOX BELOW EMERGENCY STOCK

NOTES

FIGURE 10 FINAL INSTALLATION 7

10

-.....::::::--...nlr-----ll

12,

1, REF

.: SHOWN MODEL 3172G

~

3

~45

· ...

:

~~

~

®

6

FIGURE 10 FINAL INSTALIATION I T

..

E

CALAVAR PART NUMBER

134354 2 92271 3 67793 4 BOW31444 5 BOW36725 6 BOW31201 7 030-G5000-00 -8 FIGURE 21 -9 FIGURE 22 10 00l-05000-lA 11 00l-04000-2A 12 00l-G5000-3B ~13 58276 f-1467470-001 1-15 287-96456-00

DESCRIPTION

QUANllTY

12345 Holder, Safety Manual Manual, Operation and Safety Clamp Washer, Flat Washer, SPL Lock Hut, Hex Set, Decals Diagram, Electrical (See Fig. 21) Schematic, Hydraulic (See Fig. 22) Installation, Platform (See Fig. 30) Installation, Lift (See Fig. 50) Installation, Chassis (See Fig 70) Paint Yellow Oil, Hydraulic Kit, 2WD Hose

1 1 1 1

1 1 1 1 1 1 1 1 1 1 1

IJt-EEL MOTORS FRONT

VELOCITY

LIFT CYLINDER

STEER CYLINDER LIFT CYLINDER

REAA

FLO\.'

CONTROLS POS I TRAC _ J VALVE

.........--r-.-.- ]

EMERGENCY LOWERING VALVE

I

--------

II

I

CROSSOVER RELIEF VALVES rrTT"Il+rn

LI FT VALVE

'I.L&............Ar-

SYSTEM RELIEF VALVE BALL

SHUT-OFF VALVE

[

DlA4P

VALVE

LO\-'

SP EEO

VALVE

___________________ J RETlRN FILTER

RESERVOIR

r-t-r-T"Tn

DRIVE VAL VE

1

FIGURE 21 ELEClRICAL DIAGRAM

i

>-

Ii i""

1 z

!'

..~

:l

••

,.,--

::. ~..-. .~

c·_::,

t

H

.

f\ NI-I--+---++-H+ ......

..

J

,

_. .'. ~

~

; •

. '._ ...

>: 4:

'

.~

~

~

FIGURE 30 PlATFORM INSTALlATION 7

8

9

10

11

12

13

f

FIGURE 30 PLATFORM INSTALLATION I I

T E

.

1 2 3 4 5

CALAVAR PART NUMBER

52963 37515 50277 58419 010-G4028-00

6 7 8 9

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 -25

010-G4048-00

392-00031-00 164-00013-00 245-00007-00 533-00001-00 BOW34272 BOW31401 BOW30006 BOW34113 245-00008-00

DESCRIPTION

QUANllTY

12345 Decal, capacity 1,500 LBS Decal, 3172 Decal, CONDOR Tape, Orange and Red 37LF Weldment, Deck Frame Weldment, Right Side Rear Guardrail Weldment, Right Rear Guardrail We I dment, Left Rear Guardrail Weldment, Right Side Front Guardrail Weldment, Left Side Rear Guardrail Assembly, Platform Control Box (See Fig. 31) Weldment, Froht Guardrail We 1 dment, Left Side Front Guardrail Guard, Control Cable switch, Foot Clipper Chain Convert, Snap Plate Link, Chain 'Weldment, Rear Movable Guardrail (Option) »ut, Lock Washer, Flat Bolt, Hex Rivet, Pop Pin, Lanyard Hitch Assembly, Platform Floor

2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 AIR AIR 1

FIGURE 31 PLATFORM CONTROL BOX ASSEMBLY

5

® 17

18

21

®

FIGURE 31 PLATFORM CONTROL BOX ASSEMBLLI I

T E

.

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

CALAVAR PART NUMBER

DESCRIPTION

370-00001-00 Receptacle, Sinqle 2P, 3W 161-00001-00 Cover, Devise W/P Sinqle Receptacle 310-00156-00 Decal, This Pluq 115 Volt

Decal, Platform Operation Sheet 310-00159-00 Decal, caution Volt Lines 310-00151-00 Decal, Read Instruction 324-00017-00 Relief, 3/4 strain t, j l , "'\-00'\

::~ie~c~

f/~ S+r~N

331-00213-00 Strain t."1llt-OO-" 324-00037-00 67124-003 Hut, Lock 324-00023-00 Pluq Button 010"'::G4013-00 Weldment, Platform Control Box 620-G4105-00 • Panel, Platform Control 620-G4110-00 • Panel, Side BOW36002 • Bolt, Hex

Decal, Platform Control Panel

50075 , .w~tch (Drive, Lift, Steer) 392":'00004-00 SWitch, Speed 275-00002-00 Knob, Emerqency stop Plastic 392-;-00015-00 SWitch, Push Pull 392~00021-00

QUANllTY

12345

Switch, Push Pull

..

157-99914-00 Rinq, Terminal 157 -oooI1-CO 157--00020-00 Rinq, Terminal

1

1 1 1 1 1 1 1 1 1 1 1 1 1 6 1 3 1 1 1 1 3

13

FIGURE 50 LIFT INSTALLATION

FIGURE 50 LIFT INSTALLATION I

T E

.

1

CALAVAR PART NUMBER 124-00028~00

2 124-00032':'00

3 4 5 6 7 8 9

12"-00013-00 BOW34278 010-S4020-00 010-S4025-00 010-S4026-00 020-H5015-00 010-S4022-00 010-S4024-00 010-S4027-00 010-S4018-00 124-00030:-00

10 11 12 13 14 167-00002r-00 15 8OW40541 16 524-00006-00

-

DESCRIPTION

QUANlllY

123 45 Bushing Cam, 2" Flowet: FoUowe.r Bol t, -"iieH 5et sse.- ""...."

Nut, stop Weldment, Upper outer Arm Weldment, Upper Inner Arm Weldment, Middle Inner Arm Assembly, Lift Cylinder (See Fig. 51) Weldment, Middle outer Arm Weldment, Lower outer Arm Weldment, Lower Inner Arm Weldment, Arm Stand (See Fig. 52) au.hing Collar, Shaft Screw, Set Cable, Arm n.df ey\ .l=U-US,

t

-

16 4 16 12 2 1 1 2 2 2 1 1 6 6 6 1

FIGURE 51 LIFT CYLINDER ASSEMBLY 2

3

L------~

7

-~: I

T E

.

1 2 3 4 5 6 7 8 9

CALAVAR PART NUMBER 621-G9131-00 128-00026-0,0 331-0009B-00 162-96438-80 253-96618-00 154-00007-00 257-00001-00 253-96609-00

DESCRIPTION

QUANllTY

12345 Pin, Lift cylinder Bolt, Hex Mut, Esna Assembly, Lift CYlinder • ]Cit, Seal Fitting Clamp, Hose Fuse, Velcty Fitting, Adapter

4 4 4 1 1 1 1 1 1

FIGURE 52 SAFETY ARM STAND ASSEMBLY \

-~~--1-3

1

5

I T

CALAVAR PART

E M

NUMBER

1 2 3 4 5 6

531-G9125-00, BOW36055, .

BOW34274 010-S4018-00 8OW34113 245-00008-00

DESCRIPTION

QUANlllY

12345 Bracket, Arm stand Pivot Bolt, Hex Nut, Lock Weldment, Arm Stand Rivet, Pop Pin, Lanyard Hitch

2 8 8 1 1 1

FIGURE 70 CHASSIS INSTALLATION 11

12

1

~,

18/

19 20

21 22 23

25

FIGURE 70 CHASSIS INSTALIATION I

T E

.

1 -2 -3 4 5

,

,..J

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

CALAVAR PART NUMBER

010-05000-3A 010-G4159-00 010-G4160-00 020-G5001-00 477-00001-00 477-00023-00 Q.Q,l,~G4.oQ.Q~lB

355-00006-00 00268 02663 322-00015-00 020-G4035-00 121-96822-00 122-00031-00 122-00032-00 122-00039-00 50070 310-00184-00 020-G4041-00 126-10005-00 529-G5060-00 219-00007-00 396-00003-00 020-G4047-00 001-G5000-6A 020-G4049-00 FIGURE 79

DESCRIPTION

QUANllTY

Weldaent, Chassis Weldaent, Cover Left "ldment, Cover Right Assembly, Rim and Tire • Rim • Tire Installation, Engine Assembly, Hydraulic Pump (See Fig. 71) Elbow, 45 (IN) Elbow, 90 (OUT) Assembly, Electric Motor Assembly, Fuel Tank (See Fig. 73) Battery 12V cable, Battery 125" Cable, Battery 22", Cable, Battery 70" Decal, Battery Service Decal, Tie Down Lifting Lug Assembly, Brake and Hub • Brake, Eskridge (See Fig. 74) • Plate, Brake Cover , , Drive • Hub • Stud, Wheel As. . . .ly, GrOWld Control Box (Seel'i9- 75) Installatiel'l, Hydraulic (See Fig. 76) AsseJlbly, Hydraulic Tank (See Fig. 78) Installation, Steering (See Fig. 79)

1 1 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1

1 2345

r

FIGURE 71 HYDRAULIC PUMP ASSEMBLY 14 13

o~ 15

3 1

5

I

T E

..

CALAVAR PART NUMBER

1 018-00110-00 -2 018-00053-00 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17

018-00114-00 018-00113-00 018-00112-00 018-00111-00

DESCRIPTlON

QUANllTY

123 45 Cover, Back Kit, Seal • O-Ring • Plate, Thrust • Plate, Wear • Shield, Heat • Gasket • V-Seal • Seal, Shift Gear, Driven Gear, Drive Section, Center Pin, Dowel Cover, Front Washer, SPL Lock Screw, Cap Screw, Hex

1 1 2 1 1 1 1 1 1 1 1 1 2 1 8

6 2

FIGURE 72 LIMIT SWITCH ASSEMBLY

1

2

3

r ....

I

T E

.

1 2 3

CALAVAR PART NUMBER 105-00003-00 392-00010-00 324-00014-00

DESCRIPTION

QU~nTY

1 2345 Ana, Actuator switch, High Speed Relief, strain

1 1 1

FIGURE 73 FUEL TANK ASSEMBLY

•

I

10.•

TO ENGINE

1

FIGURE 73 FUEL TANK ASSEMBLY T'

.~

CALAVAR PART NUMBER

DESCRIPTION

QUANlllY

12345

1 010-G4051-QO Weldment, Fuel Tank 2 BOW34272 Hut, Lock 3 BOW36701 Washer, Flat 4 BOW36005 Bolt, Hex 5 259-00001-00 Gasket, Tank 6 010-G4065-00 Weldment, Fuel Tank Cover 7 BOW3'6725' Washer, SPL Lock 8 BOW36002 Bolt, Hex 9 152-00006-00 Cap, Fuel Tank 10 253-96618-00 Elbow, 90 ·11 BOW24108 Clamp, Hose ·12 597-G4001-00 Line, Flame Resistant Fuel

1 4 8 4 1 1 8 8 1 1 1 1

FIGURE 74 ESKRIDGE BRAKE ASSEMBLY 9

21,.

16

23

22

FIGURE 74 ESKRIDGE BRAKE ASSEMBLY I

T E

..

CALAVAR PART NUMBER

1 DRJ01034 2 DRJ01035 3 DRJ01036 4 DRJQ1037 5 DRJ01038 6 DRJ01039 7 DRJ01040 8 DRJ01041 9 DRJ01042 10 DRJ01043 11 DRJ01044 12 DRJ01045 13,DRJ01047 1~ DRJ01048 15 DRJ01049 16 DRJ01050 -17 DRJ01051 18 19 20 21 22 23

DESCRIPTION

QUANllTY

12345 Nut, Slotted Jam Screw, Socket Head Cap Plug, Hollow Hex Case, Brake Bearing, output Key Shaft Spacer Plate, Separate Plata, Bronze Friction Piston· Spring, Blue Cover, Brake Bearing, Input Ring, Snap Ring, Snap Kit, Seal • Ring, Piston Backup • O-Ring, Piston • O-Ring, Piston • Ring, Piston Backup • O-Ring, Case Seal • Gasket Mounting

1 4 1

1 1 1

1 1 9 8 1

12 1 1 1 1 1 1 1 1 1 1 1

FIGURE 75 GROUND CONTROL BOX ASSEMBLY

-

13 14

15.

16 17

20

\ 2

3

1

FIGURE 75 GROUND CONlROL BOX ASSEMBLY I

T E

.

1 2 3 4 5 6 , 7 8

CALAVAR PART NUMBER 245-00004-00 245-00007-00 245-00003-00 370-00002-00 BOW31129 275-00002-00

9 010-G4033-00 10 80049 11 374-00001-00 12 390-00007-00 13 150-00002-00 14 152-00023-00 15158-00022-00 16 157-00009-00 17 157-00020-00 18 123-00210-00 19 80042 20 80029 21 206-00001-00 22 220-00030-00 23 392-00005-00 24 392-00017-00 25 392-00015-00 26 392-00016-GO

DESCRIPTION

QUANlllY

12345 Retainer, Stainless Steel Cover, snap Plate screw, Slotted Decal, Lower Control Panel Receptacle, Flange Screw, SLT RD Head Knob, Plastic Emergency stop Decal, Operation Sheet Weldment, Lower Control Panel Socket, 8 Pin Octal Relay, 24 Volt KRPA 11 DN Spring, Relay Hold Down Wire, 14GA Red ,Wire, 14GA Green 10LF Wire, 18TFFN Black 84LF Terminal, 14 AWG Ring Terminal, 18 - 22 RinSJ/ Screw, RND Head· w-~2." 'I End, Terminal Block Block, Terminal Diode Breaker, Circuit Switch, Lift ,_ 1 switch, s.Js •••• il"TD~4u, ml1,~i/\teo Switch, Push and Pull Switch, 3 position Ignition

1 1 1 1 1 6 1 2 1 2 2

2 4 1 1 6

14 2 1

16 9 1 1 1 1 1

FIGURE 76 HYDRAUUC INSTALlATION

10 I

Ill.

. 12' 13

6

_---15

6.

\ NH HGf

~ty

t OWl HHHi VIUV\ ;

.,.

.

FIGURE 76 HYDRAULIC INSTALlATION I I

T

.

E

,

CALAVAR PART NUMBER

1 315-00001-00 2 279-96717-00 3 253-96510-00 4 253-96513-00 5 253-96646-00 6 250-00012-00 7 250-00016-00 8 253-96626-00 9 253-96513-00 10 020-G9003-00 11 450-00056-00 12 450-00055-00 13 450-00054-00 14 279-96716-00 15 279-96718-00 16 020-G4041-00 17 450-00061-00 18 253-96589-00 19 253-96560-00 20 450-00060-00 21 310-00183-00

DESCRIPTION

QUANllTY

Assembly, Hydraulic Manifold (See Fig. 77) Assembly, Tube Tee Connector, STR Connector, STR Filter, High Pressure • Element, High Pressure Filter Elbow, 90 Reducer Assembly, Dump Valve • Body, Dump Valve • Coil, Dump Valve • Valve, Dump Assembly, Tube Assembly, Tube Assembly, SIP Valve Valve, Flow Control Fitting, Adapter Connector, STR Valve, Emergency Lowering Decal, Emergency Lowering

1 1 1 1

"

1 2345

I

2

1 1 1 1 1 1 1 1 1 1 1 2 2 2

1 1

FIGURE 77 HYDRAULIC MANIFOLD ASSEMBLY

4

2

18

16

14 7

FIGURE 77 HYDRAULIC MANIFOLD ASSEMBLY I

CALAVAR PART

.I

NUMBER

1 2 3 4 5 6 7 S 9 1.0 11 12 13 14 15 16 17 18 19 2.0

315-.0.0.0.01-.01 315-.0.0.0.01-.02 315-.0.0.0.01-.03 315-.0.0.0.01-.04 315-.0.0.0.01-.05 315-.0.0.0.01-.06 315-.0.0.0.01-.07 315-.0.0.0.01-.08 315-.0.0.0.01-.09 315-.0.0.0.01-1.0 315-.0.0.0.01-11 315-.0.0.0.01-12 315-.0.0.0.01-13 315-.0.0.0.01-14 315-.0.0.0.01-15 315-.0.0.0.01-16 315-.0.0.0.01-17 315-.0.0.0.01-18 315-.0.0.0.01-19 315-.0.0.0.01-2.0

DESCRIPTION

I

QUANllTY

12345 Body, Manifold Valve, Complete 4 Way Valve, Lift Valve (HC Lowerinq, Two-Speed) Valve, Relief Relief, Crossover Fittinq, 9.0· Fittinq, str.

Valve, Check Pluq Pluq Valve (Two-Speed, Lower) Nut, Lock Screw, Cap Socket Gasket Bousinq Screw Gasket I.D. Plate Screw

1 2 1

2 1

2 3 4 1 3 6 2 3 4 1 1 2 1 1 4

FIGURE 78 HYDRAULIC TANK ASSEMBLY

15

6

~-

<~ ~

t

2

19

1

10

FIGURE 78 HYDRAULIC TANK ASSEMBLY \ I

T E

I

! i

CALAVAR PART

.

NUMBER

1 2 3 4 .5 6 7 8 9 10 11 12 13 14 ·15 16 17 18 19

010-S4012-00 8OW34272 8OW36701 BOW36005 260-00001-00 254-00042-00 254-00009-00 450-00052-00 254-00009-00 254-00051-00 259_-00001-00 529-G4076-00 8OW36725 BOW36002 250-00003-00 02444 00324 33430 67408

DESCRIPTION

QUANllTY

12345 Weldaent, Hydraulic Tank Hut, Lock Washer, Flat Bolt, Hex Gauge, oil Level Elbow, 90 street !8/~ ~ Hipple, Gleee Pipe lP"--~!tt?:J/ 64lL Valve, Bell SMl~ 8ff~· Hipple, BlilSi'k Pipe P, p-.R. 6/-1:)( ~ I ~ PlUC), Black Steel Gasket, Tank Cover, Hydraulic Tank Washer, SPL Lock Bolt, Hex Assembly, Filler Cap and Lens oil Elbow, 90 ElbOw, 90 Filter, Return • Element, Filter

d

!

,

1 4 4 4 1 3 2

1-

1 2 1 1 8 8 1 1 1 1 1

FIGURE 79 STEERING IN STALlATION

11

1

81

I

13 I

lsI

16

®

FIGURE 79 STEERING INSTALlATION ~

CALAVAR PART NUMBER

1 2 3 4 5 6 7 8 91 10 11 12 13 14 15 16 17 18 19 20 21 22

020-G4042-00 321-00002-00 253-96610-00 BOW3611 BOW36729 219-00004-00 396-00003-00 663-G4151-00 BOW32278 119-00012-00 BOW30160-350 BOW34278 020-H5020-00 253-96590-00 162-96442-00 018-00037-00 010-G5062-00 128-00033-00 124-00033-00 324-00036-00 010-G4059-00 010-G4060-00

I T

DESCRIPTION

QUANllTY

1 2:3 45 Assembly, Motor and Hub • Motor, Wheel • Connector, STR • Bolt, Hex • Washer, SPL Lock • Hub, Drive • stud, Wheel Rod, Tie Nut, Jam End, Male Rod Bolt, Hex Nut, stop Elastic Assembly, steer Cylinder • Elbow, 90 • Cylinder, Steering • • Kit, Seal Weldment, King Pin Bolt, Hex Bushing, Flanged Plug, Freeze Weldment, Left Wheel Motor Mount Weldment, Right Wheel Motor Mount

2 1 2 4

4 1 5 1 2 2 3 3 1 2 1 1 4 8 4 4

1 1

NOTES

20 Feet To 210 Feet

OPERATION AND SAFETY MANUAL

SELF-PROPELLED AERIAL WORK PLATFORM

3172 SCISS

For Your Own Safety and Protection • Read This Manual Completely Before Operating the BBNJIR • Retain This Manual on the eaNJIR at all times.

SHOWN MODEL 3172G

CORPORATION

8300 IJIIERIAL DRIVE. WACO, TEXAS 76712 (817)666-4545 FAX (817)666-4544

PART NO. 92271 FROM SERIAL NO. 2698 ISSUED SEPTEMBER 1991

SPECIFICATIONS SPECIFICATIONS

MODEL 3172 ELECTRIC

MODEL 3172 GAS

Maximum Working Height Extended Platform Height Stowed Platform Height Overall Length Overall Width Removable Safety Rails Inside Platform Size Platform Capacity Gross Weight Powe r Sys tem Stabilizers Battery Capacity Number of Batteries Battery Voltage Battery Charger Toe Plate Wheel Base Wheel Track Tires Inside Turning Radius

31 ft.

25 ft.

31 ft.

25 ft.

12 ft.

12 ft.

4 ft. 3.5 in.

4

6 ft.

3 ft. 6

6 ft.

3 ft. 6

in.

140 x 68.5 in.

1,500 lbs.

5,520 lbs.

24 volt

ft.

3.5 in.

Optional 375 amp

Optional 95 amp

8 6 volt

1

12 volt N/A 6 in.

40 amp

6 in.

7 ft. 6 5 ft. 1

in. in.

in.

140 x 68.5 in.

1,500 lbs.

5,120 1bs.

18 hp

7 ft. 6 5 ft. 1

in. in.

26 x 12.00 x 12

26 x 12.00 x 12

9 ft.

9 ft.

3.5 in.

3.5 in.

OPERATIONAL FUNCTION TIMES (+ 10%)

Lift Up Lower Down

19

sec.

19

sec.

22 sec.

22 sec.

3.2 mph 2.5 mph 0.75 mph 8 ft.

2.5 mph

DRIVE SYSTEM TIMES

High Speed Low Speed Creep Speed High Speed Cut Out Creep Speed Cut Out

11 ft. 6

1 mph

0.75 mph 8 ft.

in.

11 ft. 6

in.

The CONDOR Model 3172 is designed and built to conform to CALAVAR1S understanding and interpretation of all applicable OSHA rules and regulations as well as ANSI standards: •

OSHA Title 29, Paragraph 1910.67 - - - - -

Vehicle Mounted Elevating and Rotating Work Platforms - Labor

•

OSHA Title 29, Paragraph 1926.556

Aerial Lifts - Construction

•

ANSI Standard A92.6-1979 - - - - - -

_ Self-Propelled Elevating Work Platforms

CAUTION' It is imperative that all owners and operators of the CONDOR read, understand and conform to these regulations.

Ultimate compliance to prevailing OSHA regulations is the RESPONSIBILITY of the employer utilizing the equipment.

1

INTRODUCTION This Safety Manual (PIN: 92271) is printed to assist the operator to better understand and operate the Self-Propelled CONDOR SCISSOR Model 3172 in a safe and proficient manner. For the operator's safety and protection, this manual MUST BE RETAINED on the CONDOR work platform at ALL TIMES. 1.

DESCRIPTION OF SCISSOR The CONDOR SCISSOR is a vertical Scissor arm aerial work platform and is rugged, maneuverable and safe. It is designed for work on firm level surfaces with normal operation controlled by an operator using a control box in the platform. All operational modes can be accomplished from the platform including drive and steer. The CONDOR provides industrial, construction and maintenance workers the ability to safely elevate and perform installation, maintenance, and replacement tasks.

The Model 3172 is powered by a Kohler Model M18 air-cooled gasoline engine rated, at 18 horsepower, at 3,000 RPM. Electrical unit is powered by six volt D.C., eight batteries producing a 24 volt D.C. system. Each battery is rated at 375 ampere hours. A 24 volt, 40 amp battery charger with 110V input is used to recharge the batteries after each day's use. Hydraulic system is 8.5 GPM @ 3,000 RPM at operating pressure of 2,400 pSi.

2.

OPERATORS QUALIFICATIONS Each CONDOR SCISSOR has undergone a thorough Quality Control inspection at CALAVAR. The design incorporates built-in safety features. A person of average skill can readily become proficient and safe in the operation of the CONDOR. It is a personnel lifting device and can be potentially DANGEROUS in the hands of UNTRAINED or CARELESS OPERATORS. Knowing the characteristics of the machine and function of the controls is important to SAFE, PROPER OPERATION AND USE. Becoming familiar with the controls and practices will result in smooth, accurate positioning. It is the responsibility of all users to READ and COMPLY with the following RULES and information designed to promote SAFETY and UNDERSTANDING of the CONDOR. •

A thorough understanding of the operating characteristics and limitations of the CONDOR is always the first requirement for any user, regardless of his prior experience with similar types of equipment.

•

Only QUALIFIED/TRAINED and AUTHORIZED personnel must be allowed to operate the CONDOR. A QUALIFIED/TRAINED operator is one who has READ and UNDERSTOOD the instructions in this manual, and is thoroughly familiar with the operating characteristics and limitations of the unit.

•

KNOW and FOLLOW all cautions, warnings and operating instructions on the CONDOR.

2

•

Repairs and adjustments should be made only by QUALIFIED/TRAINED personnel.

•

No MODIFICATION is to be made to the unit without prior written consent of the CALAVAR Engineering Department.

•

UNDERSTAND and OBEY all Federal, State and Local statutes and regulations applying to safe operation and use of aerial work platform.

YOUR SAFETY IS OUR UTMOST CONCERN AND YOUR RESPONSIBILITY

3. DANGER, CAUTION and WARNING DECALS are designed for your protection. and adhere to the information they provide.

STOP

CAUTION GUARD RAILS AND SAFETY CHAINS MUST BE SECURED AND USED AT ALL TIMES

READ OPERATING INSTRUCTIONS BEFORE OPERATING MACHINE

-WARNINGDO NOT WORK UNDERNEATH THIS LIFT UNLESS ARM STAND IS LOCKED IN PLACE See Service Manual for Location

UNLAWFUL TO OPERATE THIS EQUIPMENT CAUTION CAUTION CAUTION CAUTION WITHIN 10 FEET OF HIGH VOLTAGE LINES

LOAD CAPACITY (EVENL Y DISTRIBUTED LOAD)

MODEL 3172 ------- 1,500 LBS.

3

Know

CHECK BATTERY WATER LEVEL ONCE A WEEK.

BATTERY CHARGER PLUG 115 VOLT ONLY

This machine has been designed and tested to meet these standards:

FREE WHEELING. VALVE )

ANSI A92.2 1969 ANSI A92.3 1973 OSHA GISO 1910.67

OPERRTION SHEET WARNING: Machine is to be used on leuel ground only.

WARNING: Don't eMceed load limit on specfic models.

1. STARTING:

3. LIfT:

A. Turn Master Disconnect Switch On

A. When raising and lowering the platform from the

B. Pull out the power switch on the lower control panel.

C. Push selector switch to UP on the lower control panel.

D. Pull out the emergency ONIOFF button in the center of the upper oontrol box.

lower control panel. make sure that the selector switch, in the lower control panel. Is in the down position. Push the toggle switch for lift to either the up or down position.

B. Raising and lowering the platform from the upper control box, first make sure that the selector switch In the lower oontrol panel is in the up position. Push in the dead man switch on the left side of the upper control box. N. the same time push the lift switch to the up position.

C. Both rift switches are of the momentary type; when the switch is released it will aotomaticaJly return to the off position.

2. STEER I NG:

A. The steering is done by pushing in on the

dead man switch on the left side of the upper control box and, by pushing the toggle switch for steering.

B. Pushing the steering switch to the left, the front wheels will go left and remain to the left until the toggle switch is pushed to the right.

C. The steering switch is a momentary type switch. When the operator releases the switch It will automatically return to the off position.

4. DR IUE: A. Forward and reverse travel is done from the upper controt box only.

B. The machine has two speeds, high and low. Select either high

or

low speed with toggle switch matked

high or low speed.

C. Push the dead man switch In and then push the toggle switch marked drive forward or reverse.

5. FREE WHEELING:

A. For loading, Unloading and free wheefing at low speed

without damage to any of the oomponents or structure.

B. Free whee6ng valve Is on cross member at rear of machine.

4

LOADING - TRANSPORTING - UNLOADING 1.

LOADING AND UNLOADING The CONDOR SCISSOR, although somewhat small in stature compared to larger type construction equipment, still requires the same care and attention in LOADING, TRANSPORTING, and UNLOADING, as does the larger, heavier type equipment. At no time should sight of this be OVERLOOKED. Before loading/ unloading the CONDOR, inspect for any physical damage or defects. DO NOT

OPERATE A DEFECTIVE OR MALFUNCTIONING UNIT.

The CONDOR SCISSOR Model 3172 electrical unit weighs approximately 5,520 lbs., and gas unit is approximately 5,120 lbs. Whatever means is used to load/unload the unit, should be of sufficient strength to withstand the weight of the CONDOR.

DO NOT attempt to OPERATE the unit UNTIL you have READ and thoroughly UNDERSTOOD all INFORMATION provided on the operation of the CONDOR. FAMILIARIZE yourself with the CONTROLS, their FUNCTION and OPERATION. 2.

3.

RAMP METHOD A.

Ensure that ramp being used is sufficiently strong to handle the weight of the unit.

8.

Ramp should be set at an angle no steeper than 18° or 32%. rise in 10 feet.

C.

Before driving the unit on the ramp, test all the controls and the brake system. Then move the CONDOR slowly back and forth.

D.

Move the unit on the truck or trailer, up or down the ramp approximately a foot at a time allowing the steering corrections to be made. Keep unit in alignment with the carrier and ramp during loading or unloading procedure.

39 inches

FORKLIFT LOADING/UNLOADING METHOD A.

Ensure that forklift has sufficient capacity to handle the weight of the

CONDOR.

8.

The forks should be long enough to completely go across the width of the frame and should be positioned as close to the inside of the tires as possible. When lifting unit, center the forklift between the CONDOR tires.

C.

Unit should be picked up from side of unit and should only be raised to a height to clear any obstructions.

D.

Keep forklift travel with CONDOR load to a minimum and set gently down to ground level.

5

4.

TRANSPORTI NG The CONDOR can be easily and safely transported from job site to job site if a few simple rules and procedures are followed:

A.

Block all wheels to prevent forward and reverse motion.

B.

T~e

down the CONDOR with chains or cables, running them through the tle-down brackets only. DO NOT chain or strap OVER the platform or GUARD RAILS. Severe damage to the scissor arms may result from excess pressure due to securing the unit over the top of the platform.

WARRANTY

1:;;:1 Self - Propelled Booms and Scissors

WARRANTY Calavar Corporation ('GaIavar') warranlS 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 weidmenlS (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 parIS, for a period of 1 year after the aerial work platform is first placed in seIYice 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 ilS factory in Waco, Texas or at an authorized repair facility designated by Calavar, the defective part. In no event shall Calavar or ilS suppliers be liable to the purchaser or any other person for transportation charges Dr tor any incidental, collateral, special or consequential damages, including without limitation damages for loss ofprofilS,loss of customers, Joss ofgoodwiIIorworkstoppage, claims by any party other than the purchaser, or any other similar damages or loss even if Calavar, ilS suppliers Dr ilS representatives have been advisad of the possibility cif such damages.

ParIS claimed to be defective and for which repair Dr replacement is desired shall be returned transportation prepaid to Calavar's factory for inspection. This Warranty applies to replacement parts , provided uncl(!r 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 Dr application of the equipment, substitution upon it of parts not approved by Calavar Dr alteration Dr 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 componenlS 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 Dr presentations by any such representative. whether. oral or written, do not constitute warranties by Galavar and should not be relied upon as limited warranties of Calavar, and no attempt, effort Dr promise to repair equipment by Calavar Dr any such representative at any time Shall modify Dr extend this Warranty in any way. If the purchaser has used ilS 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 plattorms manufactured by Calavar.

ProduC1S Dr parIS 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 me.rchantability 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, W...... Texas 76702·1447.817_ _, 800-8n·5544, 817-666-4544 FAX Form No. 513-3M..-

6

PRE-OPERATION

INSPECTION

The CONDITION of the unit prior to start-up is a very IMPORTANT FACTOR as it directly affects the operator·s SAFETY. It should be a common practice that the operator perform a general inspection before each day·s operation of the work platform.

The purpose of the operator·s inspection is to keep the CONDOR in PROPER working condition and to DETECT any sign of malfunction during normal operations between scheduled maintenance checks.

DOWNTIME is COSTLY and can be prevented by taking a few minutes prior to start-up. A thorough walk-around inspection must be performed each day before the CONDOR is operated. Report damage of faulty operation immediately. Attach a Repair any sign at the ground control area stating 1100 NOT OPERATL discrepancies before use. Some of the major items to check are: II

1.

2.

OVERAll CONDOR CONDITION A.

Ground/platform controls - all controls are to function properly.

B.

Hydraulic leaks.

C.

Electrical system for frayed or broken wires or loose connections.

D.

Missing, broken, or damaged parts, pin retainers, bolts and nuts.

E.

External structural damage, or cracked welds.

F.

Condition of tires - pits, tears, cracks, or cuts.

G.

Steering connections, tie rod, cylinder.

H.

Wheel lug nuts - missing or loose.

I.

Decals, placards, and warning signs.

J.

Proper tire pressure.

K.

Scissor arms - pivots, connections, and lift cylinders.

PLATFORM A.

Pivot points, connections.

B.

Structural condition - damaged railings, flooring.

C.

Control box - electrical wiring for frayed or broken wires, damaged components, hoses, loose connections.

D. Access opening, chain, fasteners.

7

3.

4.

5.

6.

BATTERIES/CHARGER A.

Electrolyte level - all caps present.

B.

Cables and connections - ground connection.

C.

Battery holddown.

D.

Charger condition, meter, electrical plug (Electrical Unit)

HYDRAULIC SYSTEM A.

Hydraulic leaks.

B.

Loose or damaged hoses, tubing.

C.

Fluid level, hydraulic tankbreathercap.

Refill only with Tellus T-32 hydraulic oil.

D.

Hydraulic valves and control levers.

E.

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

ENGINE (ENGINE POWERED UNIT) A.

Mounts and mounting bolts.

B.

Fuel tank level and connections

C.

Fuel leaks

D.

Condition of belts

E.

Oil condition, level and leaks

MULTI-AXIS SOSLOPE SENSOR (OPTIONAL) A.

General condition

B.

Loose or damaged wires

C.

Push to test.

D.

Warning buzzer in platform is operable

Moveable on mounting

KNOW THE UNIT AND ITS CAPABILITIES. Report any unusual operation. sway or motion of arms or platform while being operated. Excessive, noise, abnormally slow or fast operation.

I

Erratic unusual

CAUTION'

Defective components, structural damage, missing parts or equipment malfunctions jeopardize the SAFETY of the operator and other personnel and can cause extensive damage to the CONDOR. A POORLY MAINTAINED machine could become the greatest OPERATIONAL HAZARD you may encounter.

8

CONTROL FAMILIARIZATION AND LIMITATIONS It is important from a SAFE operational standpoint that you, the operator, know the function of each control, its limitations, as well as that of the unit. A good understanding of the controls, limitations and capabilities will enhance operation and assure maximum operating efficiency and safety.

1.

PLATFORM CAPACITY The platform capacity of the CONDOR SCISSOR is unrestricted and is applicable within the operational envelop/positions when operated on a firm level surface and slope not exceeding 5°. The capacity includes the required OSHA and ANSI safety margin. DO NOT lessen the SAFETY MARGIN by overloading the platform beyond RATED CAPACITY. PLATFORM CAPACITY - - - - - - 1,500 lbs.

The platform capacity noted above is the COMBINED WEIGHT of all personnel, their tools, and any other equipment or materials carried by the platform.

Larger platforms require de-rating capacity.

I

WARNING

I

Proper stability of the CONDOR is based and tested on the standard unit and all of its components as supplied by CALAVAR. Any modifications of the unit, either by the addition or removal of parts and/or weight can greatly affect the unit1s STABILITY and SAFETY. 2.

TRAVEL Travel can be accomplished from both the stowed position or with platform elevated. Although the gradability of the unit is 18° or 32%, this should only be negotiated with the platform in stowed position. The CONDOR is designed to travel with platform elevated on FIRM LEVEL surfaces and slopes not exceeding 5°. The parking brake is spring applied and hydraulically released. This brake releases when the drive circuit is energized.

Maximum travel speed is 2.5 MPH for gas unit and 3.2 MPH for electrical unit.

This is high speed travel and is available when platform is in the stowed position (fully lowered). Low speed mode is available by moving high/low SPEED toggle switch to LOW. Creep speed mode is automatically shifted when scissor is elevated 1116" high.

II

II

Steering is accomplished through a tie rod and hydraulic cylinder arrangement. Although the STEERING toggle switch is momentary, return to center position, the steering system itself is not self-centering. Therefore, the toggle switch direction must be reversed when turn is completed in order to return to straight line travel. DEPRESS and HOLD appropriate side of switch for desired steering direction. "FORWARD" motion is determined with STEERING wheels leading the way. DRIVE toggle switch AWAY from the operator for FORWARD motion; TOWARD the operator for REVERSE motion.

9

Prior to making any attempt to operate the CONDOR SCISSOR, it is essential that the operator be thoroughly familiar with the location and function of each control. The following will assist in accomplishing this required understanding.

3.

GROUND CONTROLS

The ground controls are primarily emergency type controls. The panel is located on the left-hand compartment facing forward. Driving and steering is not possible from this location.

•

KEY SWITCH

The ground control has a MASTER DISCONNECT SWITCH. The key straight up center position is IIOFF II and disconnects power. With switch in IION II position, the electrical circuit is energized. Gasoline engine unit, actuate switch IISTART II to start engi ne. Switch must be IION II to energi ze ground or platform controls.

•

CHOKE SWITCH

Pump switch to activate engine choke. May be used in conjunction with engine Purpose to assist starting of engine first time in morning or after long periods of non-use. Actuate CHOKE switch IIPUSH IN II for operation.

START key switch.

•

POWER BUTTON

The control panel has a 2 position POWER switch: IIPUSH OFF II position disconnects all power from the batteries; the IIPULL ON II position energizes the power circuit.

•

SELECT SWITCH

Two-positioned toggle switch for selection of operation from ground control or platform controls. The II DOWN II position directs the power to the ground control panel. The IIUpll position directs the power to the aerial platform controls.

•

LI FT SWITCH

Momentarily, return to center, toggle switch to raise or lower scissors.

Actuate switch to IIUp· position RAISES scissors; DOWN position LOWERS scissors.

II

•

II

CIRCUIT BREAKER

A 20 amp circuit breaker is used to protect the electrical system. Should it pop out, it is due to overload or short-circuit; and cause should be investigated before further operation.

10

4.

PLATFORM CONTROLS The platform controls are located on a movable console and can be slid over the top railing of the platform which gives the best control advantage for the operator. The platform control box contains controls for complete operation of the units. The controls are energized only when the FOOT SWITCH is depressed and held. The platform control box contains the following controls:

• EMERGENCY ON/OFF BUTTON "PULL" to turn ON and PUSH to turn OFF. NOTE - This is also an emergency PUSH TO STOP ALL FUNCTIONS. II

II

switch.

• DRIVE FORWARD/REVERSE "FORWARD" motion is determined with STEERING wheels leading the way.

REVERSE motion is determined with DRIVE wheels leading the way.

II

II

• HIGH/LOW SPEED Toggle switch for selection of travel speed. Actuate switch "AWAY" from operator for HIGH speed; "TOWARD" operator for LOW speed.

NOTE - High speed can only be obtained with stowed position. CONDOR has three speeds; at 8 ft., the LOW speed, and at 11 ft. 6 in., the LOW speed will automatically be activated. This will occur even if HIGH/LOW switch is in HIGH position.

• STEER - LEFT/RIGHT Toggle switch for control of steering wheels. Switch is momentary, meaning it returns to center position when released. Actuate switch to "LEFT" to turn wheels for LEFT turn; "RIGHT" for RIGHT turn.

• LIFT - UP/DOWN Toggle switch for raising or lowering scissor. Move switch "AWAY· from operator to UP scissor; "TOWARD" operator to DOWN scissor.

STEER LEFT

RIGHT

(Q)

LIFT

EMERGENCY

SPEED

ORIUE

UP

PULLaN

HfGf

(Q)

(Q)

o

FORWARD

PUSH OFF

LOW

DOWN

11

(Q) REVERSE

OPERATIONAL PROCEDURE Prior to operation of the CONDOR for your OWN SAFETY, it is your RESPONSIBILITY to ensure that the unit is in proper working condition and that the PRE-OPERATION INSPECTION has been performed.

I

CAUTION

I

Located on the inside cover of this manual (PIN: 92271) are a few DO NOTS relative to proper operation and maintenance. ACQUAINT yourself with these simple RULES and be ALERT to their signs.

I

WARNING'

OBSERVE ALL SAFETY PRECAUTIONS WHILE OPERATING THE CONDOR. Before starting, on battery power units, disconnect the external power source from the machine's battery charger. On engine powered units, check fuel level for any leaks in fuel system.

1. OPERATION FROM GROUND CONTROLS •

Pull out the POWER switch to "ON" position.

•

Gas unit, turn KEY switch "ON" to position. Engine power unit required .1 START • I. It may be necessary to choke engi ne. Actuate CHOKE switch, "PUSH IN" for operation.

•

The propane-gas fuel SELECTOR switch is used for engaging the propane or gas fuel solenoid. When the selector is in the "GAS· position, the gas solenoid in the engine has been energized so as to allow fuel to flow through.

Conversely, when the selector switch is in the npROPANE" position, the propane solenoid has been energized. When the gas solenoid is energized, fuel will not flow through the propane solenoid, as it has not been energized; and when the propane solenoid has been energized, fuel will not flow through the gas solenoid.

• As the fuel in the propane tank is under pressure, the propane fuel will flow toward the solenoid at all times. (Fuel will not flow through the solenoid unless the solenoid is energized.) The primer button located in the upper control box and on the lower control panel energizes the propane solenoid only if the propane selector switch is on position and only as long as the button is depressed, to allow propane to flow to the carburetor, which facilitates easier starting.

•

Raise platform by actuating the LIFT toggle switch to nUp" position.

WARNING - Check for overhead obstructions as well as at each end before raising platform. For lowering platform, actuate toggle switch to "DOWN" position.

• At the end of the operation, push in POWER switch to "OFF" position at both control panels. If the machine will not be used for a period of time, reconnect power source to battery charger on electric units.

12

2.

OPERATION FROM PLATFORM CONTROLS

• Disconnect external power from battery charger on electric powered units.

• At the ground controls, pull out POWER switch to "ON" position, and turn KEY switch to IION" position.

• Start engine on engine powered units. either the ground panel or platform.

NOTE - Engine can be started from

• Move SELECTOR switch to "UP" position, then enter the platform of the CONDOR with the access provided. Close the platform entrance with the chains provided.

• On the control console, pull POWER switch to HON" position. For units equipped with engines, START button must be activated to START engine.

• Depress the FOOT SWITCH and HOLD. This will energize the control circuit as long as the foot switch is depressed.

• DRIVE To operate DRIVE toggle switch in desired direction of travel, make SURE area around the machine is CLEAR before traveling. FORWARDoREVERSE directions indicated on control panel refer to control with the platform control console mounted on the guard rail at the end of the platform farthest from the entry.

All directions are relative to FACING the control console while in the platform. CONDOR has three speeds: high, low and creep. Select either high or low speed. Maximum high travel speed is 3.2 MPH (Elec.) or 2.5 MPH (Gas). Maximum gradability 18° or 32%.

•

STEERING Controlled by actuation of the toggle switch. Move switch in desired direction and hold until turn is complete. Switch will return to center position; however, steering wheels will remain in last activated position. To center wheels, move switch in appropriate direction until travel is straight.

•

LIFT UP/DOWN PLATFORM To LIFT platform, move the UP/DOWN switch to HUP" position, holding until desired height is obtained. To LOWER platform, move the UpoDOWN switch to "DOWN" position.

I

WARNING

I

You are head and shoulders above the platform railings. Be sure sufficient OVERHEAD clearance exists before raising platform. When lowering platform, make sure area is clear of personnel and obstructions in path of platform.

13

3. LIMIT SWITCH Raising the platform to 8 ft. will cut out the high speed drive and will automatically put the CONDOR into LOW speed drive. Raising the platform to 11 ft. 6 in. will cut out the low speed drive and automatically put the CONDOR into CREEP speed drive.

4. SHUT DOWN Turn KEY switch at ground controls to "OFF H position, then "PUSH OFF II POWER switch. Electrical power unit must recharge batteries after each work shift.

When the CONDOR is not being used, batteries should be charged at least once a week.

5. EMERGENCY LOWERING For emergency use when no power exists, the platform can be lowered by a manual means. This can only be accomplished at ground level. The emergency lowering valve is located inside the compartment where ground control is located.

To operate, turn valve handle COUNTERCLOCKWISE. allowing platform to descent under gravity.

To stop descent, turn valve handle CLOCKWISE. stopping descent.

This will open the line This will close the line

Be sure valve is closed before performing normal operation, otherwise platform cannot be raised.

6. BRAKE RELEASED/FREE WHEELING The brakes are a multiple disc brake, liquid cooled (hydraulic oil). The brake(s) is released by hydraulic pressure (400 to 500 psi), applied to the piston to compress the springs. The brake is self-applying with zero pressure, producing maximum brake torque.

Since the incorporation of an open center spool, the need for a freewheeling valve has been eliminated.

To set the CONDOR in freewheel mode - Energize drive circuit, with SCISSOR in low speed, while simultaneously closing the needle valve (black handle) on the pressure reducing valve. This lock opens the piston inside the brake.

To reinstate braking, open the freewheeling needle valve.

A CAREFUL, TRAINED, AND OBSERVANT OPERATOR IS THE GREATEST SAFETY DEVICE AVAILABLE

14

PREVENTIVE MAINTENANCE In conjunction with the PRE-OPERATION INSPECTION, a good preventive maintenance program will enhance a properly operating machine and the SAFETY of those operating and using the equipment. AN OUNCE OF PREVENTION IS A POUND OF CURE. This section of the manual is directed to those items of maintenance of which the operator should be aware and which can be accomplished by or for him prior to operation of the equipment. Refer to SERVICE MANUAL for a more detailed breakdown and recommended time interval of PREVENTIVE MAINTENANCE.

I

CAUTION

I

DO NOT perform any maintenance or repair on the CONDOR unless safety arm stand weldment is used to hold arms in elevated position.

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

A. Volt/OHM meter.

B. Hydraulic pressure gauge (0-3000 psi).

C.

#6 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 Keep system clean and use only TEllUS T-32.

DO NOT MIX hydraulic oil.

A. Fluid Level - Check level daily.

Maintain fluid level at full mark on side gauge with the unit 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. Thereafter, change the filter every 3 months or 300 hours of operation.

C.

Tank Breather - Clean every 50 hours of operation. clean with solvent. Air blow dry.

D.

Hydraulic Tank - Drain oil from tank every 500 hours of operation or yearly, whichever comes first, and replace filter element. Add oil to tank to required level.

15

Remove from tank and

3. BAmRIES 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.

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

C.

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.

I

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 unit with a battery DISCHARGED or that has a specific gravity of 1.130 or LESS.

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. spark in the CHARGING AREA. E.

DO NOT smoke or INTRODUCE a FLAME or

Use protective face and eye equipment when checking the condition of charging batteries.

I

DANGER'

Lead acid batteries generate highly explosive hydrogen gas especially during the cycle. To AVOID the possibility of an explosion, charge batteries ONLY 1n 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. ~harging

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

16

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NOTES

20 Feet To 210 Feet

19

DO NOT RULES Everyday application of product knowledge and common sense will help make your CONDOR the safest tool you operate.

1.

DO NOT operate the CONDOR unless you are qualified by training and experience in its safe operation.

2.

DO NOT overload the platform; know the rated capacity.

3.

DO NOT operate the CONDOR on soft or uneven surfaces. DO NOT elevate the CONDOR platform when machine is on a slope. (The CONDOR is designed to be used on firm and level surfaces only.)

4.

DO NOT elevate the CONDOR platform unless the guard rails access opening (entrance) is closed with the chains provided.

5.

DO NOT operate the CONDOR when the wind velocity exceeds 25 mph.

6.

DO NOT tow the CONDOR unless equipped with option for in-plant towing (5 mph

max) .

7.

DO NOT jerk controls. movements.

8.

DO NOT force the platform or its railing against any adjacent structure to brace the CONDOR unit.

9.

DO NOT sit or climb on platform railing. floor at all times.

Operate smoothly and deliberately into and out of

Keep both feet on the platform

10.

DO NOT allow overhanging loads on the work platform.

11.

DO NOT use ladders, planks, or other devices on the aerial platform for achieving additional height or reach.

12.

DO NOT operate a CONDOR that is malfunctioning.

13.

DO NOT perform maintenance with platform in an elevated position without the safety bar in place.

14.

DO NOT make any modifications to the CONDOR without prior written consent of the CALAVAR CORPORATION Engineering Department. DO NOT alter or disable any interlocks or other safety devices on the CONDOR.

15. DO NOT operate near energized electrical conductors. This is a NONINSULATED aerial work platform. You must maintain a clearance of AT LEAST 10 FEET between any part of the machine or its load and any electrical power line.

16.

DO NOT use the CONDOR for any other purpose than to position personnel and their tools or equipment. The CONDOR is not designed for use as a crane.

17.

DO NOT recharge batteries near sparks or open flame. being charged emit highly explosive hydrogen gas.

Batteries that are

WHEN PROPERLY MAINTAINED AND OPERATED CONDORS ARE SAFETY AERIAL WORK PLATFORMS! 20

For Your Own Safety and Protection • Read This Manual Completely Before Operating the BatDlR' • Retain This Manual on the BaIlJl:R at all times.

SHOWN MODEL 3172G

CORPORATION

8300 IMPERIAL DRIVE, WACO, TEXAS 76712 (817)666-4545 FAX (817)666-4544

Distrtbuted by

Copies of this manual (PIN: 92271) can be obtained from CALAVAR CORPORATION.