Condor 36N - 46N - 60N - 92260

OPERATION AND SAFETY MANUAL
INDUSTRIAL SELF-PROPELLED
AERIAL WORK PLATFORM
MODELS 36N, 46N, AND 60N
For Your Own Safety and Protection

Read This Manual
Completely Before
Operating the Condor.
Retain This Manual
on the Condor at all times.
CORPORATION
PART NO. 92260
8300 Imperial Dr. P.O. Box 21447. Waco. TX 76702-1447
FROM SERIAL NO. 0450 ISSUED ~ 1990
(817) 666-4545 - Fax (817) 666-4544
SPECIFICATIONS
SPECIFICATIONS MODEL 36N MODEL 46N MODEL 60N

Maximum Platform Height 30 FT. 40 FT. 54 FT.
Maximum Work Height 36 FT. 46 FT. 60 FT.
Platform Size (Tubular Steel) 60x36x43.5 IN. 60x36x43.5 IN. 60x36x43.5 IN.
Platform Capacity (Unrestricted) 1,000 LBS. 500 LBS. 500 LBS.
Overall Length (Stowed) 18 FT. 6 IN. 20 FT. 6 IN. 22 FT. 6 IN.
Overall Height (Stowed) 6 FT. 9 IN. 6 FT. 11 IN. 7 FT. 8 IN.
Overall Width 5 FT. 9 IN. 5 FT. 9 IN. 5 FT. 11 IN.
Outside Turning Radius 14 FT. 6 IN. 14 FT. 6 IN. 18 FT. 6 IN.
Wheelbase 6 FT. 6 FT. 7 FT.
Travel Speed (Raised) 3 MPH 3 MPH 3 MPH
Gross Weight (Approximate) 17,500 LBS. 17 ,500 LBS. 26,500 LBS.
Gradability 11 (20%) 0 11 (20%)
0 11 (20%)
0
Tires (Foam Filled) 11x15LT 31/11.5x16.5 14x17.5

TRACKER AT LOAD RANGE C LOAD RANGE E
Turret Tail Swing ZERO ZERO ZERO
Hydraulic Tank Capacity 35 U.S. GAL 35 U.S. GAL 35 U.S. GAL
Fuel Tank Capacity 35 U.S. GAL 35 U.S. GAL 35 U. S. GAL
OPERATIONAL FUNCTION TIMES ( 10%)
Topping (UP) 32 SEC. 32 SEC. 40 SEC.
Topping (Down) 30 SEC. 30 SEC. 30 SEC.
Boom (Extension) 31 SEC. 31 SEC. 31 SEC.
Boom (Retraction) 28 SEC. 28 SEC. 21 SEC.
Turret Rotation 100 SEC. 100 SEC. 120 SEC.
DRIVE SYSTEMS TIMES (200 ft. on firm level ground)
High Speed (Forward) 45 SEC. 45 SEC. 50 SEC.
High Speed (Reverse) 45 SEC. 45 SEC. 50 SEC.
Low Speed (Forward) 86 SEC. 86 SEC. 100 SEC.
Low Speed (Reverse) 86 SEC. 86 SEC. 100 SEC.
The CONDOR Models 361, 46N and 60N are 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
OSHA TITLE A92.6 - 1979 - Self-Propelled Elevating
Work Platforms
I CAUTION'
It is imperative that all owners and operators of the CONDOR read, understand
and conform to these regulations. Ultimate compliance to prevailing OSHA
regulations is the RESPONSIBILITY of the employer utilizing the equipment.
-1-
BOOM ANGLE VS REACH AND HEIGHT
ZERO TAIL SWING
MOL 36N - 5 FT. 9 IN.

MOL 46N - 5 FT. 9 IN.
MOL 60N - 5 FT. 11 IN.
INDUSTRIAL CONDOR HEIGHT MOL 36N BOOM Al6I.. YS REACH AID HEIGHT
--.- - -_.- - - - - - - - . - - - - - - -. - tiO
-----------------------t=!I---55 30'
(9.14m)

1-
----------~~------~---4; 27'S"
(8.38m)
--.---..- - - - -......--.--+--- 40 t
24'
(7.32m)
- . . - - - - - . - - - - - - .... ----35
. - - '-30 19'
(5.79m)
...-------25
13'6"
. . .- - - - - 2 0 (4.11in)
- - - - - j. . . ------15 --r
7'e/'
(2.29m)
----- . - - - 10
,
1'e/'
'---0 (O.oI6m)
38N 48N 80N
-2-
BOOM ANGLE VS REACH AND HEIGHT
till 4611 B()(Jt AIHiLE YS REACH AND HE I 61fT till 60N B()(Jt ANGLE YS REACH AND HEI6IfT
2'Sectlon Boom with
Top-Mounted Platform (Standard) Top Mounted platform (standard)
6' 11.83m) wor~'ng height
., I" -=::;----------,-
54' O' (16.46m)
37
,-
11128m) 49'S"
---.- ---,-
(IS.09m)
32
42'0'
19.75m) (12.8Om)
---.-,-
25'
(762m) 33'0'
(10.06m)
17
(S.lBm)
- ,.
~===II(]J========~ 8'S'
12,S9m)
I
-5'11"";
20'6" 16.2Sm) ~ 30'

(9,14m)-
,(l,8Om,
2'Section Boom with

Tip-Mounted Platform (Optional)
I TIp Mounted platform (optional)
t I
,
39' (11,89m)
52'1" (t6.00m)
I
46'
I (14.83m)
,
35'6"
(10.82m)
40'1"
(t2.34m)
30'
(9.14ml
I
31'
(9.45111)
23'6"
(716m)
44'I"~T
(13.sem, (6. tOm)
~1t:J 46~--r
-)
0"
~'"_'" i~~_(2_':..m_'
~
'9"~
(1,75m)
, ~ (7.47m) 24'1" I ~--r:-
(t3.5em=-i) -4
22' I S , 7 1 m ) - (1.22111)
-3-
INTRODUCTION
This Safety Manual (PIN 92260) is printed to assist the operator to better
understand and operate the Industrial Self-Propelled CONDOR Aerial Work
Platforms, Models 36M, 46N and 601, in a safe and proficient manner. For the
operator's safety and protection, this manual MUST BE RETAINED on the CONDOR
industrial work platform at ALL TIMES.
1. DESCRIPTION OF INDUSTRIAL CONDOR

The CONDOR is a telescopic aerial work platform and is rugged, maneuverable,
and safe. It is designed for work on firm level surfaces, with normal
operation controlled by an operator using a control box in the platform.
All operational modes can be accomplished from the platform, including drive
and steer. The CONDOR provides industrial, construction, and maintenance
workers the ability to safely elevate and perform installation maintenance
and replacement tasks.
The CONDOR Models 36N and 46N are powered by a Wisconsin Model VH4D air-
cooled gasoline engine rated, at 30 horsepower, at 2,150 R.P.M. As an
option, a Deutz diesel engine Model F2L511 is utilized having a nominal
horsepower rating of 23.
The CONDOR Model 60N is utilized by a Wisconsin Model VG4D air-cooled
gasoline engine rated, at 37 horsepower, at 2,400 R.P.M. Optional Oeutz
diesel engine Model F2L912, 27.5 horsepower at 2,300 R.P.M.
2. OPERATOR'S QUALIFICATION
Each INDUSTRIAL CONDOR UNIT 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.
-4-
INTRODUCTION AND SAFETY DECAL
KNOW and FOLLOW all cautions, warnings and operating

instructions on the INDUSTRIAL CONDOR.
REPAIR and ADJUSTMENTS should be made only by QUALIFIED/TRAINED
personnel.
No MODIFICATION is to be made to the machine without prior
written consent of the CALAVAR Engineering Department.
UNDERSTAND and OBEY all Federal, State, and Local statutes and
regulations applying to safe operation and use of aerial work
platforms.
YOUR SAFETY IS OUR UTMOST CONCERN AND

YOUR RESPONSIBILITY
3. DANGER, CAUTION AND WARNING DECALS are designed for your protection. Know
and adhere to the information they provide.
WARNINGS-
1. BEFORE OPeRATING CONOOFI, READ AND UNDEASTAND ALL INFORMATION IN THE OPeRAT1ONI
SAFETY MANUAL AND ON ALL DECAl.SlPl.ACAFDS DISPlAYeD ON THIS UNIT.
2. BE FAMIUAA WITH THE CONTFIOl FUNCTIONS ON THE OPeRATOR CONSOLES.
3. BE SURE THAT CONDOR IS PAOPEFILY MAINTAINED IN ACCOFIDANCE WITH CALAVAR'S
REQUIREMENTS AS SPECIFIED IN THE OPERATIONIMAINTENANCE MANUAL.
4. DO NOT OPERATE THIS MACHINE IF IT DOES NOT FUNCTION PROPERLY.
5. DO NOT OPERATE THE CONDOR WHEN WIND VELOCITY EXCEEDS 25 M.P.H.
. DO NOT REMOVE ANY WEIGHT FROM UNIT. STABILITY WILL BE AFFECTED.
7. DO NOT MAKE ANY MODIFICATIONS TO CONDOR WITHOUT WRITTEN CONSENT OF CALAVAR
DALY INSPECTION CHICKLIST IIFOII! USING CONDOR-
1. CHECK FLUID LVEl.S IN HVDAAuLIG AND FUEL TANKS AND BATTERY.
2. CHECK ENGINE CFlANKCASE OIL, AND COOLANT FOR WATER-COOLED ENGINES ONLY.
3. VISUAl!.Y INSPECT CONDOFI FOR LOOSE OR MISSING PARTS, WEAR, WELD CRACKS, OENTS. OR
OTHER SIGHS OF DAMAGE.
4. CHECK TIRES FOR WEAR, CUTS, AND INFlATION PRESSURE (PNEUMATIC T1RES ONLy).
5. CHECK ALL VlSlBl. BOLTS, NUTS, PINS AND FASTENERS FOR PROPER INSTALLAT1ON.
. CHECK HYDRAULIC COMPONENTS, FLUID UNES AND"FITTlNGS OR LEAKS.
7. IN$PCT ELECTRICAl HARNESSES, CONNECTORS, CIRCUITS, AND BOOM MECHANICAL CABLES
(3-SECTION lOOMS ONLy) FOR DAMAGE AND PROPER INSTALLATION.
CHECK 5- SLOPe SENSOR AND INDICATOR UGHTISOUND ALARM FOR PROPER OPERAT10N.
I. CHECK ROTATION GEAR lOX, RING GEAR BOLTS, LOCK.sTRIPS FOR PROPER INSTALLATION
10. ANY DEFECTS FOUND DURING INSPECTION AND FUNCTIONAL TEST MUST BE CORRECTED
BEFORE OPeRATING THE CONDOR. (REFER TO OPeRATIONIMAINTENANCE MANUAl. FOR
FACTORY RECOMMENDATIONS).
CIINIIW. OPIRATING INSTRUCTIONS-

1. CHECK THAT TURRET LOCK.fIIN IS REMOVED (APPLJCA8LE ONLY TO CONDOR MODELS WITH
TURRET ROTATION LOCKING FEATURE FOR TFlANSPORTING).
2. TURN POWeFI SWITCH "ON" AT GROUND CONTROl. CONSOLE. START ENGINUAOTOR AND
ALLOW UNIT TO WARM TO OPeFIATlNG TEMPERATURE.
3. POSITION SELECTOR SWITCH TO "GROUND" CONTROL AND TEST OPERATE ALL AERIAL FUNCnONS
FROM THE GROUND CONTROL CONSOLE.
4. POSITION SELECTOR SWITCH TO "PlAl'FORMI'CONTAOL. THEN ENTER THE WORK PLATFORM AND
ATTACH THE SAFETY BELT/\,ANYAAD.
5. ALL PERSONNEL IN PlATFORM MUST WEAR APPROVED HARD HATS, & BODY BELTS WITH
LANYARDS ATTACHED TO DESIGNATED POINTS IN THE PlATFORM ASSEMBL.Y.
. REFER TO WORK PlATFORM "CAUTION" DECALS FOR ALL OPERATlONS IN THE PlATFORM.
7. FOR TRANSPORTING, USE EXTREME CAUTION WHILE I.OADINGIIJNLOADtNG THE CONDOR UNDER
ITS OWN POWER:
TAAVEL IN LOW SPEED MODE ONLY.
MAKE SURE PLATFORM IS LOWERED (BOOM FULLY RETRACTED & 8ELOW HORIZONTAL.,
ROTATE TURRET IN UNE WITH CHASSIS.
DO NOT EXCEED RAMP ANGLE OF 14- (2.5 FEET RISE IN 10 FEET).
-5-
SAFETY DECALS
( )
1. DO NOT OPERATE THIS MAC. . UNUSS YOU ARE ATRAINED AND
AUTIfOIUZED OPERATOR FOR THIS CONDOR MODEl. BE FAMILIAR
WITH UNIVERSAL SYM8Ot.S USED ON CONSOlES.
2. CHECK ALL MACHINE FUNCTIONS. INCLUDING BRAKES. PRIOR TO
ELEaROCUTIOI HAZARD
KEEP CLEAR
EACH DAY'S USE.
3. ALL PERSONNEL IN PlATFORM MUST WEAR APPROVED HARD HATS
AND BOOY BELTS WITH LANYARDS ATTACHED TO DESIGNATED
POINTS ON THE PlATFORM ASSEMBlY.
tIIl\'1l . . SRIOIK _.,tAII IISUlI '10M
(OII'IAn WIllI IllS IOUINIIII .. VIIml
IF II SIIOIlI .. 1tK'IIIUU, CJUIUI. ,_ .
4. OPERATE ALL CONTROlS SLOWLY FOR SMOOTH PlATFORM
MOVEMENT. WATCH FOR OBSTRUCTIONS WHICH MAY STRIKE
PlATFORM. PERSONNEL. CONTROLS OR MACHINE.
5. DO NOT OPERATE THE CONDOR ON SOFT OR UNEVEN SURFACES OR
ON SLOPES IN EXCESS OF 5 (10.5" RISE IN 10 FEETJ.
6. DO NOT OPERATE THE CONDOR WHEN WIND VELOClTY EXCEEDS
25 MPH.
7. NORMAL TRAVEL POSITION IS WITH THE BOOM FULLY RETRACTED
ANO "TURRET COUNTERWEIGHr POSITIONED OVER THE DRIVING
(FRONn AXLE. THE BOOM MUST BE ELEVATED TO PROVIDE
ADEQUATE GROUNO CLEARANCE FOR THE PlATFORM ASSEMBlY.
DIRECTION OF PlATFORM TRAVEL REVERSES IN RELATION TO
CONTROLLER MOTION WHEN THE BOOM IS OVER THE FRONT AXLE. DO
NOT DRIVE THE CONDOR WITH THE BOOM ELEVATED IF ANY PART OF
THE MACHINE IS WITHIN 6 FEET OF AN OBSTRUCTION .
. THIS CONDOR IS EQUII'I'EO WITH ASLOPE SENSOR ANO AN INDICA TOR
LIGHT ON AEIIW. CONTROl CONSOlE TO INDICATE A5 OUTOF
LEVEL CONDITlOII. ALL BOOM FUNCTIONS ARE IN0PERA8LE WHEN
CONDOR IS MOllE THAN 5" OUT-OFlEVEL.
NOTE: TO CORIIKT THIS CONOITION. REVERSEI CHANGE DIRECTION
OF GllGUNO TRAVEL UNTllINOlCATOR LIGHTS GOES OFF. THIS MACHINE IS NOT INSULATED
9. HI6It SPHD MODE FOR TRAVEL WORKS 0fIIlY WHEN SELECTOR
SWITCH IS It "HIGH" AND 800M IS BELOW HORtZONTAL. AERIAL
FIJI:1'1CINS DO NOT OPERATE WITH UNIT IN HIGH SPEED.
11. .. CASE OF EMERGENCY. DEPRESS EMERGENCY "STOP" BUTTON.
ELECTROCUTION HAZARD
353115 \lAINTAIN SAFE CLEARANCES FROM ELECTRiCAl LINES AND
Al'PAAATUS. fOU toIUST ALLOW fOR BOOM SNAY. ROCK OR
SAG AND ELECTRiCAl LINE AND LOOI SNAYING.
THIS AERIAl. WORK PlATFORM DOES NOT PROVIDE
PROTECTION fROM CONTACT WITH OR PfIOXIMITY TO AN
ELECTRiCAlLY CHARGED CONDUCTOR.
YOU MUST MAINTAIN ACLEARANCE Of AT LEAST 10 fEET
BETWEEN ANY fUT Of THE WORK PlATFORM OR L~D AND
ANY ELECTRiCAl LINE OR AmRATUS CARRYING UP TO
50.000 VOlTS. ONE fOOT ADDITIONAl CLEARANCE IS
REQUIRED FOR EVERY ADDITIONAl. 30.000 VOlTS OR LEss.
OEATH OR SERIOUS INJURY WILL RESULT FROM CONTACT OR
INADEQUATE CLEARANCE
IIUZZ
YOU MUST NOT OPERATE THIS MACHINE

UNLESS YOU ARE QUALIFIED BY TRAINING AND EXPERIENCE
IN THE SAFE OPERATION Of THIS MACHINE.
TUINING INCLUOES COMPLETE KNOWLEDGE OF
YOUR EMPLOYER'S WORK RULES. ALL GOVERNMENTAL
REGULATIONS. AND MANUFACTURERS OPERATOR
. AND SAFETY MANUALS RELATIVE TO THIS
MlCHINE"S SAFE USE
AN UNTRAINED OPERATOR SUIIECTS HIMSELF AHO OTHUS TO
DO NOT LIFT WHEELS
DEATH OR SERIOUS INJURY WITH BOOM
CAUTION - CAUTION - CAUTION

REMOVE TURRET LOCK-PIN
BEFORE ROTATING TURRET
40191
-6-
LOADING TRANSPORTING AND UNLOADING
1
1. LOADING AND UNLOADING

The INDUSTRIAL CONDOR UNIT, 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.
ICAUTION I
The CONDOR Model 36N and 46N weighs approximately 17,500 lbs., and Model 60N
approximately 26,500 lbs. Whatever means is used to load/unload the unit,
it should be of sufficient strength to withstand the weight of the CONDOR.
DO NOT attempt to OPERATE the unit UNTIL you have READ and thoroughly
UNDERSTAND all INFORMATION provided on the operation of the INDUSTRIAL CONDOR
UNIT. FAMILIARIZE yourself with the CONTROLS, their FUNCTION and OPERATION.
IWARNING I
REMOVE TURRET LOCK-PIN BEFORE ROTATING TURRET, IF SO EQUIPPED
2. 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 14 or 25%, 30 inches
rise in 10 feet.
C. The normal driving position of the CONDOR is with the turret counter-
weight over the drive wheels. The controller movement is based on
this configuration. When the counterweight is positioned over the
steering wheels, the drive and steering controls will be reversed.
Try each control momentarily to orient yourself with the direction of
operation.
D. Before driving the unit on the ramp, test all the controls and the brake
system. Make sure that the operating levers return smoothly to the
neutral, center position. Then move the CONDOR slowly back and forth
and ensure the brakes automatically apply each time the drive control
lever goes back to the neutral position.
E. 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.
F. It may be necessary to elevate the boom or lift arms slightly to clear the
ground or ramp as you load or unload. The unit is equipped with a slope
sensor which senses 5 out of level condition. When unit encounters a
slope of 5 or more and is in low speed, a warning horn will sound.
-7-
LOADING TRANSPORTING AND UNLOADING
1
IIOOOEI
PALLETS
3. TRANSPORTING
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. Tie down the CONDOR with chains or cables, running them through the
tie-down brackets.
C. Place wooden pallets under platform, then tie down platform as
indicated.
-8-
-
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
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
schedule 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 or faulty operation immediately. Attach a sign at
the ground control area stating DO NOT OPERATE. Repair any discrepancies before
use. Some of the major items to check are:
1. OVERALL MACHINE CONDITION

A. Ground controls/platform controls -Controls return to neutral (center)
when actuated.
B. 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, warning signs.
J. Proper tire pressure.
K. Boom - pivot pin areas, wearpads, cylinder.
L. Check bolts securing ring gear to chassis and turret for tightness and
that all lock tabs are in place.
M. Inspect boom cables for fraying or damage and tightness and proper
installation on sheave (3-section boom units).
2. PLATFORM
A. Pivot points, connections.
B. Structural condition - damaged railings, flooring.
C. Control box - electrical wiring for frayed or broken wires, damaged
components, hoses, loose connections.
-9-
D. Access openings, slide bar freely moves.
E. Foot switch and guard.
3. BAillRY
A. Electrolyte level - all caps present.
B. Cables and connections - ground connection.
C. Battery hold down.
4. ENGINE
A. Fuel level.
B. Oil level.
C. Mounting.
D. Check for fuel, oil leaks.
5. HYDRAULIC SYSTEM
A. Hydraulic leaks.
B. Loose or damaged hoses, tubing.
C. Fluid level, hydraulic tank breather cap. Refill only with Automatic
Transmission Fluid - Dextron II.
D. Hydraulic valves and control levers.
E. Cleanliness of hydraulic fluid - non-milky, bright in color.
6. MULTI-AXIS 5 SLOPE SENSOR
A. General condition.
B. Loose or damaged wires.
C. Push to test. Moveable on mounting.
D. Warning buzzer in platform is operable.
KNOW THE UNIT AND ITS CAPABILITIES. Report any unusual operation, erratic sway
or motion of boom or platform while being operated, excessive, unusual noise,
abnormally slow or fast operation.
I 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.
-10-

COMPONENT IDENTIFICATION
u..;;::,....,..-- SAFETY LI6IfT

(OPTIOII)
PLATFOIII ASSEIISLY
HYDRAULIC
COYER
GROUIID COIITROI. BOX
5 SLOPE SElSOR
:.-_ _ _ _ _ _ THRUST LOCKING PIN
~~)".-_ _- - - - LIMIT SWITCH
},..-_ _ _ _ TOPPING CYLINDER
TURRET WEUIIEIIT
-11-
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 INDUSTRIAL CONDOR UNIT is unrestricted and is
applicable within the operational envelope/positions when operated on firm
surfaces and slopes not exceeding 5. The capacity includes the required
OSHA and ANSI safety margins. DO NOT lessen the SAFETY ~RGIN by over-
loading the platform beyond RATED CAPACITY.
Model 36N - - - - - - - - - - - - 1000 LBS. (5 FT. PLATFORM)
Model 46N and 60N - - - - - - - - 500 LBS. (5 FT. PLATFORM)
The platform capacity noted above is the combined weight of all personnel,
their tools and any other equipment or materials carried by the platform.
Larger platforms require de-rating capacity.
IWARNING'
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 unit's 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 14 (25%), this should
only be negotiated with the platform in stowed position. The CONDOR is
designed to travel with platform elevated on FIRM LEVEL SURFACES ONLY.
The brake of the unit is automatically applied when drive control is
returned to neutral. It is automatically released when drive control is
activated. RELEASE of drive lever will APPLY the brake. AVOID RELEASING of
drive lever at full speed, as drive function will CEASE ABRUPTLY, causing a
sudden movement of the platform.
Maximum travel speed is 3.0 MPH. This is high speed travel and is only
available with boom below horizontal.
Low speed is available by moving HIGH/LOW SPEED toggle switch to LOW. Low
speed is automatically shifted when boom is elevated above horizontal.
3. GROUND CONTROLS
The ground controls are located on the turret. No means is provided to
DRIVE or STEER the unit from the GROUND CONTROLS. Only the aerial functions
can be accomplished. The boom can be raised or lowered, extended, or
retracted; and the turret can also be rotated.
-12-
LEFT
TUIIIIET ROTATICII
RIGHT
EXTEND
IIOCIt
RETRACT
FUSE
START
ElSIE
STOP
IfOUR JETER
rm--~---~ KEY SIIITCH
_JETER
GROUND CONTROL BOX IDENTIFICATION
KEY SWITCH
The ground panel has a POWER KEY SWITCH. The key straight up center
position is -OFF- and disconnects all power. With switch in -ON-
position, the electrical circuit is energized. Switch must be -ON- to
energize ground or platform controls.
ENGINE START/STOP - SWITCH
Toggle switch for start-stop of engine. Switch is momentary, meaning it
returns to center position when released. Actuate switch UP to START
engine; DOWN to STOP engine.
CHOKE SWITCH
Toggle switch to activate engine choke. May be used in conjunction with
engine START toggle switch. Purpose to assist starting of engine first
time in morning or after long periods of non-use. Actual CHOKE switch
-UP- for operation.
-13-

AERIAL/GROUND SELECT SWITCH
Two-position toggle switch for selection of operation from ground
control or platform controls. The -GROUND- position directs the power
to the ground control panel. The -AERIAL- position directs the power to
the aerial control console, energizing it for operation of the platform
controls. NOTE: When in -AERIAL- position, the control can be moved to
-GROUND- at any time, making aerial controls inoperable.
BOOM RAISE/LOWER
Momentary, return to center, toggle switch to raise or lower boom.
Actuate switch to -UP- position RAISES boom; -DOWN- position LOWERS
boom.
TURRET - ROTATE
Momentary, return to center, toggle switch to rotate turret. Actuate
switch to -RIGHT- rotates turret CLOCKWISE; to -LEFT- rotates turret
COUNTERCLOCKWISE.
BOOM - EffiND/RETRACT
Momentary, return to center, toggle switch to extend or retract boom.
Actuate switch to -UP- position to EffiND boom; -DOWN- position to
RETRACT boom.
SPEED CONTROL
Since a toggle switch control does not offer feathering of function, the
speed of the function can be controlled by use of the SPEED CONTROL.
With knob set at TURTLE speed, the function is MINIMUM/SLOW. Turning
knob toward RABBIT/FAST increases speed.
EMERGENCY CONTROL
The momentary toggle switch positioned in the triangle border is used to
activate the emergency pump and motor. Actuate and hold EMERGENCY switch
in conjunction with desired aerial function; boom up-down; turret rotate
or boom extend-retract.
CIRCUIT BREAKERS (FUSE)
Circuit breakers are used to protect the electrical system. These are
of the fuse type. Should one burn out, it is due to overload or short-
circuit; and cause should be investigated before further operation.
HOURMETER AND AllETER
Hourmeter is used to record number of hours machine is used. NOTE: The
key switch energizes the hourmeter which records even if engine is not
running.
-14-
4. PLATFORM CONTROLS
The platform controls are only ENERGIZED when the key switch at ground panel
is -ON- and the SELECTOR switch is in AERIAL position.
The platform control console provides for complete operation of the unit.
The controls are energized only when the FOOT SWITCH is depressed and held.
UP LEFT EXTEND FORWARD
IIOCIt LIFT TUllllET IOTATICII IIOCIt DRIVE
DOWN RIGHT RETRACT REVERSE
LEFT
PlATFOM IIOTATICII FAST
RIGHT DRIVE SPEED
SLOW
5 SlOPE ALARM
LEFT
STEER
RIGHT
PLATFORM CONTROL BOX IDENTIFICATION

POWER ON/OFF SWITCH
Pull to turn on, START engine ------- push to turn off, STOP engine.
NOTE: This is also the emergency switch. PUSH TO STOP ALL FUNCTIONS.
I NOTE,
The controls for drive and the aerial functions of the boom and turret
are a proportional control. This type control enables the operator to
obtain a higher degree of ~ontrollability by feathering the controller.
The controller contains a safety lock feature which is released by
pulling UP on the KNOB. The lever is also spring return to neutral.
DRIVE FORWARD/REVERSE
Forward motion is determined with DRIVE wheels leading the way. REVERSE
motion is determined with STEERING wheels leading the way. Actuate
lever AWAY from the operator for FORWARD motion; TOWARD the operator for
REVERSE motion.
INOTE,
The recommended travel position is with TURRET COUNTERWEIGHT over the
DRIVE wheels.
-15-
-
HIGH/LOW SPEED
Two (2) position toggle switch for selection of travel speed. Actuate
switch AWAY from operator for HIGH speed; TOWARD operator for LOW speed.
NOTE: High speed can only be obtained with boom below HORIZONTAL.
Speed will be AUTOMATICALLY switched to LOW if boom is RAISED
above HORIZONTAL. This will occur even if HIGH-LOW switch is in
HIGH position.
STEER - LEFT/RIGHT
Toggle switch for control of steering wheels. Switch is momentary,
meaning it returns to center position. when released. Actuate switch to
LEFT to turn wheels for LEFT turn; RIGHT for RIGHT turn.
BOOM - RAISE/LOWER
Proportional control for raising or lowering boom. Move lever AWAY from
operator to RAISE boom; TOWARD operator to LOWER boom.
BOOM - EXTEND/RETRACT
Proportional control for extending or retracting telescopic section of
boom. Move lever TOWARD operator to EXTEND boom; AWAY from operator to
RETRACT boom.
TURRET - ROTATE
Proportional control for rotation of turret. Move lever TOWARD operator
to rotate turret CLOCKWISE; AWAY from operator to rotate COUNTERCLOCKWISE.
PLATFORM TILT
Toggle switch for control of changing the attitude of the platform in
the relation to the ground. It is powered means of adjusting the
levelness of the platform. To TILT platform UP, actuate toggle switch
away from operator; TOWARD operator to tilt platform DOWN.
PLATFORM ROTATION
Toggle switch for control of platform rotation 90 either side of
center. Actuate switch to RIGHT, platform will rotate to operator's
RIGHT. Actuate switch to LEFT to rotate to LEFT.
SLOPE - WARNING LIGHT
This light is used to indicate that unit is being operated on slope in
excess of 5. When light is -ON,- the aerial functions are INOPERABLE.
When this occurs, unit must be repositioned.
EMERGENCY CONTROL
The momentary toggle switch positioned in the triangle border is used to
activate the emergency pump and motor. Actuate and hold EMERGENCY switch,
then actuate desired aerial function toggle switch; boom down; turret
rotate; boom retract.
-16-
SYMBOL CONVERSION
I,
~

UP ON
BOOM
EMERGENCY ./ I
SYSTEM LIGHTS I
DOWN ACTIVATION
OFF
(OPTION)
~
TURRET
ROTATION EMERGENCY
BOOM
RETRACTION START
AUX. ENGINE
@ STOP
t
RETRACTION
BOOM
EMERGENCY
EXTENSION BOOM
ROTATION
REVERSE
@ START
ENGINE
t () STOP
DRIVE EMERGENCY
FORWARD BOOM
LOWER
~r" KEY SWITCH

~
FAST
~
V STEER TRAVEL SPEED

R/l SLOW
J HOUR METER
~,
UP HORN AMP METER
PLATFORM c:J1
DOWN
IS] CHOKE
AERIAL CONTROL
BOX ACTIVATED
c
PLATFORM
..?F.. ROTATION
GASOLINE
GROUND CONTROL
BOX ACTIVATED
C@ PULL TO START
ENGINE DUAL FUEL
I ! PUSH TO STOP (OPTION)
L--------------------- 17 - - - - - - - - - - - - - - - - - - - - - - -
OPERATIONAL PROCEDURE
Prior to operation of the CONDOR t for your OWN SAFETY, it is your RESPONSIBILITY
to ensure that the unit is in proper working condition and the PRE-OPERATION
INSPECTION has been performed.
ICAUTION.
Located on the inside back cover of this safety manual (PIN: 92260) are a few DO
NOTIS relative to proper operation and maintenance. ACQUAINT yourself with
these simple RULES and be ALERT to their signs.
IWARNING I
OBSERVE ALL SAFETY PRECAUTIONS WHILE OPERATING THE MACHINE. Before starting
engine, check fuel level and for any leaks in the fuel system.
1. OPERATION FROM GROUND CONTROLS
Turn KEY SWITCH to HON- position.
Move START-STOP toggle switch to START position. NOTE: It may be
necessary to choke engine. Actuate CHOKE switch, holding into position
while actuating START switch.
Place AERIAL-GROUND selection switch to GROUND position.
IWARNING I
Check for overhead obstructions directly over machine as well as over platform.
Also, if unit is to be rotated, check for obstructions on either side of the
machine.
GROUND CONTROl BOX
UP LEFT
1'VRIIET ROTAn III
BOOM LIFT
DOWN
EXTEND
BOOM
RETRACT
FUSE
START
~-+-_---EII6IN
STOP
-18-
Raise platform by actuating boom RAISE-LOWER toggle switch to RAISE
position.
Extend boom by actuating boom EXTEND-RETRACT toggle switch to EXTEND
position.
I WARNING_
REJl)VE TURRET LOCK PIN BEFORE ROTATIN6 TURRET IF SO EQUIPPED.
Rotate turret by actuating ROTATION toggle switch to desired position.
RIGHT for CLOCKWISE rotation; LEFT for COUNTERCLOCKWISE rotation.
I NOTE'
Ground panel is equipped with a SPEED CONTROL for the aerial functions.
Rotating knob toward TURTLE slows function; toward RABBIT increases speed.
I CAUTION _
Exercise extreme care in operating these controls. AVOID JERKY MOVEMENTS.
Always LOOK in the direction of platform and turret movement. Make SURE there
is no OBSTRUCTION and that SUFFICIENT CLEARANCE exists for the platform.
To lower platform, activate appropriate functions' toggle switch for
LOWER, RETRACT or ROTATION modes.
At the end of the operation, STOP engine and turn KEY SWITCH to OFF
pOSition.
2. OPERATION FROM PLATFORM CONTROLS

At ground control console, turn KEY SWITCH to -ON-. Move AERIAL-6ROUND
selector switch to AERIAL position.
Enter the platform of the CONDOR with the access provided. Ensure that
the platform entrance SLIDE BAR is in the DOWN position.
PLATFORM CONTROL BOX
UP
_LIFT
DOWN
LEFT
PtATF_ IIJTATIOI
RIGHT
LEFT
STEI
RIGHT
-19-
At the control console, pull the POWER switch to -ON- position. This
will start the engine.
Depress the FOOT SWITCH and HOLD. This will energize the control
circuit as long as the foot switch is depressed.
FOOT SIIITCH
FOOT SWITCH
DRIVE
To operate drive, lift up on knob and gradually move lever in desired
direction of travel. Make SURE area around the machine is CLEAR before
traveling.
FORWARD/REVERSE and LEFT/RIGHT steering movement directions indicated on the

control panel refer to control with the platform and boom over the STEER wheels.
The speed of operation is dependent on the position of the control
lever; full position will give full speed. The brakes are automatically
released when drive control is activated and automatically applied when
control is returned to neutral/center pOSition.
Start and stop the operation GRADUALLY. The SMOOTHER you move the
control lever the SMOOTHER the unit will respond. AVOID releasing the
lever COMPLETELY.
STEERING
Is controlled by activation of the toggle switch. Move switch in desired
direction and HOLD until the 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.
BOOM - RAISE/LOWER
To raise boom, depress foot switch and move lever on control console
AWAY from operator. To LOWER boom, move lever TOWARD operator.
-20-
BOOM - EXTEND/RETRACT
Depress foot switch and move lever TOWARD operator to EXTEND; AWAY from
the operator to RETRACT.
TURRET ROTATION - CLOCKWISE/COUNTERCLOCKWISE
To rotate turret, depress foot switch and move lever in desired
direction for desired movement; TOWARD operator for CLOCKWISE rotation;
AWAY from operator for COUNTERCLOCKWISE rotation.
TILT - UP/DOWN
To make adjustment for leveling of platform or tilting to facilitate
loading of materials, depress foot switch and actuate toggle switch
toward operator to LOWER; AWAY from operator to RAISE.
PLATFORM ROTATION
To rotate platform, depress foot switch and actuate toggle switch to
RIGHT to rotate platform RIGHT; to LEFT to rotate platform LEFT.
IWARNING'
When operating control levers in UP or EXTEND mode, remember you are head and
shoulders above the platform railings. BE SURE sufficient OVERHEAD clearance
exists before you activate control.
Also, when activating control to LOWER or RETRACT mode, ensure that the path
below platform is CLEAR.
Only ROTATE turret after you are SURE no OBSTRUCTIONS exist to side of intended
movement.
3. StIJT DOMN
Push POWER switch -IN- on the platform control console. This will STOP
engine as well as DEACTIVATE control circuit.
At ground panel, turn KEY SWITCH to OFF position.
4. EMERGENCY OPERATION
The emergency controls at the ground console and platform console are
operated in the same manner.
Actuate and HOLD toggle switch located inside triangle and actuate
appropriate toggle sw,itch for boom raise/lower; boom extend/retract or
turret rotate.
A CAREFUL, TRAINED AND OBSERVANT OPERATOR
IS THE GREATEST SAFETY DEVICE AVAILABLE
-21-
PREVENTATIVE MAINTENANCE
In conjunction with the PRE-OPERATION INSPECTION, a good preventative
maintenance program will enhance a properly operating machine and the SAFETY of
those 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 ~ERVICE MANUAL for a more
detailed breakdown and recommended time interval of PREVENTATIVE MAINTENANCE.
LUBRICATION
Refer to the CONDOR lubrication diagram for the location of items requiring
lubrication. Recommended lubricating intervals are based on normal use in
normal environmental conditions. User is cautioned to adjust the lubricating
interval, accordingly, to meet each individual condition and usage.
Specific lubricants recommended, are generally the best choice. Should
these lubricants be unavailable in your area, consult your local supplier
for an equivalent.
TYPE OF LUlRICMT
Cfi - atASSlS &lEASE:
SlELL DAaA AI 70330 OR EQUAL
EO - Ell611E Oil:
LUBRICATION CHART SHOWN IIJDEL &ON
SA[ 30 IlEIIiItT
60 - SEAR OIL:
SA[ 90 IlElliItT EP
lIP - HEAVY DUTY OPEN GEAR:

C.... 7045 OR EQUAL
CHECK SPEED REDUCER
iii - HEl BEARllKi IiREASE
IITERVAl SYIIIOL
o 50 HOURS or SEMI-IOIJHLY
D 100 HOURS or IOITHL Y
o 500 HOURS or AllllAlLY
CRMKCASE FIll
LUBRICATION CHART
-22-
LUBRICATION
1. PRESSURE GUN LUBE POINTS

A. Lubricant - - - - - - - - - - Chassis grease (Shell Darna AX70330
or equal).
B. Time Interval - - - - - - - - Once a week or every 50 hours of
operation.
C. Procedure - - - - - - - - - - Service all fitting as indicated on
chart. Clean lube fittings and apply
with pressure gun. Wipe away all
excess lubricant from exposed surfaces.
Excess lubrication can collect dirt
and foreign matter both of which act
as abrasives.
2. STEERING CYLINDER
A. Lubricant - - - - - - - S.A.E. 30 weight engine oil.
B. Time Interval - - - - - Once a week or every 50 hours of
operation.
C. Procedure - - - - - - - - - - Apply with oil can to both sides of
pivot.
3. WHEEL BEARINGS
A. Lubricant - Wheel bearing grease.
B. Time Interval - - - - - - - - 500 hours or yearly, whichever
comes first, or upon reassembly.
C. Procedure - - - - - - - - - - Remove hub cap, clean out old
lubricant and repack.
4. ROTATION GEAR TEETH AND PINION

A. Lubricant - - - - - - - - - - Crown 7045 heavy duty open gear oil
or equal.
B. Time Interval - - - - - - - - 500 hours of operation or yearly,
whichever comes first.
C. Procedure - - - - - - - - - - Wipe gear teeth clean on rotation
ring and pinion. Spray on lubricant.
-23-
5. ROTATION GEAR BOX
A. Lubricant -- S.A.E. 90 weight EP oil.
B. Time Interval - - - Check every 50 hours. Change every
500 hours of operation or year1Y9
whichever comes first.
C. Procedure - - - - - - - - - - Remove drain plug. Refill until
level reaches about 1" from top of
fill hole.
6. DRIVE TORQUE HUBS

A. Lubricant -- S.A.E. 90 weight EP oil.
B. Time Interval Check periodically and fill as
required. Change every 500 hours
or year1Y9 whichever comes first.
C. Procedure - - - - - - - - - - To check 1eve1 9 rotate wheel so
that level plug is horizontal.
Remove plug. If steady flow of oil
pours forth, unit is sufficiently
full.
7. HYDRAULIC SYSTEM - KEEP SYSTEM CLEAN

A. Fluid Level - - - - - - - - - Check level daily. Maintain fluid
level at full mark on dipstick with
the unit in fully retracted position.
B. Hydraulic Oil Filters - - - - Change return line filter located
in hydraulic tank after the first
30 days or 50 hours of operation.
Thereafter, change the filter every
3 months or 300 hours of operation.
C. Tank Breather - - - - - - - - Clean every 50 hours of operation.
Remove from tank and clean with
solvent. Air blow dry.
D. Hydraulic Tank - - - - - - - - Drain oil tank every 500 hours or
yearlY9 whichever comes first, and
replace filter element. Add oil to
tank to required level.
I NOTE.
Use only ATF DEXTROI II or equal. DO NOT MIX hydraulic oil.
It may be necessary to lubricate or service the hydraulic system more frequently
when operating in abnormal environments such as dusty conditions.
-24-
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CONDOR JlJDEL 361 AID 461 HYDRAULIC SCIIEMTIC

28
2WD HYDRAULIC SCHEMATIC (60N)
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COftDOR MODEL 6011 HYDRAULIC SCHEMATIC
29
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 slide bar provided.
5. DO NOT operate the CONDOR when the wind velocity exceeds 25 mph.
6. DO NOT tow the CONDOR unless equipped with option for in-plant towing
(5 mph max.).
7. DO NOT jerk controls. Operate smoothly and deliberately into and out of
movements.
8. DO NOT force the platform or its railing against any adjacent structure to
brace the CONDOR unit.
9. DO NOT sit or climb on platform railing. Keep both feet on the platform
floor at all times.
10. DO NOT allow overhanging loads on the work platform.
11. DO NOT use ladders, planks, or other devices on the aerial platform for
achieving additional height or reach.
12. DO NOT operate a 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 CALAYAR CORPORATION Engineering Department. DO NOT alter or disable
any interlocks or other safety devices on the CONDOR.
15. DO NOT operate near energized electrical conductors. This is a NON-INSULATED
aerial work 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. Batteries that are
being charged emit highly explosive hydrogen gas.
WHEN PROPERLY MAINTAINED AND OPERATED

CONDORS ARE SAFE AERIAL WORK PLATFORMS!
--
ATTENTION
MANUAL OF RESPONSIBILITIES
for
Dealers, Owners, Users, Operators,
Lessors and Lessees
of
ANSIISIA A92.5-2006
Boom-Supported Elevating Work Platforms
WARNING
FAILURE TO COMPLY with your REQUIRED
RESPONSIBILITIES in the use and operation of the Aerial
Platform could result in DEATH OR SERIOUS INJURY.
IMPORTANT
You are required by ANSI/SIA A92.5-2006 to read and understand YOUR

RESPONSIBILITIES before you use or operate this Aerial Platfonn.
This Manual and the manufacturer's operation and safety manuals are considered integral
the Aerial Platfonn and are VITAL TO COMMUNICATE NECESSARY SAFETY
INFORMATION to users and operators. They MUST BE KEPT ON THE AERIAL
in the storage compartment.
The operation of any aerial platfonn is subject to certain HAZARDS that can
only by the exercise of INTELLIGENCE, CARE, AND COMMON
have COMPETENT, CAREFUL PERSONNEL, TRAINED in the
OPERATION, MAINTENANCE AND SERVICE of this type of
The USER and OPERATOR MUST MAKE DECISIONS on the operation

of the Aerial Platfonn with due consideration for the fact the
OPERATOR AND OTHER PERSONNEL is dependent
COMPLY with your REQUIRED
Platfonn could result in DEATH OR SERIOUS
Refer to the manufacturer's operation and USE of the aerial

platfonn and for further INFORMATION OPERATION.
The ANSI/SIA A92.5-2006 ., ...<..._...< Elevating Work Platfonns became

from that standard as follows:
Definitions Page 2
Responsibilities of Page 3
Responsibilities of Section 6 Page 5
Responsibilities of Section 7 Page 7
Section 8 Page 11
Section 9 Page 14
Section 10 Page 14
Figure 1 Page 15
Id I Association, Inc.
ce Box 20574
, AZ 85036-0574
e: (602) 257-11441 Fax: (602) 257-1166
sia@scaffold.org 1 web: www.scaffold.org
Copyright 2006 by Scaffold Industry Association, Inc.

All rights reserved.
No part of this publication may be reproduced in any form,
in an electronic retrieval system or otherwise, without
the prior written permission of the publisher.
Printed in the United States of America
1
Reprint from ANSI/SIA A92.5-2006 RESPONSIBILITIES MANUAL
Instability: A condition of an aerial platfonn in which

the sum of the moments which tend to overturn the unit
3 Definitions exceeds the sum of the moments tending to resist
overturning.
Aerial platform: A mobile device that has an adjustable Insulated platform: A platfonn designed and
position platfonn, supported from ground level by a to meet the specific electrical insulation
structure. consistent with the manufacturer's ,,'.."1.1Ull",,,"
Alternative configuration(s): Arrangements of the Interlock: A control or mechanism
aerial platfonn or its components which differ from each specified conditions, automatically
other. Alternative configurations mayor may not have the operation of another control or
the same rated workload. Lessee: A person(s) or entity
Anchorage(s): A secure point of attachment to be used platfonn is provided by
with personal fall protection equipment (PFPE). arrangement. A lessee may
Authorized personnel (authorized person): Personnel user or operator.
Lessor: A _~. ~~_.f.
approved or assigned to perfonn a specific type of duty or
duties at a specific location or locations at a work site.
Base: The relevant contact points of the aerial platfonn
that fonn the stability fulcrum (e.g., wheels, casters,
outriggers, stabilizers).
Boom: A cantilever beam which supports the platfonn.
Broker: An independent business entity or person that
arranges a lease or transfer of ownership of an aerial
platfonn, but does not own the aerial platfonn. If the : A document containing
entity or person is an employee of the buyer, seller, lessor 3) and the requirements
.:>e''';UlJIl
or lessee of the aerial platfonn, he shall not be "UUlHueJ this Standard for the following entities:
a broker. 5); Owners (Section 6): Users
Chassis: The integral part of the aerial platfonn Operators (Section 8); Lessors (Section 9);
provides mobility and support for the (Section 10); and Brokers (Section 11).
~Hllfal~tlllrer: A person or entity who
Configurations: All positions in which an
platfonn or any part thereof can be placed makes, builds, or produces an aerial platfonn.
intended operating limits. Maximum travel height: The maximum platfonn
Critical component(s): Load height or the most adverse configuration(s) with
support or stabilize the I.Ha.UU.Llll.ol respect to stability in which travel is pennitted by the
Dealer: A person or entity manufacturer.
manufacturer or Uli>LllL'ULl Modification, modifies: To make a change(s) to an
aerial platfonn which affects the operation, stability,
safety factors, rated load, or safety of the aerial
platfonn in any way.
or entity to
Most adverse stability conditions: The permitted
mitiate functions that configuration of the aerial platfonn most likely to cause
the aerial platfonn. instability. Factors to be considered shall include:
1 With zero load to maximum test load.
a minimum
2. Up to and including maximum platfonn height.
(50.8mm).
3. All positions and configurations of the platfonn(s).
The mechanisms used to position
4. All wheel and axle positions.
to the aerial platfonn chassis.
5. Forward and backward configurations of the
Providing infonnation regarding the
elevating assembly.
and safety devices for the aerial
6. All other moveable features which affect the
to a qualified person or operator who controls
stability of the aerial platfonn.
of an aerial platfonn.
Multiple rating(s), multiple rated loads: Two or
system: A vertical barrier primarily intended
more different rated work loads based on alternative
against personnel falling to lower levels.
configurations of the aerial platfonn.
Hazardous location: Any location that contains, or has
Non-ductile materials: Materials having an
the potential to contain an explosive or flammable
elongation ofless than 10% in 2 inches (50.8mm).
atmosphere as defined in ANSIINFPA 505 for Powered
Operation: Perfonnance of functions of an aerial
Industrial Trucks, Including Type Designations, Areas of
platfonn within the scope of its specifications and in
Use, Maintenance, and Operation.
accordance with the manufacturer's instructions, the
2
Reprint from ANSIISIA A92.5-2006 RESPONSIBILITIES MANUAL
user's work rules, and applicable governmental Should: The word "should" indicates that the rule is a
regulations. recommendation, the advisability of which depends on
Operator: A qualified person who controls the the facts in each situation.
movement of an aerial platform. Stability/Stable: A condition of an aerial
Outriggers: Devices that increase the stability of the which the sum of the moments which tend
aerial platform and that are capable of lifting and leveling the unit is less than the sum of the t11{1,t11pnt...
the aerial platform. resist overturning.
Override: To take over aerial platform movement Stabilizers: Devices that increase
control functions at the upper control station by those at aerial platform but are not capable
the lower control station. the aerial platform.
Owner: A person or entity who has possession of an Training: Instruction to
aerial platform by virtue of proof of purchase. a qualified person regarding
Passive: Under specified conditions, automatically including knowledge
performed and not requiring any specific action to Unintended
accomplish.
Platform: The portion of an aerial platform intended for
occupation by personnel with their necessary tools and maximum
materials. aerial platform
Platform height: The vertical distance measured from in all operating
the floor of the platform to the surface upon which the
aerial platform is being supported. ) that has care, control,
Platform reach: The horizontal distance measured from platform. This person or
the center line of rotation to the outer most edge of the also be the employer of the operator, a
platform. owner, lessor, lessee, or operator.
Powered functions: Those which control motion of .,,,.....,,,, of Dealers
platform or the aerial platform and are caused by Principles. Sound principles of
electromechanical, hydraulic, or pneumatic , training, inspection, maintenance, application,
Qualified person: One who, by possession operation consistent with all data available
recognized degree, certificate, or professional regarding the parameters of intended use and expected
by extensive knowledge, training, environment shall be applied in the training of
successfully demonstrated hislher operators, in maintenance, application, safety
resolve problems related to the provisions and operation of the aerial platform with due
or the project. consideration of the knowledge that the unit will be
Rated horizontal force: carrying personnel.
5.2 Manuals
5.2.1 Machine Manual(s). Dealers shall keep and
maintain a copy(ies) of the:
(1) Operating manual
(2) Maintenance manual
(3) Parts manual
(4) Repair manual
The operating manual and maintenance manual shall be
provided with each rental, lease, or sale delivery and
shall be stored in the weather resistant storage
compartment on the aerial platform. Manual(s) are
The modification of an aerial platform, considered an integral part of the aerial platform and
its original manufacturer or another qualified are vital to communicate necessary safety information
that the aerial platform will comply with the to owners, users and operators. In addition, repair
,,,.,,,,,,,,,, in effect on the date the modification is and parts manuals should be provided with each sale
delivery.
Repair: The act of restoring to good condition that 5.2.2 Manual of Responsibilities. The current
which has been broken, damaged or worn due to use, Manual of Responsibilities for dealers, owners, users,
abuse or other reasons. operators, lessors, lessees and brokers of boom-
Shall: The word "shall" is to be understood as supported elevating work platforms shall be provided
mandatory. and stored in the weather resistant storage
compartment.
3
5.3 Predelivery Preparation. Aerial platforms shall of use), the dealer shall assume the responsibilities of
be inspected, serviced and adjusted to manufacturer's users as specified in Section 7 of this standard. All
requirements prior to each delivery by sale, lease, or personnel authorized to operate the aerial PlaltIO,rm
rental. shall have been:
5.4 Maintenance, Inspection and Repair. (1) Trained
5.4.1 Maintenance. When a dealer accomplishes (2) Familiarized with the aerial
preventive maintenance on the aerial platform, it shall be operated
in accordance with the manufacturer's recommendations (3) Made aware of the reS1POncSlO'111
and based on the environment and severity of use. operators as outlined in Section 8
5.4.2 Inspection. When the dealer accomplishes standard
frequent and annual inspections, they shall be in 5.10 Assistance to
accordance with the manufacturer's manuals and unable to answer an owner's
instructions. relating to rated
5.4.3 Repairs. Repairs accomplished to correct repair, inspection,
malfunctions and problems shall be in accordance with the dealer shall
the manufacturer's manuals and instructions.
5.5 Maintenance Safety Precautions. Before
adjustments and repairs are started on an aerial platform,
the following precautions shall be taken as applicable:
(1) Power plant stopped and starting means rendered
inoperative at least four years:
(2) All controls in the "Off' position and all operating of the purchaser of each aerial
systems secured from inadvertent motion by brakes, number and date of delivery
blocks, or other means of the pre-delivery preparation
(3) Boom and platform lowered to the full down to each delivery
position, if possible, or otherwise secured by Records of frequent and annual machine
cribbing to prevent dropping accomplished
(4) Hydraulic oil pressure relieved from Records of repairs accomplished to correct
circuits before loosening or removing malfunctions and problems
components (5) Name of the person(s) trained
(5) Safety props or latches (6) Name of the person(s) providing the training
as prescribed by the U>C'Luu.a" (7) Date of Training
5.6 Replacement Parts. (8) Name ofperson(s) receiving familiarization with
replaced, they shall be the aerial platform upon each delivery unless this
aerial platform parts or individual has been provided with familiarization on
5.7 Training. the same model, or one having characteristics
The dealer shall consistent with the one being delivered, within the
requirements prior 90 days
inspection, 5.11.2 Proof of training. The dealer should
operation of the aerial provide trainees who successfully complete training a
means to evidence they are trained. The dealer shall
Delivery. provide such proof if requested by the trainee. The
sale, rental or any form of use, document evidencing training shall include the
the responsibility with the person following information:
receiving entity for accepting the aerial (1) Name of trainee
(2) Name of entity providing training or retraining
the weather resistant compartment (for (3) Name oftrainer(s)
storage) (4) Clear identification that training covered Boom-
,",V<JLHU,U that the manual(s), as specified by the Supported Elevating Work Platforms
are on the aerial platform (5) Date of training
(3) Review control functions 5.11.3 Record dissemination. Upon request, the
(4) Review safety devices specific to the model aerial dealer shall provide the following information:
platform being delivered (1) To the owner of the aerial platform, a copy of
5.9 Dealer as User. Whenever a dealer directs frequent or annual inspections performed
personnel to operate an aerial platform (loading, (2) To the owner of the aerial platform, a copy of
unloading, inspecting, sales demonstrations, or any form repairs accomplished
4
(3) To a user, proof of training for an operator, is part of the aerial platform. The manual(s) is
including name of trainer and date of training considered an integral part of the aerial platform and is
(4) To a user, the name of the person(s) receiving vital to communicate necessary safety information
familiarization upon delivery of the aerial platform owners, users and operators. In addition, repair
5.12 Modifications. Modification, alteration or parts manual(s) should be provided with
remanufacture of an aerial platform shall be made only delivery.
with prior written permission of the manufacturer. 6.3.2 Manual of Responsibilities.
5.13 Manufacturer's safety bulletins. The dealer Manual of Responsibilities for
shall comply with safety-related bulletins as received operators, lessors, lessees and
from the manufacturer. supported elevating work
5.14 Responsibilities upon sale. When the aerial and stored in the weather
platform is sold, the dealer: compartment.
(1) Shall, upon delivery, ensure the operating and 6.4 Maintenance,
maintenance manuals are conveyed to the owner 6.4.1
(2) Shall, upon delivery, provide a copy of the current
Manual of Responsibilities
(3) Should, within 60 days of sale, provide repair and
parts manuals
(4) Shall, within 60 days of the sale, notify the
manufacturer or its successor (if existing) of the sale,
providing the full name and address of the purchaser
(5) Should, if the aerial platform is used, accomplish an
annual machine inspection
prior to delivery and provide a copy to the purchaser
within 60 days of the sale
(6) Shall, upon delivery, familiarize the person and problems identified in the inspection
designated by the receiving entity with the corrected before the aerial platform is returned
being acquired.
6 Responsibilities of Owners 6.4.3 Repairs. When the aerial platform is damaged
6.1 Basic Principles. Sound or in need of repair, all malfunctions and problems
training, inspection, maintenance, identified shall be corrected before the aerial platform
operation consistent with all is returned to service.
parameters of intended use and 6.5 Pre-delivery Preparation. Aerial platforms
shall be applied in the shall be inspected, serviced, and adjusted in accordance
of owners WIth due with the manufacturer's specifications prior to each
the aerial platform delivery by sale, lease, or rental.
6.2 n~:'I'UIII:!iIUIIJl~ 6.6 Frequent Inspection. The owner of an aerial
platform shall ensure that a frequent inspection is
performed in accordance with the manufacturer's
instructions, on an aerial platform:
(1) That was purchased used. This inspection shall
be accomplished unless it is determined that the
sixty (60) of acquisition of the frequent and annual inspections are current
. the manufacturer with the full (2) That has been in service for three months or 150
of the buyer along with the model and hours, whichever comes first
aerial platform acquired (3) That has been out of service for a period longer
the aerial platform is used, ensure the than 3 months
inspection and annual inspections are current The inspection shall be made by a person
become familiar with and conform to the qualified as a mechanic on the specific type
of owners as set forth in the Manual of aerial platform or one having similar design
Responsibilities for Boom-Supported Elevating Work characteristics. The inspection shall be in
Platforms accordance with items specified by the
6.3 Manuals manufacturer for a frequent inspection and shall
6.3.1 Machine Manual(s). Owners shall provide a include, but not limited to the following:
copy(ies) of the operating and maintenance manual(s) (1) All functions and their controls for speed(s),
with each rental, lease, or sales delivery by ensuring they smoothness, and limits of motion
are properly stored in the weatherproof compartment that
5
(2) Lower controls including the provisions for specified in Section 7 of this standard and shall ensure
overriding of upper controls the person has been:
(3) All chain and cable mechanisms for adjustment and (1) Trained
worn or damaged parts (2) Familiarized with the aerial platform to
(4) All emergency and safety devices operated
(5) Lubrication of all moving parts, inspection of filter (3) Made aware ofthe responsibilities
element(s), hydraulic oil, engine oil, and coolant as as outlined in Section 8 of this stanrulrd
specified by the manufacturer 6.11.2 Assistance to user.
(6) Visual inspection of structural components and when an owner sells, leases, rents
other critical components such as fasteners, pins, shafts, platform for any form of
and locking devices that time shall offer to do
(7) Placards, warnings and control markings
(8) Items specified by the manufacturer
(9) Emergency lowering means
6.7 Annual Inspection. The owner of an aerial
platform shall ensure that an annual inspection is
performed on the aerial platform no later than thirteen
(13) months from the date ofthe prior annual inspection. '''''''.''LaJllL compartment (for
The inspection shall be made by a person(s) qualified as a
mechanic on the specific type of aerial platform or one as specified by the
having similar design characteristics. The inspection shall aerial platform
be in accordance with items specified by the manufacturer functions with the operator or
for an annual inspection. The owner shall not place the U"~"~.laL"iU by the user
aerial platform into service until all malfunctions and safety devices specific to the model
problems have been corrected. being delivered
6.8 Maintenance safety precautions. Before Operation. When an owner operates an aerial
adjustments and repairs are started on an the owner shall have the responsibilities of
the following precautions shall be taken as as specified in Section 7 of this standard and his
(1) Power plant stopped and starting means operating personnel shall have responsibilities of
inoperative operators as specified in Section 8 of this standard.
(2) All controls in the "Off' 6.14 Assistance to users and operators.
systems secured from in<llh,,rtpnt If an owner is unable to answer a user's or operator's
blocks, or other means question(s) relating to rated capacity, intended use,
(3) Elevating assembly maintenance, repair, inspection, or operation of the
down position, if vv",u ..., aerial platform, the owner shall obtain the proper
blocking or ,",UL'VU.'F. information from the dealer or manufacturer and
(4) Hydraulic provide that information to the user or operator.
circuits 6.15 Record Retention and Dissemination.
6.15.1 Record Retention. The owner shall date and
(5) retain the following records for at least 4 years:
(1) Name and address of the purchaser of each aerial
by the manufacturer platform by serial number and date of delivery
When parts or components are (2) Written records of the frequent and annual
be identical or equivalent to original inspections performed. The record shall include
or components. deficiencies found, corrective action accomplished and
training. The owners shall train identification of the person(s) performing the
linteiian(;e personnel in inspection and inspection and repairs
of the aerial platform in accordance with the (3) Written records of repairs accomplished on the
s recommendations and Sections 6.2, 6.3, aerial platform. The records shall include corrective
,6.6,6.7,6.8,6.9 and 6.11 of this standard and action accomplished and identification of the person(s)
with the manufacturer's recommendations. performing the repairs
6.11 Training (4) Pre-delivery preparation performed prior to each
6.11.1 Operator training. Whenever an owner directs delivery
or authorizes an employee to operate an aerial platform, (5) Name of the person(s) trained
(loading, unloading, inspecting or any form of use) the (6) Name ofperson(s) providing training
owner shall assume the responsibilities of the user as (7) Name ofperson(s) receiving familiarization upon
each delivery unless the individual has been provided
6
Reprint from ANSUSIA A92.5-2006 RESPONSIBILITIES MANUAL
with familiarization on the same model, or one having 7.2.1 Machine manuals. Users shall keep and
characteristics consistent with the one being delivered, maintain a copy(ies) of the operating and maintenance
within the prior 90 days manual( s) in the weather resistant storage "''''''''1'\'~rl1''''''''nt
(8)Name ofperson(s) providing familiarization upon provided by the manufacturer. The manual(s)
delivery considered an integral part of the aerial
6.15.2 Proof of Training. Owners providing training vital to communicate necessary safety
should provide successful trainees a means to evidence users and operators.
their training and shall provide such proof if requested by 7.2.2 Manual of Resp(IDsiibilitie:s..
the trainee. The document evidencing training shall Manual of Responsibilities for
include the following information: operators, lessors, lessees and
(1) Name of entity providing training or retraining supported elevating work
(2) Name oftrainer(s) and stored in the weather
(3) Clear identification that training covered Boom- compartment.
Supported Elevating Work Platforms 7.3 Inspection
(4) Date of training inspect and . required to
(3) Name of trainee of inspection
6.15.3 Record dissemination. Upon request, an by the
owner accomplishing training and/or familiarization "".,,,v,,., and be compatible
shall provide the following: the severity of the
(1) To a user, proof of training for an operator, platforms that are not in
including name of trainer and date of training shall be immediately
(2) To a user, the name of the person(s) receiving until repaired. Repairs shall be
familiarization upon delivery of the aerial platform person and the repairs shall be in
... L><UU",U
6.16 Modifications. The owner shall not modify or with the manufacturer's
concur in modification or alteration to the aerial
without the modifications being approved and Frequent Inspection. Users of an aerial
writing by the manufacturer. shall ensure that frequent inspections are
6.17 Manufacturer's Safety Bulletins. ~11\"""'""U as outlined in Section 6.6 of this standard.
The owner shall comply with safety related 7.3.2 Annual Inspection. Users ofan aerial
received from the manufacturer or platform shall ensure that annual inspections are
6.18 Responsibilities upon conducted as outlined in Section 6.7 of this_standard.
aerial platform, the seller: 7.3.3 Pre-start inspection. Before use each day or
(1) Shall, upon delivery, at the beginning of each shift, the aerial platform shall
maintenance manuals are be given a visual inspection and functional test
(2) Shall, upon including, but not limited to, the following:
Manual Re!;polt1sillilil:i~ (1) Operating and emergency controls
(3) Should (2) Safety devices
(3) Air, hydraulic and fuel system leaks
(4) Cables and wiring harness
(5) Loose or missing parts
(6) Tires and wheels
(7) Placards, warnings, control markings, and
information in this standard operating manual( s)
by good job management, safety (8) Outriggers, stabilizers, extendable axles and
I-'I-'Jll""LUVll of sound principles of safety, other structures
maintenance, application and (9) Guardrail system
vU'''''''""U' with all data available regarding the (10) Items specified by the manufacturer
of intended use and expected environment. 7.3.4 Maintenance Safety Precautions.
user has direct control over the application and Before adjustments and repairs are started on an aerial
of aerial platforms, conformance with good platform, the following precautions shall be taken as
practices in this area is the responsibility of the applicable:
user and the operating personnel, including the operator. (l) Power plant stopped and starting means rendered
Decisions on the use and operation of the aerial platform inoperative
must always be made with due consideration for the fact (2) All controls in the "Off' position and all
that the aerial platform will be carrying personnel whose operating systems secured from inadvertent motion by
safety is dependent on those decisions. brakes, blocks, or other means
7.2 Manuals
7
(3) Boom and platfonn lowered to the full down (6) Hazardous locations and atmospheres (reference
position, if possible, or otherwise secured by blocking or ANSIINFPA 505-1996)
cribbing to prevent dropping (7) Inadequate surface and support to withstand
(4) Hydraulic oil pressure relieved from all hydraulic load forces imposed by the aerial platfonn in
circuits before loosening or removing hydraulic operating configurations
components (8) Wind and weather conditions
(5) Safety props or latches installed where applicable (9) Presence of unauthorized
as prescribed by the manufacturer (10) Other possible unsafe
(6) Precautions specified by the manufacturer 7.9 Determination of
7.4 Replacement Parts. When parts or components are be the responsibility of the
replaced, they shall be identical or equivalent to original classification of the intended
aerial platfonn parts or components. Aerial platfonns operated in
7.5 Maintenance Training. The user shall ensure be approved in
only qualified personnel inspect and maintain the aerial required, by
platfonn in accordance with the manufacturer's 7.10
recommendations and Section 7.3, 7.4 and 7.6 of this
standard and with the manufacturer's recommendations.
7.6 Operator Training and Retraining. their perfonnance and
Whenever a user directs or authorizes an individual to the use, application, and
operate an aerial platfonn, the user shall ensure that the olHU.V.,l. . is in confonnance with
person has been: Section 8 of this standard,
(1) Trained before being assigned to operate the aerial hazards, provide means to
platfonn ''',",.u ....,",,, hazards, and explain the
(2) Familiarized with the aerial platfonn to be ope:ratt:Q of not following proper
(3) Made aware of responsibilities of operators as ~Hlellnes. Instructions and guidelines
outlined in Section 8 of this standard proper operation shall include, but not
(4) Retrained, if necessary, based on the be limited to the following issues and
observation and evaluation of the operator. ects:
7.6.1 Trainee Records. A record of the (1) Fall Protection. Principal fall protection is
aerial platfonn instruction shall be provided by the guardrail system. The user shall direct
for at least four (4) years. and monitor the operator to ensure that all components
7.7 Familiarization Before U of the guardrail system are in place. The user shall
only properly trained personnel direct and monitor occupants of the work platfonn to
platfonn. The user shall ensure that they wear a personal fall arrest system to
operator is familiar with protect against the potential effects of ejection or a fall
to be operated, and restraint system to prevent free fall.
(1) Knows compartment (a) Election of Systems: The user may elect to
for manual(s) use either a restraint or an arrest system
(2) Knows 1. Fall Restraint Systems - An anchorage, belt or
supplied by the harness and a lanyard which prevent free fall. These
resistant . with the operating systems are arranged to keep occupants in the platfonn
in the event of dynamic forces which might cause
ejection.
(1.1) Occupants shall use a restraint system to
understands all safety devices keep the occupant(s) within the platfonn.
aerial platfonn being used (1.2) Restraint systems may include either belts or
Inspection. Before the aerial platfonn harnesses and do not include arresting or deceleration
during use, the user shall check the area in devices.
aerial platfonn is to be used for possible 2. Fall Arrest System - An anchorage, full
such as, but not limited to: body harness and a lanyard used to arrest an employee
(1) Drop-offs or holes, including those concealed by in a fall from an aerial platfonn. Such systems allow a
water, ice, mud, etc. fall over the guardrail system. The force applied to the
(2) Slope(s) body shall be limited to 1800 lbs. (8,000N).
(3) Bumps and floor obstructions (2.1) A fall arrest system shall allow workers to
(4) Debris move around the platfonn but provide a minimum of
(5) Overhead obstructions and electrical conductors lanyard slack.
8
(2.2) A fall arrest system for aerial lifts shall include supervisor any problem(s) or malfunction(s) that
a lanyard, and full body harness. A deceleration device if become evident during operation. The user shall
used will not allow a fall further than that required to ensure all problems and malfunctions that affect
arrest the fall without exceeding 1800 lbs. (8,000N) of safety of operations are repaired prior to .
force on the worker. Fall arrest systems, beyond the (12) Reporting potentially hazardous
anchorage, are not part of the aerial work platform and The user shall direct the operator to
are to be specified and supplied by the user of the aerial to a supervisor any potentially ha:lar,do,\;
work platform. that become evident during nn,~,.<>hn.
(2) Slope and grade. The aerial platform shall not be (13) Hazardous location
operated in any manner on grades, side slopes or ramps aerial platforms not approved
exceeding those for which the aerial platform is rated by in a hazardous location shall
the manufacturer. (14) Entanglement. Care
(3) Deployment of stability enhancing means. rope, electric cords,
Outriggers, stabilizers, extendable axles, oscillating axles entangled in the
or other stability enhancing means shall be deployed and (15)
locked into place as required by the manufacturer. rated number exceeded when
(4) Guardrail system. Guardrails shall be installed at any height.
and positioned, and access gates or openings shall be direct the operator
properly closed per the manufacturer's instructions. the aerial platform is
(5) Distribution of load. The load and its distribution ~qtilplmeJnt before lowering the
on the platform and any platform extension(s) shall be in
accordance with the engine (if applicable) shall be
manufacturer's rated capacity for that specific tanks are being filled. Fueling
configuration. in a well-ventilated area free of flame,
(6) Maintaining overhead clearance. The nnp'rl'lt..... hazards that may cause fire or
shall be instructed to ensure that adequate
maintained from overhead obstructions and Battery charging. Batteries shall be charged in
electrical conductors and parts. ventilated area free of flame, sparks, or other
(7) Electrocution hazard. All applicable hazards that may cause fire or explosion.
related work practices intended to electric (19) Improper platform stabilization. The aerial
covered by the Code of Federal (CFR) platform shall not be positioned against another object
1910.333 shall be defined and the operator to steady the platform or improve stability.
by a qualified person. In shall (20) Misuse as a crane. The aerial platform shall
direct the operator not be used as a crane.
qualifications to maJntalI1 (21) Unusual operating support conditions. The
(MAD) from enelrgi~~ aerial platform shall not be operated from a position on
CFRI91O.333c. trucks, trailers, railway cars, floating vessels, scaffolds,
(8) The user or similar equipment unless the application is approved
shall direct personnel on the in writing by the manufacturer or a qualified person.
equipment (PPE) as (22) Travel speeds. The user shall direct the
operator to limit travel speed according to conditions,
"'pr~"1.nnpl shall maintain a firm including the condition of the support surface,
while working thereon. congestion, visibility, slope, location of personnel, and
on the mid-rail or top-rail of the other factors leading to hazards which may cause
'prc,hit)ited. The use of planks, ladders, collision(s) or result in potential injury(ies) to
on the platform for achieving personnel.
or reach is prohibited. (23) Driving requirements. Before and during
rn!Callltilm for other moving equipment. When driving while the platform is elevated, the user shall
equipment and vehicles are present, special direct the operator to:
shall be taken to comply with local (a) Maintain a clear view ofthe support
ordinances or safety standards established for the surface and route of travel
workplace. Warnings such as, but not limited to, flags, (b) Ensure personnel in the worksite area
roped off areas, flashing lights, and barricades shall be that may be affected are aware of the
used as appropriate. movement, communicating and
(11) Reporting problems or malfunctions. The user maneuvering the aerial platform as
shall direct the operator to immediately report to a required to protect against personal
9
injury (35) Adequate support requirements. The user
(c) Maintain a safe distance from obstacles, shall ensure the support surface is adequate for the
debris, drop-offs, holes, depressions, aerial platfonn and the load carried.
ramps, and other hazards to ensure safe (36) Leveling the aerial platform.
travel leveling devices supplied by the manutacture.J
(d) Maintain a safe distance from overhead utilized to level the aerial platfonn when
obstructions and energized electrical conductors. (37) Protecting against u ..,,,u ....,,
(24) Stunt driving. Stunt driving and horseplay are user shall direct the operator not to
prohibited. provide the aerial platfonn for any
(25) Securing the aerial platform. The user shall use unless so authorized.
direct the operator to implement means provided to 7.11 User as Operator. If
protect against use by an unauthorized person(s). of an aerial platfonn, the user
(26) Altering safety devices. Interlocks or other safety responsibilities of
devices shall not be altered or disabled. this standard as
(27) Snagged platform. If the platfonn or elevating
assembly becomes caught, snagged, or otherwise
prevented from nonnal motion by adjacent structures or ~enmnnel to cease
other obstacles such that control reversal does not free the mcase of any
platfonn, all personnel shall be removed from the aerial platfonn, or any
platfonn before attempts are made to free the platfonn condition('S) that may be
using lower controls. further infonnation as to
(28) Vacating (or entering) an elevated aerial owner, dealer, or manufacturer
platform. If pennitted by the manufacturer, personnel operation of the aerial platfonn.
shall only vacate or enter a raised aerial platfonn by Retention and Dissemination.
following the guidelines and instructions provided by Retention. The user shall retain the
manufacturer. records for at least 4 years:
(29) Modifications. Modification or Names of the operator(s) trained and retrained
aerial platfonn or the fabrication and attlcbllnt Names of operator(s) provided familiarization
frameworks, or the mounting of attachments (3) The owner (or the entity designated by the
tools or materials onto the platfonn owner) is responsible to ensure frequent and annual
system shall only be accomplished inspections are conducted and written records are
permission of the manufacturer. maintained. The records shall include the date of the
(30) Assistance to the nn'~r,.tl inspection, any deficiencies found, the corrective action
encounters any suspected recommended and identification of the person(s)
platfonn, or any hazard performing the inspection.
relating to capacity," (4) When employees of the user accomplish repairs
aerial platfonn, on the aerial platfonn, the user shall maintain written
aerial nl<lt1"n,rrn records. The record shall include the date of repair, a
user. description of the work accomplished and identification
Any problem(s) or of the person(s) performing the repair.
of operations shall be 7.13.2 Record Dissemination
aerial platfonn. (1) When the user directs personnel to accomplish
' . . AU;Il'A", (larger than the platform). frequent or annual inspections, not later than 60 days
that only properly secured tools and after the inspections, the appropriate records shall be
evenly distributed and can be safely provided to the owner of the aerial platfonn
) working from the platfonn, are (2) When the user directs personnel to accomplish
repairs on the aerial platfonn, not later than 60 days
horizontal force. The user shall direct the after the repairs are accomplished, the appropriate
not to exceed the manufacturer's rated horizontal records shall be provided to the owner
7.13.3 Proof of Training. Users providing training
(34) Bridge cranes. When an aerial platform is to should provide successful trainees a means to evidence
operate within the area of travel of a bridge crane or their training and shall provide such proof if requested
similar equipment, steps shall be taken to prevent a by the trainee. The document evidencing training shall
collision with the aerial platfonn. include the following infonnation:
(1) Name of entity providing training or retraining
(2) Name oftrainer(s)
10
(3) Clear identification that training covered Boom- 8.4 Problems or malfunctions. Any problems or
Supported Elevating Work Platforms malfunctions that affect the safety of operations shall
(4) Date of training be repaired prior to the use of the aerial platform.
(5) Name of trainee 8.5 Training, Retraining, and Familiarizati~
7.14 Modifications. Modification, alteration or 8.5.1 General Training. Only np~'''{''',"pi
remanufacture of an aerial platform shall be made only received general instructions regarding
with prior written permission of the manufacturer. application and operation of aerial
7.15 Manufacturer's Safety Bulletins. The user shall recognition and avoidance of
comply with safety related bulletins as received from the their operation, shall operate an
manufacturer, dealer, or owner. items covered shall include,
8 Responsibilities of Operators limited to, the following'
8.1 Basic Principles. The information in this standard (1) The purpose and use of
shall be supplemented by good judgment, safety control, (2) That operating
and caution in evaluating each situation. Since the aerial platform and
operator is in direct control of the aerial platform,
conformance with good safety practices in this area is the
responsibility of the operator. The operator shall make
decisions on the use and operation of the aerial platform
with due consideration for the fact that his or her own
safety as well as the safety of others is dependent on those
decisions.
8.2 Manuals
8.2.1 Machine Manuals. The operator shall -ensure and regulations
the operating and maintenance manuals are stored in lonzatlOn to operate
weather resistant storage compartment on the aerial warnings and instructions
platform. The manual(s) is considered an integral operation of the aerial platform Under
the aerial platform and is vital to communicate of a qualified person, the trainee shall
safety information to the operator. The the aerial platform for a sufficient period of
familiar with the manuals and reference them time to demonstrate proficiency in the actual operation
8.2.2 Manual of Responsibilities. of the aerial platform.
be familiar with the requirements 8.5.2 Retraining. The operator shall be retrained,
forth in Section 8 of the Hu,uua... when so directed by the user, based on the user's
observation and evaluation of the operator.
8.5.3 Familiarization. When an operator is
directed to operate an aerial platform he/she is not
familiar with, the operator shall receive instructions
regarding the following items:
day or at the (1) The location of the weather resistant
Plauorrn shall be given compartment (for manual(s) storage)
test including, but not (2) The purpose and function of all controls
(3) Safety devices and operating character-
istics specific to the aerial platform
Pn1,P,.,yp>",..." controls 8.6 Before Operation. Before operation, the
operator shall:
devices
htp('.ti,rp (1) Read and understand the manufacturer's
and fuel system(s) leaks operating instruction(s) and user's safety rules, or have
and wiring harness them explained
or missing parts (2) Understand all labels, warnings, and instructions
and wheels displayed on the aerial platform or have them explained
Placards, warnings, control markings and operating (3) Ensure all occupants of the aerial platform wear
manual(s) appropriate personal protective equipment (PPE) for
(9) Outriggers, stabilizers, extendable axles and other the conditions, including the environment in which the
structures aerial platform will be operated
(10) Guardrail system 8.7 Workplace Inspection. Before the aerial
(11) Items specified by the manufacturer platform is used and during use, the operator shall
check the area in which the aerial platform is to be used
for possible hazards such as, but not limited to:
11
(1) Drop-offs or holes, including those concealed by (3) Deployment of stability enhancing means.
water, ice, mud, etc. Outriggers, stabilizers, extendable axles or other
(2) Slope(s) stability enhancing means shall be deployed and
(3) Bumps and floor obstructions into place as required by the manufacturer.
(4) Debris (4) Guardrail system. Guardrails shall
(5) Overhead obstructions and electrical conductors installed and positioned, and access gates
(6) Hazardous locations and atmospheres (reference openings shall be properly closed per
ANSIINFPA 505-1987) manufacturer's instructions.
(7) Inadequate surface and support to withstand all load (5) Distribution of load. The
forces imposed by the aerial platform in all operating distribution on the platform
configurations extension( s) shall be in
(8) Wind and weather conditions manufacturer's rated capacity
(9) Presence of unauthorized persons configuration.
(10) Other possible unsafe conditions (6) Maintaining The operator
8.8 Prior to each operation. Before each operation shall be n~.~'n+,,"rI clearance is
of the platform, the operator shall ensure: and energized
(1) Outriggers, stabilizers, extendable axles, or other
stability enhancing means, are used as required by the operator shall
manufacturer he or she is qualified,
(2) Guardrails are installed ilVVU"~"Hv safety related work
and access gates or openings are closed per electric shock covered by
manufacturer's instructions >'""');;,u>a,.vu" (CFR) 1910.333. The
(3) The load and its distribution on the platform and level competence shall be established
any platform extension(s) are in accordance with the qualified to do so. Operators shall
manufacturer's rated capacity for that specific appropriate minimum approach distance
configuration energized power lines and parts covered
(4) All personnel on the aerial platform 1910.333 (c)
appropriate safety gear for the work and Personal Protective Equipment. The operator
envisioned. shall ensure all personnel on the platform wear
8.9 Understanding of Hazardous personal protective equipment as required.
It shall be the responsibility of the (9) Personnel footing. Personnel shall maintain a
the hazard classification of . firm footing on the platform floor while working
operation according to thereon. Climbing by occupants on the mid-rail or top-
8.10 Operator rail of the aerial platform is prohibited. The use of
The operator shall direct planks, ladders, or any other devices on the platform
platform to be in VV'.W".'<I- for achieving additional height or reach is prohibited.
in this standard. (10) Precaution for other moving equipment.
performance ensure the use, When other moving equipment and vehicles are
application, platform is in present, special precautions shall be taken to comply
conformance set forth in Section 8 of with local ordinances or safety standards established
this standard, potential hazards, for the workplace. Warnings such as, but not limited to,
identified hazards, and flags, roped off areas, flashing lights, and barricades
ll".r",,,.nN><' of not following shall be used as appropriate.
Instructions and guidelines (11) Reporting problems or malfunctions. The
bpt:ratlon shall include, but not operator shall immediately report to a supervisor any
to the following issues and problem(s) or malfunction(s) that become evident
during operation. The operator shall ensure all
protection. While the guardrail system of the problems and malfunctions that affect the safety of
provides primary fall protection all operations are repaired prior to continued use.
of the work platform shall wear either fall (12) Reporting potentially hazardous locations.
restraint or fall arrest equipment as directed by their The operator shall immediately report to a supervisor
employer. any potentially hazardous location(s) that become
(2) Slope and grade. The aerial platform evident during operation.
shall not be operated in any manner on grades, side (13) Hazardous location operation. Operation of
slopes, or ramps exceeding those for which the aerial aerial platforms not approved and marked for operation
platform is rated by the manufacturer. in a hazardous location shall be prohibited.
12
(14) Entanglement. Care shall be taken platform, all personnel shall be removed from the
to prevent rope, electric cords, and hoses, etc., from platform before attempts are made to free the platform
becoming entangled in the aerial platform. using lower controls.
(15) Capacity limitations. Rated capacities shall not (28) Vacating (or entering) an elevated
be exceeded when loads are transferred to the platform at platform. If permitted by the manufacturer
any height. shall only vacate or enter a raised aerial
(16) Work area. The operator shall ensure the area following the guidelines and ""r-nl("tHw
surrounding the aerial platform is clear of personnel and the manufacturer.
equipment before lowering the platform. (29) Modifications. M(]ldltlcal10Ii'
(17) Fueling. The engine (if applicable) shall be shut aerial platform or the
down while fuel tanks are being filled. Fueling shall be frameworks, or the mounting
done in a well-ventilated area free of flame, sparks, or holding tools or materials onto
other hazards that may cause fire or explosion. guardrail system
(18) Battery charging. Batteries shall be charged in a prior written
well-ventilated area free of flame, sparks or other hazards (30) Assiistall~e
that may cause fire or explosion.
(19) Improper platform stabilization. The aerial
platform shall not be positioned against another object to or safe operation of
steady the platform or improve stability. shall cease operation
(20) Misuse as a crane. The aerial platform shall not """...,,,,,,.,,,+ further information
be used as a crane.
(21) Unusual operating support conditions. malfunction(s). Any
The aerial platform shall not be operated from a position luaHUllvUUU" that affect the safety of
on trucks, trailers, railway cars, floating be repaired prior to the use of the aerial
vessels, scaffolds, or similar equipment unless the
application is approved in writing by the manu:tac:tl.lil1Ot r""rrvino materials (larger than
a qualified person. The operator shall ensure that only
(22) Travel speeds. The operator shall secured tools and materials which are evenly
speed according to conditions, including the distributed and can be safely handled by a person( s)
the support surface, congestion, . slope, working from the platform, shall be moved.
of personnel, and other factors (33) Rated horizontal force. The operator shall not
may cause collision(s) or result exceed the manufacturer's rated horizontal force.
personnel. (34) Bridge cranes or contact with any electrical
(23) Driving ..""mh"", conductors. When an aerial platform is to operate
driving while the within the area of travel of a bridge crane or similar
(a) Maintain a equipment, steps shall be taken to prevent a collision
route of travel with the aerial platform.
(b) Ensure (35) Adequate support requirements. The
maybe operator shall insure the support surface is adequate for
communicating the aerial platform and the load carried.
personal injury (36) Leveling the aerial platform. Outriggers and
from obstacles, leveling devices supplied by the manufacturer shall be
epression,s, ramps, and other utilized to level the aerial platform when provided.
(37) Protecting against unauthorized use. The
distance from overhead obstacles operator shall not use, rent, lease, or provide the aerial
Stunt driving and platform for any form of beneficial use unless so
authorized.
the aerial platform. The
,,;""....iinn
shall implement means provided to protect 8.11 Record of training. When provided or when
use by an unauthorized person(s). obtained upon the operator's request, proof of training
(26) Altering safety devices. Interlocks or other safety by the training entity should be retained by the
devices shall not be altered or disabled. operator. Records shall contain the following
(27) Snagged platform. If the platform or elevating information:
assembly becomes caught, snagged, or otherwise (1) Name of entity providing training or retraining
prevented from normal motion by adjacent structures or (2) Name oftrainer(s)
other obstacles such that control reversal does not free the
13
(3) Clear identification that training covered Boom-
Supported Elevating Work Platforms
(4) Date of training
(5) Name of trainee
9 Responsibilities of Lessors
9.1 Basic principles. Sound principles of safety,
training inspections, maintenance, application, and
operation consistent with all data available regarding the
parameters of intended use and expected environment
shall be applied in the performance of responsibilities of
lessors with due consideration of the knowledge that the
aerial platform will be carrying personnel.
9.2 Lessor as a Dealer. When a lessor uses the aerial
platform as a dealer, the lessor shall have the
responsibilities of dealers as specified in Section 5 of this
standard.
9.3 Lessor as an Owner. When a lessor uses the
aerial platform as an owner, the lessor shall have the
responsibilities of owners as specified in Section 6 of this
standard.
9.4 Lessor as a User. When a lessor uses the aerial
platform as a user, the lessor shall have the
responsibilities of users as specified in Section 7 of this
standard.
9.5 Lessor as an Operator. When a lessor uses
aerial platform as an operator, the lessor shall
responsibilities of operators as specified in
this standard.
10 Responsibilities of Lessees
10.1 Basic Principles. Sound
training, inspections, ma,mtenllnc:e,
operation consistent with all
parameters of intended use and
shall be applied in the
lessees with due COlllSlO,er
aerial platform will
10.2 Lessee as
a User. When a lessee uses the

as a user, the lessee shall have the
of users as specified in Section 7 of
Lessee as an Operator. When a lessee uses

aerial platform as an operator, the lessee shall
have the responsibilities of operators as specified in
Section 8 of this standard.
14
Figure 1 - Typical Examples of Equipment Covered
15
For Your Own
Safety and Protection
Read This Manual
Completely Before
Operating the Condor.
Retain This Manual
on the Condor at all times.
Distributed by
Copies of this manual (PIN: 92260) can be obtained from CALAVAR CORPORATION.
RING-GEAR UP
SERVICE MANUALii
cauIM e.L _TI. ,rov1 ... this __ 1 fe,. ttte p1Hnee .f

all owners, operators, and servicing personnel in order to
obtain the longest possible trouble-free service. It contains
general data, operating instructions, lubrication procedures,
, maintenance and repair procedures and illustrated parts
breakdown.
Serial No.
Date Delivered
NOTE:
CUSTOMER
-
'lIST am.: . - . _
:........ 111.: .R'1I
8300 Imperial Dr., P.O. Box 21447, Waco, TX 76702-1447

(817) 666-4545 - Fax (817) 666-4544
....
,
i ... llucriptfon . f III.,action eN' Jest

Initial If
'.1. ....rtts
j
,
AERIAL COITROL STATI<II
A Enaine start Ii
B Boom liftina control Up Down
C
0
Boom extension
Turret rotation
Out
CW
In
CCW
Ii
E Platform rotation Left Right
F Platform tilt Left Riaht I',
G Drive hiah Forward Reverse
H Dri ve low Forward Reverse
I Steeri ng Left Right
J Brakes Forward Reverse
, K 2-speed shi ft Low Hiah
L Enaine stop
M 5 slope 1iaht
It HYDRAULIC CCIFOIIEIITS
A Platform swina actuator

B Pin retainer
C Boom lift cylinder
0 Pin retainer
E Master leveling cylinder
F Pin retainer
G Slave level ina cv1 inder
H Pin retainer
I Boom extension cylinder
J Pin retainer
K Steerina cylinder
L Pin retainer
M Drive motors Left Right
N Brake assemb1v Left Right
0 Drive block
P Positive traction
0 Turret rotation aear box
R Turret rotation motor
S Hvdraul ic pump
T Hvdrau1 i c tank
U Hydraulic filter
V Valve Panel (Proportional)
W Valve (Solenoid)
7 ELECTRICAL C(JIt()IEllTS
A Moving warnina horn

B Two-speed limit switch
C Deadman foot switch
0 Hour meter
I GEllERAL SERVICING
A Hydraul ic oil level

B Air cleaner oil level
C Turret lube points
0 Chassis lube ooints
E Boom Lub~ ooi nts
Ins,..:ti on performe4 by _ _ _ _ _ _ _ _ _ _ __
Mallie Title Date
,
8. Special forms and tags will be sent to you with authorization.
(Copy enclosed)
NOTE: DO NOT SHIP ANY RETURN PART WITHOUT RETURN AUTHORIZATION. DOing so
part will get lost in the syste. and delay approval of claim.
11
GENERAL SPECIFICATIONS: MODEL 46N RING-GEAR UP
PLATFORM CONTROL CONSOLE: Sealed, spring-loaded proportional

controllers for turret rotation, boom extension/retraction and
elevation. Foot-operated power switch. Toggle switches for platform
tilt and rotation, and emergency power functions. Electric motor
start/stop button. All functions marked with permanent-type universal
symbols. Flip top box allows fast entry to all components and
connections.
WEIGHT: 10,000 lbs. (approx.).
SAFETY FEATURES: Lift/lower warning horn. Emergency power system for
retraction, rotation and lowering. Meets or exceeds all ANSI
A92.S-1980 and OSHA requirements.
OPTIONS: - 180 0 Platform rotation
- Rotating beacon
- Air line to platform
- Turret 360 0 continuous rotation (Rotary coupling with
electric slip ring)
110 volt to platform
- Remote ground control box (Calavar #36464)
CENTER UNE
OF ROTATION
74.50 80.00
52.25
43.38
1.0---------162.00-----------1
...
' - - - - - - - - - - 196.00 ---------001
35' 30' 25' 20' 15' 10' 5' o 5' 10' 15' 20' 25' 30' 35'
45' 45'
/ ........
40' /' \ J "')--- "'- 40'
35'
1/" \: ~ ~ 35'
30' / \1 /I 1,\ \
30'
25' / 1/ 1\ 25'
20'
j .~~
rJ
20'
15'
I
~K \ 15'
10'
I
I ~ \ 10'
~ .~
[(J -I
5'
/; 5'
o .) ~N I--
I:;:
o
.~ ~
V- ~
-5'
- /
~
CEl<m! UNE
OF ROTATION
~
"...... :....... 1=
r--
/ -5'
~
-10' -10'
35' 30' 25' 20' 15' 10' 5' o 5' 10' 15' 20' 25' 30' 35'
14
Engine start and stop at the aerial station and ground station are inde-
pendent circuits. The Condor can be started or stopped at any time from
either position. After the master switch has been turned on, depress
start button. To stop takes only a momentary touch of the stop button.
NOTE
The engine stop circuit is considered a safety feature
and must be maintained as a safety item.
To perform electrical checks, turn master switch on. Remove engine coil
wire from coil and depress engine start button momentarily. This resets
the main latching relay and will energize the entire electrical system.
NOTE
Watch ammeter for a discharge condition. Should a dis-
charge reading occur, momentarily depress start button
again, and continue this procedure until a no discharge
condition prevails.
See troubleshooting procedures of SIDiItrlRd/HQneywell Literature in Vendor
Section.
18
CORPORATION
HYDRAULIC
OIL SPECIFICATIONS
for
CONDOR AERIAL WORK PLATFORMS
OIL COMPANY Chevron Gulf Shell Union Mobil Conoeo
Brand Name ATF ATF ATF ATF Dexron

Dextron 11 Dexron 11 Donax T6 Dexron 220
D Series " II
Viscosity, SUS @ 100 0 F 205 195 175 200 187 170
SUS @ 210 0 F 50.1 50.4 49 52.3 50 50
Ii
Viscosity Index 150 155 160 172 159 145 I'
Flash Point of 350 0 405 0 390 0 395 0 320 0 365<3
Pour Point of -45 0 -50 0 -45 0 -50 0 -50 0 -45<3

TROUBLESHOOTING GUIDE
In the following section are possible problems and their solutions. This
will save down time and provide a starting point for the mechanic to troub1&-
. . . . . . i ..lete tile e.u for .1fuacti...
PART I, - ELECTRICAL
1. BATTERY DEAD
A Master switch left on with start circuit energized
B Alternator inoperative (regulator or rectifier module)
C Battery not to full charge
a Dead Battery
b Condor battery used to jlJl1P start other equipment
2. FUNCTION INOPERATIVE FROM GROUND AND AERIAL
A Check controller and toggle switch
B Check wiring for continuity
C Check solenoid coils
D Check for voltage into circuit
3. FUNCTION INOPERATIVE FROM EITHER GROUND OR AERIAL
A Refer to Item 2 above
4. FUNCTION INOPERATIVE (Solenoid valve assembly)
A Check coil on solenoid valve
B Refer to Items 2 and 3
C Check toggle switch
5. NO HYDRAULIC PRESSURE (engine running no high rpm)
A Check oil level in hydraulic tank
B Test operate the manual override of any function
C Open hydraulic tank gate valve
6. FUNCTION WILL CREEP WHEN NOT IN USE (high engine rpm)
A Check controller for null
B Check for voltage crossing over into another circuit
C Air in end cap
n
I' PaT : ~ ~~: - HYDRAULI C
1. FUNCTION INOPERATIVE (engine running high rpm, hydraulic

pressure at 2,500 psi).
A Check if auxiliary function solenoid energized
B Check for studt spool 1n auxiliary function valve
lROdule
2. Ml LOPD SENSING DIFFERENTIAL PRESSURE

A Flow compensator spool stuck
3. LOW OR NO HYDRAULIC PRESSURE
A Refer to Item 5 - Electrical
B Check compensator on pump
C Qeci .n taM . . . . .1.
PART I - ~ OPERATION
1. NO LIFTING POWER
A. Internal leak (cylinder).
B. Check system hydraulic pressure. Refer to
specification page for applicable unit.
2. BOOM BLEEDS DOWN
A. Holding valve topping cylinder.
B. Internal leak (cylinder).
3. BOOM RETRACTS (bleeds in or out)
A. Check holding valve.
B. Internal leak (cylinder).
4. EXCESSIVE BOOM PLAY
A. Missing or worn wear pads.
PART. - TURRET
1. EXCESSIVE TURRET ROTATION BACKLASH (turret rotation)
A. Check rotation gear box (loose).
B. Check brake in gear box (tighten).
C. Check ring gear bolts for torque (205 ft-lbs. turret,
105 ft-lbs. base)
2. BROKEN PIN RETAINERS BOTH TURRET AND BOOM
A. Lack of lubrication
121
1
PREVENTATIVE MAINTENANCE CHECK lIST
50 100 500 1,000

ITEM REQUIRING ATTENTION DAIl Y HOURS HOURS HOURS HOURS YEARLY
G) Platform Control Console (continued)
7 - Check Control Lever Returns to Center X
8 - Check Toggle Switches Return to Center X
9 - Engine IIStop-Start" Retains Position X
10- Inspect 110 Volt Outlet for Damage X
H) Hydraulic System
1 - Check Hydraulic Tank Fluid Level X
2 - Clean Hydraulic Tank Breather X
3 - Change Hydraulic Filter X
4 - Change Hydraulic Fluid in Tank X X
5 - Check Hydraulic Fittings and Hoses I
X
l I
I
34
8. HYDRAULIC SYSTEM (Continued)
C. Tank Breather Clean every 50 hours of operation
Procedure Remove from tank and clean with solvent,
air blow dry
D. Hydraulic Tank
Procedure Change every 500 hours or yearly, which-
ever comes first. Drain oil from tank
and replace filter element. Add oil to
tank required level.
Use only ATF Dexron II or equal. Do not
mix _yOrlulie oil.
RING-GEAR UP
BaNI PARTS SECTION
DASH(-) iTEM NOT ILLUSTRATED
....
This caIIll 411 RIll-lIAR UP parts section is illustrated as:
461-00-00
CALAYAI PAm SECTI.
Table of Contents
-01 How to Use Parts List
-02 How to Order Parts
GROUP 10 FINAL INSPECTIOII
461-10-00 Table of Contents
-01 Final Installation
-02 Fiberglass Cover Installation
-03 Decal Installation
GROUP 20 SCHEMTICS
-01 Electrical Schematic
-02 Hydraulic Schematic
GROUP 30 PLATFORM IISTALLATION
-01 Platform Installation
-02 Aerial Control Console Assembly
-03 Top-Mounted Platform Rotation Assembly
-04 Hydraulic Rotary Actuator
-05 Rotation Holding Valve Assembly
GROUP 40 3-SECTION BOOM IISTALLATION
-01 Final Boom Installation (3-SECT)
-02 Intermediate Boom Assembly
-03 Outer Boom Assembly
-04 Inner Boom Assembly
-05 Boom Cable Installation
-06 Boom Cylinder Installation
-07 Slave Cylinder Assembly
-08 Slave Leveling Cylinder
-09 Leveling Holding Valve Assembly
-10 Extension Cylinder Assembly
-11 Extension Cylinder
-12 Counterbalance Valve Assa.bly
-13 Master Cylinder Assembly
LIFT IISTALLATIOI
4611-58-00 N/A 46N Ring-Gear Up
CORPORA TlON
8300 Imperial Dr., P.O. Box 21447, Waco, TX 76702-1447 ISSUED . . . 1990
FROM SERIAL NO. 6270
(817)666-4545 - Fax(817)666~
RING-GEAR UP
4&1 PARTS SECTION
DASH(-) ITEM NOT ;LLUSTRATED
TUBET IISTALLATI.
&ROUP "
-01 Turret Installation
-02 Ground Control Console Assembly
-03 Turret Lift Installation
-04 Topping Cylinder Assembly
-05 Topping Cylinder
-06 Topping Counterbalance Valve Assembly
-01 Solenoid Valve Assembly
-OS 3-Bank Proportional Control Valve Assembly
-09 Turret Rotation Installation
-10 Rotation Hydraulic Motor Assembly
-11 Speed Reducer Assembly
-12 Rotary Coupling Assembly
-13 7-Port Rotary Coupling
-14 Slip Ring Assembly
GROUP 10 BASE PLATE AID RING-GEAR INSTALLATION
46N-10-00 Table of Contents
-01 Base Plate and Ring-Gear Installation
GROUP 80 OPTIONAL INSTALLATION
4ON-80-00 Table of Contents
-01 Optional Installation
-02 Platform Work Light Installation
-03 Air Line to Platform Installation
-04 Safety Light Installation
-05 Remote Control Box Assembly
-06 100 VAC to Platform Installation
GROUP 90 POWER PACK INSTALLATION
4ON-9O-00 Table of Contents
-01 Power Pack Installation
-02 Hydraulic Tank Assembly
-03 Hydraulic Pump Assembly
-04 Eaergency System Installation
FI... Tal .. CMlD'S ,

~vnR
CORPORATION

(817) 666-4545 - Fax (817) 666-4544
46M - 010 - 00- 02
FROM SERIAL NO. 6270 ISSUED JlIIE 1990
RING-GEAR UP
PARTS SECTION
DASH(-) ITEM NOT ILLUSTRATED
This document is prepared, issued and revised by CALAYAR COIPIIATIGI

for the exclusive use of its customers and is intended for use in provisioning,
requisitioning, storing and issuing replaceable CONDOR 461 RIIG-GEAR UP parts
and units and in identifying parts. The contents are proprietary to CALAVAR
and are subject to change without notice. The use of any part of this document
by any other person or persons or for any other purpose without the written
consent of CALAVAR is expressly prohibited. In addition, CALAVAR expressly
disclaims any and all responsibility arising in or any way related to such use
without CALAVAR'S prior written consent thereto.
The parts number content of this document, arrangement and breakdown
sequence of items is compatible with Military Standard (MS), Air Transport
Association Specification (ATA) and CALAVAR Standard (CL337).
GElEIAL SYSTEM OF ASSEMBLY ORDER - Detailed Parts List (Refer to Next Page)
1. This area refers to the corresponding illustration.
UIIT - GROUP - FIGURE - PAGE
A. UIIT shows which is CALAVAR'S model number (such as 150S, 2532,
37AG, 46N Ring-Gear Up, 47AE, 66Q8, RT48A, etc.)
B. GROUP should be divided with:
00 INTRODUCTION
10 FINAL INSTALLATION
20 SCHEMATICS
30 PLATFORM INSTALLATION
40 BOOM INSTALLATION
50 LIFT INSTALLATION (N/A 46N RING-GEAR UP)
60 TURRET INSTALLATION
70 BASE PLATE INSTALLATION
80 OPTIONAL INSTALLATION
90 POWER PACK INSTALLATION
C. FIGURE belongs to the Group. Please see page of contents and
each group. (Color pages)
D. PAGE numbers follow to the right of each figure number.
2. The ITEM lUMBER corresponds to the item number shown for the part in
illustration. Parts with items numbers preceded by a dash (such as
-1, -5, -15, -17, etc.) are not illustrated.
3. PART ~ that carry a CALAYAI part nUliMr.
II _ 11 . . IiiTs LIST
....,,,~,... R

4&4-00- 01-01
FROM SERIAL NO. 6270 ISSUED . . . 1990
(817)666-4545 - Fax(817)666-4544
RING-GEAR UP
BaNI PARTS SECTION
DASH() ITEM NOT ILLUSTRATED
RING-GIAil UP
2-----1
6
CALAVAR
PART NllllER
Installation. 46N Ri ......r Up Final Ref

Installation. Fiber,l Cover 1
(See 46N-10-02 for DEl)
3 46N-10-03 Installation. Decal
-4 33422 Scheletic Electric
-5 33423 Schematic. Hydraulic
6 46N-3O-01 Installation. 46N Platform
(See 46N-30-01 for DET)
7 30456 Installation. 3-Sect. Boom
(See 46N-4O-01 for DET)
Installation. 46N Turret
Installation. Base Plate
Installation. 46N Optional
Installation. Power Pack
Paint. Yellow
011. Hydraulic
FIGURE 01 FIlIAL IlSlALLATICli
46M 0- 01-01
ISSUED'" 1190
i f l ' " II _ lIS( PARTS LIST

(817) 666-4545 Fax (817) 666-4544
_-0.0- 01-02
1FROM SERIAL NO. 6270 . ISSUED ME 1990
RING-GEAR UP
89NJ PARTS SECTION
A. The 111111111 SYSTEI used in the detail parts list shows the
relationship of one part to another. For a given item, the
number of indentures depicts the relationship of the item to the,
associated installation, Next Higher Assembly (NHA), or
components of the item as follows:
1 2 3 4 5
Assembly (or Installation)
Detail parts for assembly
Sub-assembly
Attaching parts for sub-assembly
Detail parts for sub-assembly
Sub-sub-assembly
Attaching parts for sub-sub-assembly
Detail parts for sub-sub-assembly
Sub-sub-sub-assembly
Attaching parts for sub-sub-sub-assembly
Sub-sub-sub-sub-assembly
B. "See 46N-1O-Ol for lHA.1I
Identifies the illustrated parts section location; indicates
where the next higher assembly (IHA) of the item is shown.
C. "See 46N-40-01 for DET. II
Identifies the illustrated parts section location; indicates

where the item and its Detailed Breakdown (DET) is shown.
D. "See 46N-80-01 for REF" or "See Vendor Section for REF.II
Identifies the illustrated parts section where the part is,
and if listed and illustrated in Vendor Section. It is used
as a cross-reference (REF).
5. QUANTITY
A. Reference (REF) indicates the item is listed previously in the
Next Higher Assembly (IHA) and then again in this figure.
B. As required (AIR) indicates the part is used in a quantity as
required.
C. A number entry indicates the quantity of the part used in its
next higher application.
i. Functionally related assemblies are illustrated in phantom, but not
listed on the detail parts list page.
. '1I11III 81 _ .. _ PMIS LIST I
_:eOb~ 01-03
(817)666~5 - Fax(817)666-4544
FROM SERIAL NO. 6210 ISSUED .JlIIE 1990
RING-GEAR UP
BaH) PARTS SECTION
DASH( -) rTE" NOT : LLUSTRA TED
_ T I - ' NITS
1. Always ,1 .. serial . - . r .nd . .1 of CllEl1 . . lIB . . . . .

(..fer to e.ch unit n. .p1.te stMNn below.)
8300 Imper@LQr.,p.Q. Box 21447

Waco, TX 76702-1447
I CONDOR MODEL-_ _ _ _ SERIAl NO-_ _ __

ASSEMBLY NO-_ _ _ _ _ _ _ _ _ __
PART NO-_ _ _ _ _ OATE OF MFG-_ _ __
MAXIMUM PLATFORM HEIGHT-_ _ _ _ _ __
. MAXIMUM HORIZONTAL REACH-_ _ _ _ _ __
RATED WORK LOAO - LBS.

HYDRAULIC OPERATING PRESSURE - PSI
U.S. PATENT 4.506.480
THIS UNIT IS NOT ELECTRICALLY INSULATEO
, .._ " U YIlt' carufII. T8 All ~ICAIU
........" IF . . AU.I-_
1111: Thh . . . l 1s beint rele.sed to cover CI _ .........

WAits starting with serial RUBbers (SIN) 1t1. to curreat
prodvct1on.
2. Always specify part number and complete name of parts ordered.

A. Turn to Table of Content in the desired section.
B. Refer to main group in which part should be listed.
C. '1_ titl. of fip" 1n which t .. part should M s...... Note,
,roup, filU" .nd total pa.. mabers.
D. Turn to c~s""i .. pi. . . "M the , ..... aM f1p.....
I. Qect "..r ,...1 .... pert Mel 1ts attachi", parts Mel _tch
with t .. l1htltrat1_ .....
f. "'er to cerres,4U", 1ta maber 1R t.. ,.rts 11 st.
L
n__ . . . . . . NIfI

(817) 666-4545 - Fax (817) 666-4544
_-00-02-01
FROM SERIAL NO. 6270 ISSUEO ME 1990
RING-GEAR UP
PARTS SECTION
DASH(-) rTEM NOT rLLUSTRATED
This ~ _ U . . . . UP Plr'tl Hct10n h illustrated as:

_ DO CAUYAI PAKIS SKTI..
__
41I-0o-I Tabl. of Contents
-01 How to Un Parts List
-02 How to Order Perts
_10
Tlbl, of Contents
_20__
-til Final In,tatt,tion
-tI2 Fibtro1asl COver Install,tion
-as Dec.' Install.tion
Tlble of COntents
-til El,ctr1eal Schalt1c
-oz
--
Hydraulic __~hlMt1c
_30
- til
-oz
-as
--- -04
..I
-tI2
-as
......-m
-04
-tMi
-Ot
-10
11
12
13
_ 50 LIFT IIISWJ.ATI.
_IO-DO MIA 4611 RI.gGo" lit>
- 00-01
-40- 0+-01

(817) 6664545 - Fax (817) 666-4544
": :.~ :00 - 02~ 02
IFRO~SERIAL
NO. "' .....0
'"',
IS. . . . . .
RING-GEAR UP
PARTS SECTION
I. When ordering variable or optional .iscellaAeOus parts which

are not found in this parts section, follow the above
outlined procedure of how to order parts.
1). When applicable, giye model and serial number of the
component for which parts are desired.
2). In a specific, difficult to describe situation, a
marked-up photograph or detailed sketch would be
helpful.
3. Do not deSignate quantity by "sets. II State specifically how many
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 is available in deSignated
areas.
5. TO ORDER
A. BY MAIL
Attention: Parts Department
CALAVAR CORPORATION
(817) 666-4545 - Fax (817) 666-4544
B. BY FAX
I Fax (817) 666-4544l
C. BY TELEX
D. BY PHONE
[l8 666-4545 1
6. Parts returned without authorization will not be accepted. If it

is necessary to return parts for any realOn, written authorization
1liiY ~ obUjaed fr-CALAI. a._TI_, Att: Parts Department,
~aco, TX 76702-1447 I. Proper sh i ppi ng tags and
instructions will be furnished upon request. (Refer to General
Section, Warranty Cla;. Procedure).
'1lIIIE. _ II MII'S "~I

......,........~...., .. R

(817) 666-4545 - Fax (817) 666-4544
46M -00- 021-0'3
I ROM SERIAL NO. 6270 IS_ ~-
RING-GEAR UP
89NJ PARTS SECTION
DASH(-) ITEM HOT ILLUSTRATED
This C._ . . RIII-IUI IP parts section laP II

Jl)L4611 RING-GEAR UP FINAL INSTALLATION is illustrated as:

-01 Final Installation
-02 Fiberglass Cover Installation
-03 Decal Installation
'1_. TAILI call1rs

_-10- 00-01
FROM SERIAL NO. WO ISSUED _ _ 1190
(817) 666-4545 - Fax (817) 666-4544
RING-GEAR UP
Gam PARTS SECTION
OASH(-) :TEM NOT :LLUSTRATEC
ITEM DESCRIPTION
~ NUMBR 1 2 j .. 5
-1 MDL46N lation, 46N ng-Gear Up nal Ref

,Installation, berglass Cover 1
( 46N-IO-02 for DET)
3 Installation, 1
(
Schema c El c 1
( 46N-20-01 for DET)
33423 Schematic, Hydraulic 1
(See 46N-20-02 )
6 46N-30-01 Installation, 46N Platform 1
( 46N-30-01 for DET)
I Installation, Sect. Boom 1
( 46N-40-01 for DET)
8 33350 Installation, 46N 1
(See 46N-60-01 for
'9 Insta n on) Pl 1
46N-80-01 latiol1, 46N 1
1 for
1
-i10- 01- 0 1
8300 Imperial Dr., P.O. Box 21447. Waco. TX 76702-1447 FROM SERIAL NO. 6270 ISSUED JUNE 1990
(817) 666-4545 - Fax (817) 666-4544
RING-GEAR UP
BORI PARTS SECTION
DASH ( -) ITEM NOT I
15
\ DOOR REF.
HOUSING REF.
~l
9
['I 14
ITDI CALAYAR DESCRIPTION QUMTITY,

NUflBER PART NUMBER 1 2
-1 32100 Installation, Fiberglass Cover Ref

(See 46N-10-01 for NHA)
2 32865 Door, Turret (L.H.) 1
3 32864 Door, Turret (R.H.) 1
4 33552 Housing, Turret (L.H.) 1
5 33551 Housing, Turret (R.H.) 1
6 33017-003 Hinge, Piano 2
7 BOW34150 Rivet, Pop 66
-8 SQKOOllO Trim, Black (10.5 LF) AIR.
9 32843 Plate, Backing 4
10 LBL00200 Latch, Horizontal Mounting 2
11 LBL00256 Bracket 2
12 BOW36004 Bolt, Hex (attaching parts) 8
13 BOW36725 Washer, SPL Lock (attaching parts) 8
14 BOW31431 Washer, Flat (attaching parts) 8
15 BOW36601 Nut, Hex (attaching parts) 8

_ -:101-021-01
FROM SERIAL NO. 6270 ISSUED .ME 1190
(817) 666-4545 - Fax (817) 666-4544
'--------
RING-GEAR UP
BaNI PARTS SECTION
llASI<t( -) ITU4 NOT :u..uSTRA TED

THIS SELF-PROPELLED CONDOR IS EQUIPPED WITH SLOPE SENSORS
AND INDICATOR LIGHT.
WHEN 800M IS ABOve HORIZONTAL AND THE MACHINE IS BEING

OIIVEN UP, DOWN, OR ON A SIDE GRADE AT S OUT OF LEVEL, THE
8 - - -.... INDICATOR liGHT Will COME ON AND All 800M FUNCTIONS WILL BE
INOPERABLE.
TO CORRECT CONDITION---(DO NOT lOWER 800M WITH EMERGENCY

I.OWERING). REVERSE DIRECTION OF GROUND TRAvel UNTIL liGHT GOES
OUT INDICATING THE CONDOR IS AGAIN LESS THAN S OUT OF lEV!lANO
'ME lOOM FUNCTIONS Ali "ON'" 0HMiU. 211..

fl_ U IIaL _lIn.
"vnln
CORPORATION
8300 Imperial Dr. P.O. Box 21447. Waco, TX 76702-1447

(817) 666-4545 - Fax (817) 666-4544
4eM-110- d31-01
FROM SERIAL NO. 6270 ISSUED ME 1990
RING-GEAR UP
PARTS SECTION
DASH( -) I TEM NOT I LLUSTRA TEO
THII UNIT II NOT INIULATED AND MUIT NOT BE OPERATED

WARNING WITH'N 10 fEET Of ENERGIZED POWER LlNEI. I
~
\~ 9~
....
1m.
-1
CALAVAR
PART NUMBER
46N-1O-03
1 2
Installation, Decal
DESCRIPTION QUMTI
Ref
Decal, CONDOR 2
2 21834 2
3 21834-003 Decal, OR
2
4 21834-002 Decal, ND
2
5 21834-001 Decal, CO
Decal, Do Not Lift Wheels With Boom 2
6
7
21971-002
35780 Decal, Platform Capacity 750 LBS. 1 !
Decal, Caution 1
8
9
21880
32200
Decal, Warning 1
Decal, Caution - Aerial Operation 1
10 35365 Decal, Keep Clear 3
11 21882-001 Decal, Danger - Not Insulated 1
12 21882-002 Decal, Danger - Qualified Operator 1
13 21882-003 Decal, Model No. 46 2
14 40103-007 Decal, N 2
15 32563 Decal, No Step 2

I
16 32156
Decal, CALAYAR CORPORATION 1
17 35682 Decal, Made in U.S.A. 1.
18 35656 Placard, Name Plate - Serial No. 1
19 15843 Decal, General Operating Instructions 1
20 35366 Decal, Caution Welding 2
21 21854 Decal, 110 Volts 1
22 15376-024 (See 46N-80-06 for REF)
Decal, Lube Fitting 1-
-23 21079 (See 46N-60-01 for REF)
Decal, Operation and Safety 1
-24 21384 (See 46N-60-02 for REF)
Decal, Turret Lock Pin 1
-25 40191 (See 46N-60-09 for REF)
Decal, Hydraulic Oil 1
26 52107 Decal, Check Battery 1
27 50070
. . . . . --.&.AT.

(817)666~45 - Fax(817)66~44
46M ~il~--I03i-Q2
FROM SERIAL NO _ 6270 ISSUED_ 1990
RING-GEAR UP
PARTS SECTION
( . u
111\. cal'
..J ..... .
n
)
1. DO NOT OPERATE THIS MACHINE UNLESS YOU ARE A TRAINED AND
AUTHORIZED OPERATOR FOR THIS CONDOR MODEL. BE FAMILIAR
WITH UNIVERSAL SYMBOLS USED ON CONSOLES.
2. CHECK ALL MACHINE FUNCTIONS, INCLUDING BRAKES, PRIOR TO
EACH DAY'S USE.
3. ALL PERSONNEL IN PLATFORM MUST WEAR APPROVED HARD HATS
AND BODY BELTS WITH LANYARDS ATTACHED TO DESIGNATED
POINTS ON THE PLATFORM ASSEMBLY.
4. OPERATE ALL CONTROLS SLOWLY FOR SMOOTH PLATFORM
MOVEMENT. WATCH FOR OBSTRUCTIONS WHICH MAY STRIKE
PLATFORM, PERSONNEL, CONTROLS OR MACHINE.
5. DO NOT OPERATE THE CONDOR ON SOFT OR UNEVEN SURFACES OR
ON SLOPES IN EXCESS OF 5 (10.5" RISE IN 10 FEET).
6. DO NOT OPERATE THE CONDOR WHEN WINO VELOCITY EXCEEDS
25 MPH.
7. NORMAL TRAVEL POSITION IS WITH THE BOOM FULLY RETRACTED
AND "TURRET COUNTERWEIGHT" POSITIONED OVER THE DRIVING
(FRONT) AXLE. THE BOOM MUST BE ELEVATED TO PROVIDE
ADEQUATE GROUND CLEARANCE FOR THE PLATFORM ASSEMBLY.
DIRECTION OF PLATFORM TRAVEL REVERSES IN RELATION TO
CONTROLLER MOTION WHEN THE BOOM IS OVER THE FRONT AXLE. DO
NOT DRIVE THE CONDOR WITH THE BOOM ELEVATED IF ANY PART OF
THE MACHINE IS WITHIN 6 FEET OF AN OBSTRUCTION.
8. THIS CONDOR IS EQUIPPED WITH A SLOPE SENSOR AND AN INDICATOR
LIGHT ON AERIAL CONTROL CONSOLE TO INDICATE A 5 OUT-OF-
LEVEL CONDITION. ALL BOOM FUNCTIONS ARE INOPERABLE WHEN
CONDOR IS MORE THAN 5 OUT-OF-LEVEL.
NOTE: TO CORRECT THIS CONDITION, REVERSE I CHANGE DIRECTION
OF GROUND TRAVEL UNTIL INDICATOR LIGHTS GOES OFF.
9. HIGH SPEED MODE FOR TRAVEL WORKS ONLY WHEN SELECTOR
SWITCH IS IN "HIGH" AND BOOM IS BELOW HORIZONTAL. AERIAL
FUNCTIONS 00 NOT OPERATE WITH UNIT IN HIGH SPEED.
10. IN CASE OF EMERGENCY, DEPRESS EMERGENCY "STOP" BunON.
35365
I
..... ~~--.&An..
~.-~--.-.----.-----------, ~
- 10:-:031- 0:31
(817)666-4545 - Fax(817)666-4544 FROM SERIAL NO. 6270 ISSUED ME 1990
RING-GEAR UP
PARTS SECTION
1IIIiIJI) ITllt., II. . . . . TED
ELEaROCUTIOI HAZARD
KEEP CLEAR
. . . . . SRIOIn .JO, (AI IUUll FIIOII
COlAW
If If _ WIll 'lIS
__.I
.l.l, _VIIIICU
_ _.
ELECTROCUTION HAZARD
MAINTAIN SAFE CLEARANCES FROM ELECTRICAL LINES MIl
N'PAAATUS. YOU MUST ALLOW FOR BOOM SNAY, ROCK 011
l/f'\
I\yi 11:
SAG AND ELECTRICAL LINE ANI! LOAD SNAYING.
THIS AERIAL WORK PlATFORM OOES NOT PROVIDE
PROTECTION FROM CONTACT WITH OR PROXIMITY TO Aft
ELECTRICALLY CHARGED CONDUCTOR.
YOU MUST MAINTAIN ACLEARANCE OF AT LEAST 10 FiT
BETWEEN ANY PART OF THE WORK PlATFORM OR LOAD MIl
ANY ELECTRICAL LINE OR APPMATUS CARRYING UP TO
50.000 VOLTS. ONE FOOT ADDmONAl CLEARANCE IS
REQUIRED FOR EVERY ADDmONAL 30,000 VOLTS OR LEss.
~ ~-=:~~~~J
DEAf" OR SEItlM NIRT WIll RESUlT FROM CONTACT OR
1MfIEUf CLEARMCE
CONDOR MOOEL-_ _ _ _ _ SERIAL NO-_ _ __
ASSEMBLY NO-
-----------------
PART NO-_ _ _ _ _ _ DATE OF MFG- _ _ __
MAXIMUM PLATFORM HEIGHT-

MAXIMUM HORIZONTAL REACH-
---------------------
--------------------------
RATED WORK LOAD - LSS
------------~~.
HYDRAULIC OPERATING PRESSURE - PSI
U.S. PATENT 4,506,480
THIS UNIT IS NOT ELECTRICALLY INSULATED YOU MUST NOT OPERATE THIS MACHINE
_ESS YOU ARE QUALIfiED BY TRAINING AND ElIf'IIIIitICl
THIS MOBILE UNIT CONFORMS TO ALL APPLICABLE IN THE SAfE OPERATION Of THIS MACHINE.
REQUIREMENTS OF ANSI Ai2.i-lua TRAINING INCLUOES COMPLETE KNOWLEDGE IF
1. . . . YOUR EMPLOYER'S WORK RULES. ALL GOVERNMlllfAl.
REGULATIONS. AND MANUfACTURER'S OPERAf8R
AND SAfETY MANUALS RELATIVE TO THIS
:,IJ'
\:!J
!.
1':
MACHINE'S SAfE USE.
IIIIIIITRAINEO OPERATOR SUBJECTS HIMSELf AND tflllllS"
DEATH OR SERIOUS INJURY
fI!i!'l
..
NO STEP~
'1"'13 IICAlIBTAUATI.

(817) 666-4545 - Fax (817) 666-4544
_-110 - 03~ 041
RING-GEAR UP
BaNI PARTS SECTION
DASH() ITE" NOT :LLUSTRA TEO
-"""
1.
2.
.
BEFORE OPERATING CONDOR, READ AND UNDERSTAND ALL INFORMATION IN THE OPERATIONI
SAFETY MANUAL AND ON ALL DECALS/PLACARDS DISPLAYED ON THIS UNIT.
BE FAMILIAR WITH THE CONTROL FUNCTIONS ON THE OPERATOR CONSOLES.
3. BE SURE THAT CONDOR IS PROPERLY MAINTAINED IN ACCORDANCE WITH CALAVAR'S
REQUIREMENTS AS SPECIFIED IN THE OPERATION/MAINTENANCE MANUAL.
4. DO NOT OPERATE THIS MACHINE IF IT OOES NOT FUNCTION PROPERLY.
5. DO NOT OPERATE THE CONDOR WHEN WIND VELOCITY EXCEEDS 25 M.P.H.
. DO NOT REMOVE ANY WEIGHT FROM UNIT. STABILITY WILL BE AFFECTED.
1. DO NOT MAKE ANY MODIFICATIONS TO CONDOR WITHOUT WRITTEN CONSENT OF CALAVAR.
MILY INSPECTION CHECKLIST BEFORE USING CONDOR-

1. CHECK FLUID LEVELS IN HYDRALIC AND FUEL TANKS AND BATTERY.
2. CHECK ENGINE CRANKCASE OIL. AND COOLANT FOR WATER-COOLED ENGINES ONLY.
3. VISUALLY INSPECT CONDOR FOR LOOSE OR MISSING PARTS, WEAR, WELD CRACKS. DENTS, OR
OTHER SIGNS OF DAMAGE.
4. CHECK TIRES FOR WEAR, CUTS, AND INFLATION PRESSURE (PNEUMATIC TIRES ONLY).
5. CHECK ALL VISIBLE BOLTS, NUTS, PINS AND FASTENERS FOR PROPER INSTALLATION.
. CHECK HYDRAULIC COMPONENTS, FLUID LINES AND FITTINGS OR LEAKS.
1. INSPECT ELECTRICAL HARNESSES, CONNECTORS, CIRCUITS, AND BOOM MECHANICAL CABLEI
(3-SECTION BOOMS ONLY) FOR DAMAGE AND PROPER INSTALLATION.
e. CHECK 5 SLOPE SENSOR AND INDICATOR LIGHT/SOUND ALARM FOR PROPER OPERATION.
t. CHECK ROTATION GEAR BOX, RING GEAR BOLTS, LOCK-STRIPS FOR PROPER INSTALLATION.
10. ANY DEFECTS FOUND DURING INSPECTION AND FUNCTIONAL TEST MUST BE CORRECTED
BEFORE OPERATING THE CONDOR. (REFER TO OPERATION/MAINTENANCE MANUAL FOR
FACTORY RECOMMENDATIONS).
GENERAL OPERATING INSTRUCTIONS-

1. CHECK THAT TURRET LOCK-PIN IS REMOVED (APPLICABLE ONLY TO CONOOR MODELS WITH
TURRET ROTATION LOCKING FEATURE FOR TRANSPORTING).
2. TURN POWER SWITCH "ON" AT GROUND CONTROL CONSOLE. START ENGINE/MOTOR AND
ALLOW UNIT TO WARM TO OPERATING TEMPERATURE.
3. POSITION SELECTOR SWITCH TO "GROUND" CONTROL AND TEST OPERATE ALL AERIAL FUNCTIONS
FROM THE GROUND CONTROL CONSOLE.
4. POSITION SELECTOR SWITCH TO "PLATFORM"CONTROL. THEN ENTER THE WORK PLATFORM AND
ATTACH THE SAFETY BELT/LANYARD.
5. ALL PERSONNEL IN PLATFORM MUST WEAR APPROVED HARD HATS, & BODY BELTS WITH
LANYARDS ATTACHED TO DESIGNATED POINTS IN THE PLATFORM ASSEMBLY.
e. REFER TO WORK PLATFORM "CAUTION" DECALS FOR ALL OPERATIONS IN THE PLATFORM.
1. FOR TRANSPORTING, USE EXTREME CAUTION WHILE LOADING/UNLOADING THE CONDOR UNDER
ITS OWN POWER:
TRAVEL IN LOW SPEED MODE ONLY.
MAKE SURE PLATFORM IS LOWERED (BOOM FULLY RETRACTED & BELOW HORIZONTAL.)
ROTATE TURRET IN LINE WITH CHASSIS.
DO NOT EXCEED RAMP ANGLE OF 14 (2.5 FEET RISE IN 10 FEET).
I
--
. '
:,.. . . U .at. .......n.
8300 Imperial Dr., P.O. Box 21447, Waco, TX 767021447

(817) 6664545 Fax (817) 6664544
46M -110 - a31- 0,'5
FROM SERIAL NO. 6270 ISSUED oUIE 1990
RING-GEAR UP
PARTS SECTION
I .~_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _~.
r CAUTKlN "
DO NOT USE CONDOR AS A WELDING GROUND
DO NOT WELD ON CONDOR 21 !
WITHOUT DISCONNECTING 80TH
POSITIVE AND NEGATIVE BATTERY LEADS
REFER TO MAINTANCE MANUAL FOR
ALL WELDING PROCEDURES
DO NOT JUMP START OTHER VEHICLES

WITH BATTERY CONNECTED TO CONDOR
~ ~

LUBE FITTING
CHECK BATTERY .
WATER LEVEL

AT LEAST .----------.i
ONCE AWEEK. OPeRATION AND
SAFETY MANUAL
II
21384 '
IZ4
HYDRAULIC OIL
AITOMATIC TRANSMISSION FLUID CAUTION - CAUTION - CAUTION
DEXRON II S2107 REMOVE TURRET LOCK-PIN
BEFORE ROTATING TURRET
401"
'1_ U . . . . . . . . . .T... l
'"' "' ' '

.. _
-1_\0 - ~- 06 ISSUEO-;bIE 1990
(817) 666-4545 - Fax (817) 666-4544
RING-GEAR UP
BaNI PARTS SECTION
DASH() ITEM NOT illUSTRATED
..... A ............. and Hei8M

1 . . .Ii........ . . .
EAgttsh Metric T............. PiaWerm (ate " II.,.,
Pletform Capacity (unrestricted) ... 500 Ibs. 227 kg
t
--------.-
Platform (tubular steel) ........... 60 "x36"x431/2" 1.S2xO.91xl.10m S' (1.83m) working height
Platform Height .................. 40' 12.2 m
Working Height .................. 46' 14.0 m --L
Length (stowed) .................. 20'6" 6.25 m 4O'S" (12.34111)
Height (stowed) .................. 6'11" 2.11 m I ----------------.-
Width ............................ 5'9" 1.75 m ~ 37'
(11.2IIm)
Outside Turning Radius .......... 14'6" 4.4 m
I
Wheel Base ...................... 6' 1.8 m
32
Gross Weight (approx.) ........... 17,500 Ibs.
Gradeability ...................... 11 (20%)
0
Fuel Tank Capacity ............... 35 US gals.

Hydraulic Tank Capacity .......... 35 US gals.
7,938 kg
11 (20%)
132 L
132 L
0
,--
(9.15m)
25'
(7.62m)
Travel Speed ..................... 0 to 3 mph 0 to 4.8 km/hr
Tires, Foam Filled ................ 31/11.5-16.5 Load Range "C"
Turret Tail Swing ................. Zero Zero
Ground Clearance ................ 7.5" 19.05 cm
Standard Equipment
Strobe Light Drive/Descent Warning Horn
Emergency Power System Fuel Gauge
5 MultiAxis Slope Sensor
Hour Meter
Optional Equipment
Hydraulic Oil Sight Gauge
FootType Deadman Switch
'9,,1
~(1.75m;i
. 20'S" (S.25m)
J 30'
(9.14m)
I
---1
Dual Fuel Carburetor (propane & gas) Special Paint (one color)
Electrical Outlet at Platform, 110 Volts Head and Tail Lights
2-Section Boom with
Platform Work Light Platform Warning Horn Tip-Mounted Platform (Optional)
Air Line to Platform Lifting Eyes
Deutz Diesel Engine 43 lb. L.P. Tank t
Platform Rotation 180 0
110 Volt Generator I 6' (1.83m) working height
AT (Rough Terrain) Package Solid Tires -1
aattery Powered Unit
Rotating Beacon
3-Section Boom Assembly
Hand Pump: Emergency
Lowering
Tip-Mounted Platform
,
39(11 .....)
31'S"
Length (stowed): 15'5" 4.7 m with 90 Platform Rotation
0 (10 ....)
Height (stowed): 7'2" 2.18 m
30'
(9.' .....)
ROUGH TERRAIN OPTION
For operation on all terrain including sand, dirt and gravel. RT option
ineludes extra large drive motors for increased torque and gradeability. 23'6"
Also works indoors, as well as out. Capable of traveling through 7-ft. (7.1 ....'
(2.13 m) high by 6 ft. (1.83 m) wide doors.
St:N!cifications
English Metric
Gradeability .................... 16 (29%)
0
16 (29%) 0
Gross Weight (approx.) ......... 17,500 Ibs. 7,938 kg

Travel Speed .................. 0-2.5 mph 0-4.0 km/h
Outside Turning Radius. ........ 17'6" 5.33 m
Tires - All Terrain ............... 12-16.5 LT
~
.9,,1
Foam Filled, Gumbo
(1.75mi1
Wide Mudder 22' (S.71m)----t
I
Ground Clearance .............. 7.5" 19.05 cm
[)raw Bar Pull Increase ......... 36% 36%
9200 Sorensen, Santa .........

800/877-5544 Tel . . . . , . .
oa=.. .... r
~
46)6~N'
.
I
'~
I
RING-GEAR UP
PARTS SECTION
This CONDOR 46N RING-GEAR UP parts section GROUP 20

SCHEMATIC DRAWINGS is illustrated as:
46N-20-00 Table of Contents
-01 Electrical Schematic
-02 Hydraulic Sch... tic
>
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on
N N N I It a
TaI.d. . . . IS
R.VnR
CORPORATION

(817) 666-4545 - Fax (817) 666-4544
. . -:~D-OO\-Ol
RING-GEAR UP
BaNI PARTS SECTION
. . -) !Till NOT rUJJSJMrEO
. .
TfIlLKlI91/0Ml:
lit 24011
811 III ENGINE

ALTERNATOR
83 42
04
..
III
II
--
R2A
"T
42
..
07
.. - 5
2
n FROIO
UI
51
18 n
3 3
11
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- .-
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13
14
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16
41l
17 1.1 S9 ROTAl1NG
BEACON
18
19
20
47
Ar~~~2~3~----________
.--4---"""'1": p\"ATfllRM TILT
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GKI4)
~>
-H
DO'w'N
PLATfORM TILT
UP
21
I r--..D.l--~
II!
,DDT S'w'ITCH 3
3 fDDT S'w'ITCH
13 RELAY
14 MT~~----~------~.~~________~E~(~ LEfT
PLATfORM
n
16
~~~
.- --
____+-________-+~)~________~2~7~<~ ROTATIDN
RIGHT
14'1
17 AUX.
VAlVE
18 \/DBJULATIIR
47 AND HORN
19
3t
31 I 6
31
I 57
I
33 I 6
I G
34
I f4)fR
I
I
6 48 67 10
47 57
" I(V) I(G>
'n" 11 ILIC1IICAI. MaaanC

.....'~IL..I"fI.. R

(817) 666-4545 - Fax (817) 666-4544
46M - i2~O - 0 1- 0 1
RING-GEAR UP
PARTS SECTION
DASH(.) ITEM NOT ILLUSTRATED
- .... 411 6 18 MY) - -

37
31 ~~~~~--~~----~~.>-----~
.- - K5
DOWN
IIO!lM
UFT
UP
RIGHT
TURRET
ROTA_
LEfT
EXTEND
IIO!lM
EXTENCa
RETRACT
_ r-,.~U~--------------------~~9~~-,
20 A MAI. W/p (. ..J. ~IIlACI< BLACKt"'i'" 15 A W/p
" T'JIST -LllCK 'tP' IQ1 101 , DPI.X. RECP.
~T~ \ ~ GREEN GREEN ) IN AERIAl.
57 SlUICE -t:: 70 70 '9 CONTROL_
'JHITE 'JHlTE
FlIOU
UNE 01
" FRIll LINE 14 >-rr:J 68

68
GTB-68
=:-"
1/0_
II LL~LINES sa. 47 .. 42
5 R3
,RIll LINE O~I-~---i
~1.\:.
~/O
.
A
OPT1ON 1406 12-V LIGHT IN PLATFORM

LINE 14 3 r----U-lili
IS
L-~1I1
, ..
67
,.
---
.. - ... - .
.....,......"vnn
CORPORATION

01- 012
(817) 6664545 Fax (817) 6664544
FROM SERIAL NO. 6270 ISSUED .JIll[ 1990
RING-GEAR UP
BaNI PARTS SECTION
OASH( -) I TEM NOT : LLUSTRA rEO
1
j
I
I
I
I
I
r--
,
, :
,,,
,
I
,L-_ _ _ _ _ _ _ _ _.--..J1
HYDRAUUC TANK
16 GPM MAX .1800 RPM
SYSTEM PRESSURE - 2500
-
CAPACITY = 36 GALLONS LOAD SENSING PRESSURE - 350 PSI
....." ..,---, . . .:.1.., .. n

(817) 666-4545 - Fax (817) 666-4544 FROM SERIAL NO. 6270 ISSUED ME 1990
RING-GEAR UP
PARTS SECTION
This CONDOR 46ft RING-GEAR UP parts section GROUP 30

PLATfORM INSTALLATION is illustrated as:
46N-3O-00 Table of Contents
-01 Platform Installation
-02 Aerial Control Console Assembly
-03 Top-Mounted Platform Rotation Assembly
-04 Hydraulic Rotary Actuator
-05 Rotation Holding Valve Assembly
.......,.. ---R.vnn

CORPORATION

_ -8]0- cg-Ol
(817) 666-4545 - Fax (817) 666-4544 FROM SERIAL NO. 6270 ISSUED oUIE 1990
RING-GEAR UP
PARTS SECTION

7
I
8
~
I
18
9--~
11
'\
\
\ ~
~ 14
b:::::===p---.-10

'UTF.. "_~"J<"''''L~o'_'
_ . . .1..... "vnn
CORPORAT;QN

(817) 666-4545 - Fax (817) 666-4544
46N - 3.0- 01- 01
: FROM SERIAL NO. 6270 ISSUED JlIIE 1990
RING-GEAR UP
BaNJ .
PARTS SECTI ON
DASH( ) ITEM NOT " LUSTMTED
'"
ITEM CALAVAR DESCRIPTION
NUMBER PART NUMBER QUANTITY
1 234 5
-1 46N-30-01 Installation, Platform Ref

(See 46N-I0-0l for NHA)
2 36643
Installation, Aerial Control Console
1
3 BOW36001 Washer,HexSPL(attaching
Bolt, parts) 4
4 BOW36725
Lock (attaching parts) 4
5 BOW36780
Nut, Hex (attaching parts) 4
6 30397
Installation, Top-Mounted Platform Rotation 1
7 67295-014
Assembly, Cable 1
8 36083
Switch, Foot 1
9 36084
Guard, Foot Switch 1
1
10
11
34667
BOW36004 Retainer, Foot Switch
Washer,HexSPL(attaching
Bolt, parts) 2
12
13
BOW36725
BOW31201
Nut,
Lock (attaching parts)
Hex (attaching parts)
2
2
14 BOW5924 Clamp, Strap Wrap Lock 1
Bolt, Hex
15
16
BOW36000
BOW31415 Washer,
(attaching parts)
Flat
Washer, SPL Lock (attaching parts)
1
1
17 BOW36725 Nut, Hex (attaching (attaching parts) 1
18 BOW36780 parts) 1

fl_

1 MD . .-IAI.lAT_ '
~vnR
CORPORATlO,,"

(817) 666-4545 - Fax (817) 666-4544
-- 3\0- 01-02 IS_ . . 1918
RING-GEAR UP
BaNI PARTS SECTION
OASH(-) ITEM NOT rLLUSTRATEO
o
o I
0-
I
7,
ll~---'
l'--~
2REF.

21
6
~
6 2AEF.
~
I
~
II
15
l'

(817) 666-4545 - Fax (817) 666-4544
46M - ,S!O-O~\- 0 1
FROM SERIAL NO. 6270 ISSUED JIIIE 1990
RING-GEAR UP
PARTS SECTION
...
OASH( ) TEl!
, NOT',LLU STAA ~EO

1 234 5
-1 36643 Installation, Aerial Control Console Ref

1
2 40870 Housing, Exterior Panel
Decal, Aerial Control 1
3 40869
Assembly, Start-Stop Switch 1
4
5
40877
92117
Boot
Knob, Red 1
1
6
7
92114
92113
. Ring, Retaining 1
8
9
RTNOI052
92115
Ring, Mounting 1
1
10 92116 Operator
Block, Contact 1
Guard, 10
11 40880 Switch Switch 2
12 50077
2
13 40872
Switch
4
14 40874
Switch
Switch 1
15
16
40876
50075 Switch
Assembly, 1
Indicator Lamp 1
17 40879
1
18 BVD01032
Lens, Amber (RTNOI056)
1
19
20
BVDOI031
BVD01030 Bulb (RTNOI064)
Socket (RTNOI055)
Panel, 1
1
21
22
40867
40865 Assembly,BaseController 3
Light, Dash 1
23 67250
1
24
-25
BOW7462
34542 Bulb, Dash Light
Jumper
Diode 4
3
-26
-27
RTNOI059
RTN01053 Strip, Terminal
Washer, 3
SPL Lock (attaching parts) 6
-28 BOW31322
-29
-30
BOW91624
RTNOI058 Capacitor
Mount, 2
Tie 4
-31 BOW23919
Ty-Rap AIR
-32 BOW23985

'1" IIIIM. clilTMLC.SIiE ASSBIILI

(817) 666-4545 - Fax (817) 666-4544
_
FROM SER:AL NO. 6270
-1 0 - 02~ 02
1
ISSUED'" It90
RING-GEAR UP
13-- 2Rf.
14----1
l]--15
'~16
2
25--
24

,... U . '" II ~_IU ...,1, Ml~11IIt ~l.jtLJi
~___~_~___~L ~
~AI_
810-
.
03!-01
(817) 666-4545 - Fax (817) 666-4544 rROM SERIAL NO. 6270 ISSUED ME 1990
RING-GEAR UP
GaH] PARTS SECTION
26--~
~--3REF.
37
<8
Jno-~ 41
1---36
f~~
31 ~ I
43- -4~
I 39
c.>
40
~-3REF.
1----44

. .I

. . - SO - 031- 0:3!
(817)666-4545 - Fax(817)666~
RING-GEAR UP
BaNI ...
PARTS SECTION
OASH( ) TEM
' NOT ., LUSTII,.A ""ED
.~

1 234 5
-1 30397 Installation, Top-Mounted Platform Rotation Ref

2 32723 Weldment, Platform (60x36x43.5) 1
1
3
4
30316
CMP00239 Assembly,
. Bushing
Skirt
1
5 BOW7596 . Fitting, Grease 1
6 30389 Bearing, Inner Race 2
SPL Lock (attachin~ parts) 4
9 BOW36729 Washer,
Bolt, Hex (attaching parts 4
10
11
BOW36105
BOW36854 Bolt, SOC Flat 1
12 32775 Washer, Stepped 1
13 68402 Bearing, Thrust 1
14 30384 Shaft, Actuator 1
15 CLKOO111-006 Bar, Flat 1
16 CLKOOI11-005 Bar, Flat 1
17 40976 Spacer 1
Washer, SPL Lock (attachin~ parts) 1
18 BOW36733
19
20
BOW36196
32536 Ring, Tie-Down 2
21 21126 Pin, Slave Cylinder to Skirt 1
22 BOW36725 Washer, SPL Lock (attachin~ parts) 1
23
24
BOW36000
30390 Pin, Boom to Skirt 1
25 BOW7578 Fitting, Grease 2
26 35460 Assembly, Hydraulic Rotary Actuator 1
28 BOW36729
29
30
BOW30116
BOW32585-1 Clamp, Wire Loom 1
35 02444 El bow, 90 2
36 30488 Assembly, Tube 2
37 02236 Elbow, 90 2
38 21479 Valve, Needle 2
39 04089 El bow, 90 2
40 21480 Assembly, Rotation Holding Valve 1
45 02827 El bow, 45 2
'1'- U ...., 10121&'8 PLAI.tiJa IltAYI. iisi-LJ.

- ......~~_O~_P'!l_RA_~_"_ _ _ _ _ _ _--,
(817) 666-4545 - Fax (817) 666-4544
~ ... ~AW
~
FROM SER:AL NO. 6270
_ so - Oil~ 04"
ISSUED . . . 1190
RING-GEAR UP
BaNJ PARTS SECTION
1---0
11----0
6-0
16--< )
5----<0
20
10
13
10
11
22
14

(817) 666-4545 - Fax (817) 666-4544 FROM SERIAL NO. 6270 ISSUED JUlIE 1990
RING-GEAR UP
BaNI PARTS SECTION
OASH(.) iTEM NOT ;LLUST~~EO

1 234 5
-1 35460 Assembly, Hydraulic Rotary Actuator Ref

2 93074 Housing 1
3 93073 Valve, Re1 ief 1
4 93082 Pinion 1
5 93075 Ring, Thrust 2
6 93076 Bushing Pinion 2
7 93077 Ring, Snap 2
8 93079 Tube, Cylinder 2
9 93081 Rack 1
10 93071 Piston 2
11 93080 Bolt, Rack 2
12 93072 Rod, Tie 8
13 93078 Cap, End 2
14 93070 Nut, Tie Rod 8
-15 93083 Kit, Seal 1
16 O-Ring, Pinion Bushing 2
17 O-Ring, Pinion 2
18 O-Ring, Cylinder Tube 2
19 . Seal, Cylinder 2
20 . Ring, Rack Bolt Back-Up 2
21 O-Ring, Rack Bo1 t 2
22 O-Ring, End Cap 2
.. _IF. Kill. ana.. i

(817)666~545 - Fax(817)666~544
.':10- Q4r02
FROM SER!Al NO. 6210 ISSUED .lIE 1990
RING-GEAR UP
GaNJ DASH( .)
PARTS SECTION
rTEM NOT [LLUSTRA TED
11. CAU'AI DESCal'TU. QUAlTITYl

_a 'AlT_a 1 2
-1 21480 Assembly, Rotation Holding Valve Ref

2 QZBOI021 Body 1
3 QZBOI023 Kit, Seal 1
4 O-Ring, Piston 1
5 O-Ring, Plug 2
6 QZB01015 Piston 1
7 QZB01022 Poppet 2
8 QZBOlO17 Ball 2
9 QZBOI019 Spring 2
10 QZB01020 Plug 2

(817) 6664545 Fax (817) 666-4544 FROM SERIAL NO. 6270
- ISD - 0/51- 0 1
ISSUED ollIE 1990
----------------~~----------~
RING-GEAR UP
PARTS SECTION
This CONDOR 461 RING-GEAR UP parts section GROUP 40

3-SECTION BOOM INSTALLATION is ill ustrated as:
-01 Final Boom Installation
-02 Intenmediate Boom Assembly
-03 Outer Boom Assembly
-04 Inner Boom Assembly
-05 Boom Cable Installation
-06 Boom Cylinder Assembly
-07 Slave Cylinder Assembly
-os Slave Leveling Cylinder
-09 Leveling Holding Valve Assembly
-10 Extension Cylinder Assembly
-11 Extension Cylinder
-12 Counterbalance Valve Assembly
-13 Master Cylinder Assembly
nllfi - . ' - . ",,11iI11_',

. ~~~~- _______ 76702-144~
8300 Impenal Dr. P.O. Box 21447. Waco. TX
_
FROM SERIAL NO 6270
- :40 - 00- 0 1
ISSUED JIII 1990
(817) 666-4545 - Fax (817) 666-4544 I .
RING-GEAR UP
BaNI PARTS SECTION
.
OASH(.) ITEM HOT 'LLUSTRAiEO
ITEM CALAYAR DESCRIPTION
1 234 5
-1 30456 Installation, 3-Section Boom Ref

2 30460 Assembly, Intermediate Boom 1
3 30420 Assembly, Outer Boom 1
4 30461 Assembly, Inner Boom 1
5 46N-40-05 Installation, Boom Cable 1
6 46N-40-06 Installation, Boom Cylinder 1
7 32536 Ring, Tie-Down 1
8 80143-011 Assembly, Hydraulic Hose 4
9 30616-002 Cable, Control 1
10 BOW32606 Clamp, Cable 5
13 BOW36727 Washer, SPL Lock (attachinj parts) 5
14 BOW34274 Nut, Lock (attaching parts 3
15 68670 Bolt, Hex Female
Bracket, Plastitrack (Pair) 1
16 BOW46002 (attaching parts) 4
17 33082-011 Track, Aero 1
18 68669 Bracket, Male Plastitrack (Pair) 1
19 BOW30624 Bolt, Slotted (attaching parts) 4
21 BOW31234 Nut, Keps (attaching parts) 4
22 30394 Spacer, Wear Pad 1
23 30227 Pad, Wear 1
26 68276 Nut, Tee (attaching parts) 6
27 33019 Bracket, Top Wear Pad Mount 1
28 30395 Bracket, Side Wear Pad Mount 2
29 68036 Plate, Back-Up 1
30 12
31
BOW36727
Washer, SPL Lock (attachinj parts)
32
BOW46055
30396 Pad, Wear 3
33 30387 Pad, Wear 1
34 58366 Plug 8
35 BOW40552 Screw, Set (attaching parts) 8
36 BOW32285 Nut, Jam (attaching parts) 8
37 68223 Plate 1
38 BOW36725 Washer, SPL Lock (attachinj parts) 4
39 BOW46000 Bolt, Hex (attaching parts
Holder, 4
40 68186 Wear Pad 6
41 BOW41513 Screw, SOC Flat (attaching parts) 18
42 30225 Pad, Wear 6
43 68183 Plug 6
41\ BOW41OB5 C:;rr~w Sat lattachinn narts)
- --
6
f l . . II fla _ IIISTM.1ATI. (J-SECT)
8300 Imperial Dr" P.O. Box 21447, Waco, TX 76702-1447

(817) 666-4545 - Fax (817) 666-4544
4&4-40- 01-02
FROM SER!AL NO. 6270 I SSUED .lIE 1990
ll-----V
...,. &---lI
3O~~1~
I _:?)5
V/
~~
29 I
34
~43
~
.
-44
r./~
;_~~4S
40 /\
41
11
12_-.t:..~
(817) ~~2:0X21447.
8300 Imperial D
_ Fax(817)~~02-1447
Waco
sa ITEM CALAVAR -
RING-GEAR UP
DESCRIPTION
PARTS 51(TI_
:lASH() ::E" NOT :llIJST1fII':'U
~TI
fllUMBR PART NUMBER 1
4 30461 As"-ly, I_r a.- il
(See 461-40-04 for DET)
5 461-40-05 Installation, . . . ea.l. i1
6 46N-40-06 Installation, Boom Cylinder 1
7 32536 Ring, Tie-Down 1
8 80143-011 Assembly, Hydraulic Hose '4
9 30616-002 Cable, Control 1
10 BOW32606 Clamp, Cable 5
11 BOW46064 Bolt, Hex (attaching parts) ,5
13 BOW36727 Washer, SPL Lock (attachin} parts) 5
14 BOW34274 Nut, Lock (attaching parts ,3
15 68670 Bracket, Female Plastitrack (Pair) J'14
16 BOW46002 Bolt, Hex (attaching parts)
17 33082-011 Track, Aero 1
18 68669 Bracket, Male Plastitrack (Pair) 1
19 BOW30624 Bolt, Slotted (attaching parts) 4
21 BOW31234 Nut, Keps (attaching parts) 4
23 30227 Pad, Wear 1
26 68276 Nut, Tee (attaching parts) 6
27 33019 Bracket, Top Wear Pad Mount 1
28 30395 Bracket, Side Wear Pad Mount 2
29 68036 Pl ate, Back-Up 1
30 BOW36727 Washer, SPL Lock {attachin} parts) 12
31 BOW46055 Bolt, Hex {attaching parts 12
32 30396 Pad, Wear 3
33 30387 Pad, Wear 1
34 58366 Plug 8
36 BOW32285 Nut, Jam (attaching parts) 8
37 68223 Plate 1
40 68186 Holder, Wear Pad 6
42 lO225 Pad, We.r 6
43
44
68183
8211
Plug
Spac.~, Nelr 'ad
6
,
k,..., Set (attlch1~ ,artsL L
JOW32277 ltut,JaIITatt.lch1ng parts) 6
3()4I1 Cover, Plate 1
30479 ! Cover, Boom 2
IOW36812 Bolt, Hex (attaching parts) 6
1OW36725 Wisher, SPL Lock (attaching parts) 6
8300 Imperial Dr. P.O. Box 21447. Waco. TX 767021447

(817) 6664545 Fax (817) 666-4544
'46k -410 - 0 1- 04
FROM SER:AL NC. 6270 ISSUED'" 1990
RING-GEAR UP
GaH] PARTS SECTION
15
19
') I
I
18
19
(
/
16

~
@ q '~
I ~
@@
/'2;.
13 I
\lo/,
\ '
14 I 34

---...,. -"",nn
CORPORATION
----

(817) 666-4545 - Fax (817) 666-4544
4ll6N -;4'0 - 0.2- 0 1
. FROM SERIAL NO. 6270 ISSUED JUlIE 1990
BaNI
ITEM
NUMBER
CALAYAR
PART NUMBER
46M RING-GEAR UP
DESCRIPTION
PARTS SECTION
OASH(.) rTEM NOT :LLUST!tA':'EO
QUANTITY
12345
-1 30460 Assembly, Intermediate Boom Ref
2 30429 Weldment, Intermediate Boom 1
3 30231 Pad, Wear 2
4 BOW36833-75 Screw, SOC Flat (attaching parts) 4
5 35688 Pad, Wear 1
6 35683 Pad, Wear 2
9 BOW36727 Washer, SPL Lock (attachin} parts) 8
10 BOW34274 Nut, Lock (attaching parts 8
11 35709 Assembly, Plastitrack Guide Bracket 1
13 BOW36725 Washer, SPL Lock 2
14 BOW34272 Nut, Lock (attaching parts) 2
15 35708 Weldment, Guide Bracket 1
16 35707 Pad, Side Wear 2
17 35711 Pad, Top Wear 1
18 BOW36812 Screw, SOC Flat (attachin} parts) 6
19 BOW32271 Nut, Jam (attaching parts 6
20 30204 Assembly, Sheave 2
21 68051 Bushing 2
22 30205 Sheave 2
24 35688 Pin, Shea.. 2
25 BOW36815 Screw, sOt Flat !(~ttachift' parts) 8

~-40-02~02
FROM SER:AL NO. 6270 ISSUED . - : 1190
(817) 6664545 Fax (817) 666-4544
RING-GEAR UP
GaNl PARTS SECTION
1lAM4 -) I* _ rUSTM'IU
OUTER BOCII
WELDMENT REF.
(PIN: 30420)
na
1.111
30420
PART _a
CALAWAI
12 l 5
Weldment, Outer Boom

Dt:SCRIPTIGI QUMTIn
Ref
-1
2 32029 . Bushing 2
CORPORATION

(817) 666-4545 - Fax (817) 666-4544
RING-GEAR UP
BON) PARTS SECTI ON
OASH(-) ITEM NOT illUSTRATED
I ----7
~8,
4
1Q
: ITDI CALAVAI D(SCII,n. QUMTI

:-':1 'AIT __
I
-1 30461 Assembly, Inner Boom Ref

2 30422 Weldment, Inner Boom 1
3 30224 Bracket, Dead End (L.H.) 1
4 30458 Bracket, Dead End (R.H.) 1
5 30231 Pad, Wear 2
6 68182 Pad, Wear 1
7 BOW36834 Bolt, SOC Flat (attaching parts) 14
8 BOW34274 Nut, Hex Lock (attaching parts) 4
9 68180 Pad, Wear 2
lO BOW36835 Bolt, SOC Flat (attaching parts) 4
a4~01
I \
I
--="'-------~-~--~-
CORPORATION

-1410-
'~ ~ ______ 1
ISSUED JIIIE 1990

(817) 666-4545 - Fax (817) 666-4544
RING-GEAR UP
BaNI PARTS SECTION
r:::26
27
OUTER 800M
WElDMENT REF. I
(PIN: 3(420) ~
1:l -25
SHEAVE WITH
INTERMEDIATE BOOM REf.
(PIN: 302(4)
@--24
DEAD END BRACKET
INNER BOOM REF.
: 30224)
23----
/~23
ai)J ~22
R.M. DEAD END SRAtlET
WITH INNER BOOM REF.
(PIN: 30458)
OUTER BOOM INTERMEDIATE

_lOMEIT REF. BOOM REf.
: 3(420) (PIN: 30460)
.... 1~NI.an
8300 Imperial Dr., P.O. Box 21447, Waco, TX 76702-1447 JUlIE 1990
(817) 666-4545 - Fax (817) 666-4544
, FROM SERIAL NO. 6270 ISSUED
RING-GEAR UP
PARTS SECTION
.
DASH! ) "'TE'" NOT " LUSTRrED
.~
ITEM CALAYAR DESCRIPTION

1 2 3 4 5
-1 46N-40-05 Installation, Boom Cable Ref

(See 46N-40-01 for REF)
Cable, Extension Wire 2
2 30374
Cable, Retraction Wire 2
3
4
30375
30216 Pin, Cable End (attaching parts)
E-Clip 4
4
5 BOW35239 Pad, Cable Wear 1
6 30229 Screw, SOC Flat (attaching parts) 4
7 BOW36834
Bracket, Cable Wear Pad Support 1
8 30232

9
10
BOW36729
BOW36106

Washer, SPL Lock (attachin parts)
Bolt, Hex (attaching parts 1 4
4
Bracket, Evener 1
11 30428 Spacer, Evener 2
12 30262
Washer, Flat (attaching parts) 4
13 BOW36703
14 BOW36657
Assembly, Sheave 2
15 30204
Bushing, Sheave Pin 2
16 68051
Sheave 2
17
18
30205
BOW7589 Fitting, Grease
Pin, Sheave 2
2
19 30398 Bolt, Hex (attaching parts) 8
20 BOW46002
Washer, SPL Lock (attaching parts) 8
21 BOW36725
Ring, Retaining 1
22 BOW35298
Washer, Flat 2
23 BOW36724
Spacer, Rotation Evener Pin 1
24 35642
Pin, Rotation Evener Bracket 1
25 30423 Washer, SPL Lock (attaching parts) 2
26 BOW36727
Bolt, Hex (attaching parts) 2
27 BOW36054

n_ ~aal IIISflIIJ.ATHI,
_COAPO_A_ATtO"_____

~ - 4[0 - 0!5~
ISSUED -- 1-
02
(817) 666-4545 Fax (817) 666-4544 FROM SER:AL NO. 6270 -. ~
RING-GEAR UP
BaNI PARTS SECTION
DASH( -) rTEM 1I0T rLLUSTAA TED
1. . _
WI 1&1 1If. .wta_
('11: 30461) -UIEl 1Ef.
(PIN: 30421)
6
11
I.JmEeIAJI
_1If.
n.
,.-lR
tALA'Ai
PART NUMBER
('/1: . . .)
1 2 345
QtjMTIn:
I
-1 46N-40-06 Installation 3-Section Boom Cylinder Ref

2 30565 Assembly, Slave Leveling Cylinder 1
(See 46N-40-07 for DEI)
3 21896 Pin, Slave Cylinder to Inner Boom 1
4 33397 Pin, Extension Cylinder to Intermediate Boom 2
6 30563 Assembly, Extension Cylinder 1
7 21809 Eccentric 2
9 32168 Pin, Extension Cylinder to Outer Boom 1
10 BOW34991 Pin, Spiral (attaching parts) 2
11 35081 Assembly, Master Cylinder 1
12 21847 Pin, Master Cylinder to Outer Boom 1
13 1OW41140 Screw, Set (attaching parts) 2
~vnR
CORPORATION

~~--------"
RING-GEAR UP
PARTS SECTION
OASH(-) [TEM NOT ILLUSTRATED
--na
-1 30565
CAlAYAI
'AiT . - : . 1 Z 345
DSCIU'TIOII
Assembly, Slave Leveling Cylinder

Ref
2 BOW7575-1 Fitting, 45 Grease 1
3 35082 Cylinder, Slave Leveling 1
4 30376 Assembly, Tube 2
6 30554 Assembly, Restrictor 2
7 30322 Valve, Leveling Holding 1
10 92030 Washer, Flat (attaching parts) 3
UK CYLlfllO . . . . ,
COR~

(817) 666-4545 - Fax (817) 666-4544
46M -40- Oi1i.. 0 1
RING-GEAR UP
PARTS SECTION
OASH( -) [rEM NOT ; ~LUSiRA ~ED
13
12 I
I
ITI. CALAVAR DESCRIPTION

.-il PART NUMBER 1 2 :3 4 5
Assembly, Slave Cyli

(See 46N-40-07 for )
2 Bushing (83008A) 1
3 Weldment, Rod 1
it End Threaded 1
Head 1
5
6 Piston 1
7 Weldment, Tube 1
8 SBWOlOOl , Bushing it
35689 t, Seal 1
1
...
Screw,
11 Pl ,Nylon 1
Wi ,Rod 1
ypak, 1
Ri I1g, 1
Ri ng, 1
1
2
1
1
--
8300 Imperial Dr. P_O. Sox 21447. Waco. TX 76702-1447
(817) 666-4545 - Fax (817) 666-4544
FROM SERIAL NO. 6210 ,SSUED JUlIE 1990
RING-GEAR UP
PARTS SECTION
DA$I:ll-) IT-iM IIOT ILWSTTU
,
4
5
7
BOTTOM VIEW 8,
10,
III 11
=J.
121
ITO. CALAVAI DfSCIIPTI. QUMIITY,

~I PAil ' - : 1 1 2 l 4 5
-1 30322 Assembly, Holding Valve Ref

2 QZB01013 Body 1
3 QZB01015 Piston 1
4 QZB01016 Poppet 2
5 QZB01017 Ball 2
6 QZB01018 Spring 2
7 QZB01019 Spring 2
8 QZB01020 Plug 2
9 QZB01014 Kit, Seal 1 I
10 O-Ring, Plug 2 I
11 O-Ring, Piston 1
12 O-Ring, Body 2
LIftlI. . . . . IIlVl AiMlltf. .

_-140- 0'1-01 ISSUED .-.E 1990
(817) 666-4545 _ Fax (817) 666-4544 FROM SERIAL NO. 6210
~----~~------~~~~----~
RING-GEAR UP
PARTS SECTION
OASH(-) rTEM NOT :LLUSTRATEO
'1" II
8300 Imperial Dr. P.O. Box 21447, Waco, TX 76702-1447

(817) 666-4545 - Fax (817) 666-4544
46M -40- 1iDr-Ol
SERIAL NO. 6270
1
ISSUED ME 1990
RING-GEAR UP
PARTS SECTION
DASH(-) iTEM NOT ILLUSTRATED
I
,
10
12
CALAVAI
PAIT . . . . 1ZJ 4
-1 35071 Installation, Texas Extension Cylinder Ref

2 Weldment, Tube 1
3 Nut, Lock 1
4 Piston 1
5 Weldment, Spacer 1
6 End Cap, Internal Threaded 1
7 Cap, Head 1
8 . Screw, Set 1 i
9 . Pl ug, Nylon 1
10 Weldment, Rod-Tube 1
-11 35700 Kit, Seal 1
12 . Ring, Wear 2
13 . Set, A-Q Seal 1
14 . O-Ring 1
15 . O-Ring 1
16 . Ring, Back-Up 1
17 . Polypak, U-Cup 1
18 . Wiper, Rod 1
'1", 11
CORPOR AllON
46M ;4\0
-I \ -
(817) 666-4545 - Fax (817) 666-4544
RING-GEAR UP
PARTS SECTION
~~(.) :'t~ ueT :
'-_----7 3
5-----.J
4
5
4
CALAVAR OSCRIPTION QijANTI

PART HUMBER 1 2 345
-1 408 Valve
2 ifol d 1
:3 0- ng, Manifold 2
'l
l~ Cartridge, Counterbalance c.
5 t, Counterbalance 2:
6 67486 dge, i 1
7 RTMO 10 10 t, Rel ief Cartri 1

(817) 6664545 - Fax (817) 666-4544
i FROM SERIAL NO. 6270 I SSUED JUNE 1990
./ I/
" I'N'~'.
. /<'6/
~'"
\",\,:!
. .~ " RING-GEAR UP
~1WtI",~ PARTS SECTION
DASH(-) ITEM NOT :LLUSTRATED
lO"--Q
1----3
lO--
,)
----,2~'
ITiM CALAVAR
NURSER PART tWMIiR DESCRIPTION 'QUANTITY
1 2 345
-1 35081
2 SBWOIOOI 4
3
if 1
5 1.
6 1
7 1
35111 1
9 1
:2
1
1
1
1
1
1
].
1.
CORPORATiON
8300 Imperial Dr" P.O. Box 21447, Waco, TX 76702-1447

- 40 - lr3 - 01
(817) 666-4545 - Fax (817) 666-4544 FROM SEW\l NO 6270 ISSUED JURE 1990
RING-GEAR UP
BaNI PARTS SECTION
DASH( -) ITE" NOT : LLUSTR.ArED
I!:::==::=!Il 74.50 80.80.
52.25
43.38
,---I.- - 6 21 .OO--------l
'---------196.00 ------_-...J
35' 30' 25' 20' 15' 10' 5' 0 5' 10' IS' 20' 25' 30' 35'
45 r----r-~-_,_--,----r--T---ir----:;:-~-.-:.;..-.:,.:::...-:;.---=~~ 45'
35'
30'
25'
1= -5'
~~
. -10' ~~~~-:---lo.:---I-:-_.J-_.J.-_'-----IL...---L_-1.._.....L._......L_..L---l -147'
. ]I JO 25 20 15' 10' 5' 0 5' 10' 15' 20' 25' 30' 35'
~vnR
CORPORA TlON

_ : RING-GEAR UP
(817) 666-4545 - Fax (817) 666-4544
RING-GEAR UP
PARTS SECTION
This e12Z. _ U. l1li parts section'" 88

TURRET IISTALLATION is ill ustrated as:
-01 Turret Installation
-02 Ground Control Console Assembly
-03 Turret Lift Installation
-04 Topping Cylinder Assembly
-05 Topping Cylinder
-06 Topping Counterbalance Valve Assembly
-07 Solenoid Valve Assembly
-08 3-Bank Proportional Control Valve Assembly
-09 Turret Rotation Installation
-10 Rotation Hydraulic Motor Assembly
-11 Speed Reducer Assembly
-12 Rotary Coupling Assembly
-13 7-Aort Rotary Cowplin,
-14 Slip R1n, Asse.bly
"&'1 . ~. T:"Ilf" _Iil'

_-60- QO;'-01
(817) 666-4545 - Fax (817) 666-4544
FROM SERIAL NO. 6270 ISSUED JlIIE 1990
RING-GEAR UP
PARTS SECTION
18
7--

B"'~;46M.l
.lp~~~~L~~~ . . . ~.. ~.. :
'----_____
- 60 - 0 1- 0 1
RING-GEAR UP
PARTS SECTION
DASH(.) iTEM NOT :LLUSTRA~ED

1 234 5
-1 33350 Installation, Turret Ref

2 36141 Assembly, Ground Control Console 1
6 80188 Assembly, Wobbulator 1
7 67200 Speaker, Horn 1
8
9
80661
BOW31145
. Wobbulator
. Screw, RD Head (attaching parts)
1
3
10 BOW31144 Screw, RD Head (attaching parts) 4
11
12
BOW31323
BOW31430
. Washer, SPL Lock (attaching parts)
Washer, Flat (attaching parts)
7
7
13 46N-60-03 Installation, Turret Lift 1
14 33336 Weldment, Turret 1
15 58189 Assembly, Solenoid Valve 1
18 BOW36052 Bolt, Hex (attaching parts 3
19 30615 Harness, Valve Cable 1
"- "~2(L ~12l_~ ______ "--~~
-+Assembl y~-P-ropor'tiona~-Ccmt..ol Vale-- ""
"1"""""
22 BOW36725
BOW36002 Bolt, Hex (attaching parts 4
23
24 46N-60-09
Installation, Turret Rotation 1
25 32546 Harness, Valve 1
-26 30616-001 Harness, Boom Cable 1
27 21079 Decal, Lube Fitting 1
{See 46N-10-03 for REF}
F . " II
CORPORATION

(817) 6664545 Fax (817) 666-4544
46M - 60- 01- 02
FROM SER:AL NO. 6270 ISSUED'" 19!JO
RING-GEAR UP
PARTS SECTION
OASH( -) ITEM NOT :LLUSTRATED
11
A-_-.r:. 12
13
11 14
'11 15
-------- 32
33
:" ...
RING-GEAR UP
PARTS SECTION
OASH(.) iTEM NOT :LLUSTRATED
1 234 5
-1 36141 Assembly, Ground Control Console Ref

2 92260 Manual, Operation and Safety 1
3 34354 Holder, Safety Manual 1
4 67793 Clamp 2
5 BOW31147 Screw, SLT (attaching parts) 2
9 21384 Decal, Operation and Safety Manual 1
(See 46N-I0-03 for REF)
10 35070 Cover 1
11 CLL00199-004 Spacer (attaching parts) 4
15 BOW45028 Nut, Lock (attaching parts) 4
16 BOW31711 Screw, MT (attaching parts) 7
17 67593 Relay 5
18 80377 Relay 1
19 BOW43582 Screw, Pan Head (attaching parts) 12
22 40874 Switch Toggle 4
23 RTNOI051 Holder, Fuse with Cap 3
24 BOW7554 Fuse, 20 AMP 3
25 50075 Switch, Toggle 1
26 80027 Meter, Hour 1
27 80043 Switch, Power Lock 1
28 NPBOI001 Key, Igni ti on 1
29 67240 Ammeter, 30 AMP 1
32 67203 Potentiometer 1
33 67204 Knob 1
-34 RTN0104 Grommet, Rubber 2
-35 34542 Jumper 3
-36 RTN01053 Strip, Terminal 4
-37 BOW31322 Washer, SPL Lock (attaching parts) 8
-38 BOW91624 Nut, Hex (attaching parts) 8
-39 BOW23919 Mount, Tie 4
-40 BOW23985 Ty-Rap AIR
-41 RTNOI059 Diode 3
_-60-02~02
I\.vnn
CORPORATION

(817) 666-4545 - Fax (817) 666-4544 FROM SERIAL NO. 6270 ISSUED . . . 1990
BaNJ ,46N RING-GEAR UP
PARTS SECTION
DASH(-) iTEM NOT ;LLUSTRArEO
3-SECTION
BOOM REF.
(PIN: 30456)
lasTER LEVELING
CYlINDER REF. _----'7
(P/ff: 35081)
\\.0---17
21

~vnR
CORPORA TlON

(817) 666-4545 - Fax (817) 666-4544
4&4- 60- 0131-01
SERIAL NO. 6270
I' __ I
ISSUED oUE 1990

RING-GEAR UP
PARTS SECTION
.
DASH( ) i TEll NOT ., LUSTRA EO
.~

1 2 3 4 5
-1 46N-60-02 Installation, Turret Lift Ref

2 32148 Plate, Boom Pin 2
4 BOW36054 Screw, Hex Cap (attaching parts) 4
5 02514 El bow, 90 2
6 02649 El bow, 45 1
7 32094 Pin, Pivot Half to Boom 2
10 32137 Pin, Master Cylinder to Turret 1
13 68241 Pin, Topping Cylinder to Boom 1
14 32136 Pin, Topping Cylinder to Turret 1
17 30564 Assembly, Topping Cylinder 1
18 32180 Pad, Rubber 2
19 32890 Pad, Boom Rest 2
20 BOW33606 Bolt, SOC Flat (attaching pads) 4
21 40207 Switch, Limit 1
""
c.c.
... " . ' . . 4
Dvn.J.L.Jc..J
.. " ..
Rasner, ~I"L LOCK ~al;l;acnln~ parts) i!
23 BOW31144 Screw, RD (attaching parts 2
_,..... R.vnn
fl-
TUUIT I..in 18t ~I I . ,
CORPORATION

_-60- 031-02
FROM SER:AL NO. 6270 ISSUED'" 1 _
(817) 666-4545 - Fax (817) 666-4544
RING-GEAR UP
PARTS SECTION
OASH(-) [TEM NOT :LLUSTRATED
3 - - -_ _(A
i-
--na
-1 30564
CALA.M
PAIT . . . . 1 2 1 4 5
Assembly, Topping Cylinder

DESCIIPTU. QUAleTI
Ref
2 36515 Cylinder, Topping 1
3 67455 Assembly, Topping Counterbalance Valve 1
4 92010 Washer, Flat (attaching parts) 2

(817) 666-4545 - Fax (817) 666-4544
46M - 60- 0!4~Ol
IFROM SERIAL NO. 6270 ISSUED JIIIE 1990
RING-GEAR UP
PARTS SECTION
,
'~ I
21
~-~~II;;.rT"----;CA:;;U~V=AI~-r~~~==~~~:.......~~===.,..i~--J l'
/11... ----a
PAiT - . 12345 O[5(ll'Tl.
-1 36515 Assembly, Topping Cylinder Ref

2 Bushing 4 I
3 Weldment, Barrel 1
4 Part, Head 1
5 Line, Fluid 1
6 Nut, Lock 1
7 Piston, Steel 1
8 Tube, Stop 1
9 Head, Threaded 1
10 Weldment, Rod 1
11 Fitting, Grease 1
-12 Kit, Seal 1
13 O-Ring, Rod Seal 1
14 Ring, Piston Wear 2
15 O-Ring, Shambam B/U 1
16 Ring Shambam GLYD 1
17 Ring, Back-Up 1
18 O-Ring, Head 1
19 Ring, Wear 2
20 Seal, Rod 1
._-60- 05~Ol
21 Wiper 1
,..
(817)666-4545 _ Fax (817) 666-4544 FROM SERIAL NO. 6270 rSSUEO ME 1990
~------~------~~~~----~
RING-GEAR UP
GaNl PARTS SECTION
DASH( -) ITEM NOT ILLUSTRATED
......re:
I CALAYAR DESCRIPTION QUANTI
"'R PART NUMBER 1 2 3 5
-1 67455 Assembly, Topping Counterbalance Valve Ref

Manifold, Topping Counterbalance 1
2 58191 Connector, STR 2
3 02448 Cartridge, Relief Valve 1
4
5
67486
RTMOIOlO . Kit, Relief Valve Seal
Connector,
1
sTR 1
6
7
00579
32585 Cartridge, Holding Valve
. Kit, Holding Valve Seal
1
1
8 RTM01009

(817) 666-4545 - Fax (817) 666-4544
46M - 60- O,6~Ol
RING-GEAR UP
PARTS SECTION
DASH( -) ITEM NOT
11
10-_ _~}:;
8
10
'-,
lTUI
. . .R
CAlAVU
PART '-:R
DlSCRIPTU. ,,'I
-1 58189 Assembly, Turret Solenoid Valve Ref
1
2
3
58185
LCB20741 Manifold,
Spool
Solenoid
1
2
4 35032 Cartridge, Check
6
5 35031 Coil, 12 3-Way
Cartridge, 2-Position
6
6
7
COQ01002
COQOlO01
Connector,
Kit, Seal
VDC
6
6
8 02525 STR (A,B)
2
9
10
00344
35033 Tee
Cartridge, Counterbalance 2
RTM01008 Kit, Counterbalance Seal 2
11 Elbow, 90 (P,T) 2
12 02857
CORPORATION

(817) 666-4545 - Fax (817) 666-4544
46M - 60- aZr0 1
FROM SERIAL NO. 6270 ISSUED .JIIIE 1990
RING-GEAR UP
GaH] PARTS SECTION
DASH() iTEM NOT ILLUSTRA TEO
10
11
12
4 7
~ 13
~.~~:71-t"''-1?\'l!I! ~ 14
~<t ""I
~ 15
~~ ~/"-~
~~~16
17
25
25
24
17 ------:
l,=:g
11
28
.~
21- -0

J. 11' _l1li1.1 . ._ USIIIILY
8300 Imperial Dr. P.O. Box 21447. Waco. TX 767021447

(817) 6664545 Fax (817) 6664544
46M - 60~ O'~Ol
RING-GEAR UP
BaNI PARTS SECTION
DASH() i rEM NOT LLUSTItA ED

1 2 3 4 5
-1 80122 Installation, 3-Bank Proportional Control Valve Ref

2 02236 o Elbow, 90 (LS) 1
3 02663 o Elbow, 90 3
4 00388 o Connector, STR 6
6 02514 o Elbow, 90 3
7 02328 o Elbow, 45 2
8 32758 o Elbow, Mod 1
10 o Assembly, Tube 1
12 18832 o Assembly, Pressure Gauge 1
13 32760 o Elbow, Mod 1
15 02219 o Elbow, 90 1
16 04134 o Connector, STR (AUX) 1
17 GNH01007 o Cartridge, Compensators 3
18 GNHOI033 o Ring, Back-Up
0 3
19 GNH01032 o O-Ring
0 3
20 GNHOI030 o O-Ring
0 3
0 3
22 o Plug 1
~? ~lIUn'nl:" "~~;;:_"ll1 'l .. I:II ..... +;nn MlIIn;.fnlA 1
... " ....... v ... v,,&. o .", ..
24 GNHOI055 o Plug
0 6
25 GNHOI047 o Plug
0 8
26 GNHOI054 o Bracket
0 2
27 BOW30001 o Bolt, Hex (attaching parts)
0 4
28 GNHOI056 o Plug
0 5
29 GNH01053 o Manifold
0 1
30 GNHOI019 o Valve, Shuttle
0 2
31 GNHOI021 o 0Ring, Back-Up
0 2
32 GNHOI020 o 0O-Ring
0 4
33 GNHOI093 o 0Body, Shuttle Valve
0 2
34 GNHOI094 o 0Ball, Steel
0 2
35 GNHOI095 o 0Seat, Shuttle Valve
0 2
36 GNHOI027 o Assembly, Relief Plate 1
37 GNHOI046 o Body, Re 1i ef
0 1
38 GNH01020 o O-Ring
0 2
39 GNHOO135 o O-Ring
0 2
40 GNH01018 o Cartridge
0 1
41 GNHOO100 o Assembly, Auxiliary Load Sensing 1
42 GNHOI048 o Body, Load Sensing
0 1
43 GNHOI047 o Pl ug
0 3
0 2
0 2
46 GNHOI019 o Valve, Shuttle
0 1
47 GNH01021 o 0Ring, Back-Up
0 1
48 GNHOI020 o 0O-Ring
0 2
49 GNHOI093 Body, Shuttle Valve 1
...
o 0 0
,-.,. ~- " . I t .11 Aqlillt'"1

'" _ _ -60-08~02
"
~.---
8300 Imperial Dr., P.O. Box 21447, Waco, TX 76702.1447
(817)666-4545 Fax (817) 666-4544 FROM SERIAL NO. 6270 ISSUED'" 1t90
~------. .
RING-GEAR UP
PARTS SECTION
a- 35 -0
51~
REf. 25
IEF.43~
4',2---1
72
II 13
74
~6
I~
89,
90

Fl... 3-. . . .IIlI-' ~ ....1 AU8 ..'
~~ 60 - 0:81- 03:
~~--I ~
. CORPORATION -
8300 Imperial Dr., P.O. Box 21447, Waco, TX 76702-1447 I i

(817) 666-4545 _ Fax (817) 666-4544 6270
FROM SERIAL NO. ISSUED ME 1990
-- RING-GEAR UP
PARTS SECTION
OASH(-) iTEM NOT ;UUSrlU;EO
I CALAVAR DESCRIPTION QUANTITY

NU..ER PART NUMBER 1 2
-.00100 _ ..... ly. Auxi11ary LM4 Settliftt"~ -1

42 ..,1041 o 0 lMy. laM Satta t ag 1
43 ..,1047 Plug 3
44 8Mf01020 o 0 O-Ring 2
45 GNH01035 o 0 O-Ri ng 2
46 GNH01019 o Valve, Shuttle 1
47 GNHOI021 0 Ring. Back-Up 1
41 ..,1020 o o-Rililt 2
49 ..,1093 o 0 locIy. Shuttle VaI" 1
SO' iGNH01~94 0 1&11, Steel 1
51 ..HI 1095 o 0 Seat, Shuttle Valve
0
1
52 'JGNH01034 o 0 Solenoid 1
53 COQ01002 o 0 Coil (only)

1
54 &NHOI089 Valve, 3 &PM Flow Control 1
55 GNHOI050 o 0 Screw (attaching parts) 2
56 GNHOI049 0 Screw (attaching parts) 2
57 GNHOI004 o Assembly, Extension Section Valve 1
58 '. &NHOI002 o Assembly, Topping Section Valve 1
59 j.GNHOI025 o Assembly, Rotation Section Valve 1
60 GNHOI037 o 0 Sub-Assembly, End Cap 3
61 :GNHOOI02 o Screw, SHCS
0 12
62, iGNHOOI03 o 0 Cap, End
0
13
it GNHOI066,
63 T-!ia'<DTn'-'-""'_ o 0 Spool, End
0
3
64~
1-"
o uup, Spri n9 3
65' UHe1et9 o Spring
66 GNHOI013 Cup, Spool End 3
67 &NHOIOza o O-Ring
0
3
68 GNHOI0lO O-Ri ng
0
15
69 GNHOI0J8 O-Ring 12
70 GNHOI040 Body/Plug 3
71 &NH00110 o Screw, Valve Mount (attaching parts)
12
72 GNH01042 o Spool (For GNHOI004)
0
1
73 GNHOI043 Spool (For &NH01002) 1
74 GNHOI041 Spool (For GNHOI025) 1
75 &"HOI0H Sub-Assembly, End Cap 3
76 GNHOI0za O-Ring
o 3
, 77 , &NHOOI03 Cap, End
o 3
78 GNHOOI02 Screw (attaching parts)
o 12
, -79 &NH01044 o Assembly, Pilot Valve
0 3
80 GNHO0114 Plate, Pilot Seal
o 3
81 GNHOOI05 oO-Ring
9
82 GNHOOI06 O-Ring 3
83 Body
o 3
84 &NH00104 Screw, SHeS 12
85 Spool, Pilot
o 3
86 92132 Solenoid
o 6
'1GNHO Coi 1 (only) 6
:,1
o 0
IGlH4IOfd Screw, Mounting (attaching parts) i 24

87 GNHOOI.
0
Connector, Solenoid
o 6
90 GNHOO101 Insert~ Thread (attachin, parts)
o : 6
J . . . .111'___ . . . . ._ L':
~.',,_,~R_~~I
..... '1I ... ...
"

.-:60----08~ 04,
(817) 666-4545 - Fax (817) 666-4544 FROM SER!Al NO, 6270 ISSUED . . . 1".,
RING-GEAR UP
BaNI PARTS SECTION
OASH(-) [TEM NOT :LLUSTRA7ED
iI~j
20
21
ROLLI X RING
GEAR REF.
(PIN: 21922)
~"----31
FI. . . TUPlE'
CORPORATION

(817) 666-4545 - Fax (817) 666-4544
46M- 60- 09\-01
RING-GEAR UP
BaNI .
PARTS SECTION
,
DASH( ) iTEM NOT LLUSTRA ED
12345
-1 46N-60-09 Installation, Turret Rotation Ref

Assembly, Speed Reducer 1
-2
3
33427
32798
Motor, Rotation Hydraulic 1
4 BOW33664 Screw, SOC Hex (attaching parts) 2
5 BOW36745-l/2
2
6 02662
Elbow, 90
1
7 32763
Va 1ve , Re 1i ef
4
8 BOW36035
Bolt, Hex (attaching parts)
9
10
BOW31445
BOW36726 Washer, Flat (attaching parts) 4
2
11
12
67486
RTMOI01O .
Cartridge, Relief Valve
Kit, Relief Valve Seal 2
13 RTMOlO04 1
14 Manifold
1
33369
Reducer, Speed
15 BOW36112 Washer,HexSPL(attaching
Bolt, parts) 4
16 Lock (attaching parts) 4
17
BOW36929
BOW36185
Bolt, SQ Head (attaching parts) 2
19 BOW31958 1
Key, Woodruff
Pin, Thrust Locking 1
20
?1
32201
401Ql nlCll"'A 1
. TllrrlCli- I nl"'... Pi n
-
1
(See 46N-I0-03 for
REF)
22 Assembly, Rotary Coupling 1
46N-60-12
BOW36038 Bolt, Hex (attaching parts) 3
23
24
25
BOW31412
BOW31374 Washer, SPL Lock (attaching parts) 3
26 BOW31202
Assembly, Slip Ring 1
27 32659
BOW36727 Washer, SPL Lock (attachin~ parts) 2
28
29 BOW36054
Gear, Ring Ref
-30 21922
Nut, Hex Flange (attaching parts) 9
31 BOW46985
32 BOW36707
33 BOW36155
34 BOW36151

<--. <
FI. . .
.....,.....I'vnn
CORPORATlO"

(817)666-4545 Fax (817) 666-4544 FROM SERIAL NO. 6270 ISSUED .ME 1990
RING-GEAR UP
GaNJ PARTS SECTION
DASH(-) iTEM NOT ;LLUSTRA,ED
12
16
\ I
11
13
CORPORATION

(817)666-4545 - Fax(817)666~544 FROM SERIAL NO. 6270 ISSUED .RIlE 1990
RING-GEAR UP
GatD PARTS SECTION

NUMBER PART NUMBER 1 2 345
-1 Assembly, on
2 Bol t, Hex
(Torque Bolt to 50
3 Cover, End
4 n
5 Assembly, ler Stater
6 . Stater
7 Va he
8 . Roner
9 93111 Plate, Wear
10 93112 Link, ve
11 Shaft
CLKOOOI Key, Woodruff
13 93114 Bearing, Thrust
14 1119
-15 , Kit, Seal
16 . Seal
17 Seal, Shaft
leather, Back-Up
19 Shim
Carrier, Seal
21
Shim
23 Ri ,Wi re
J\.vnn
':ORPQRA i"J~

-60-10-02
(817) 666-4545 - Fax (817) 666-4544 FROM SER:AL NO. 6270 rSSUED JlIIE 1990
BaNI
7
33 13
/
J
/
12
29--
13
13
28
I\.VIIA
CORPORA riON
-- - --
8300 Imperial Or., P.O. Box 21447, Waco, TX 76702-1447
- 60-11- 0 1
(817) 666-4545 - Fax (817) 666-4544 FROM SERIAL NO. 6270 ISSUED JUNE 1990
RING-GEAR UP
PARTS SECTION
OASH( . ) .'
rTE" NOT 'LLUSTRA~EO
ITEM CALAVAR
NUMBER PART NUMBER DESCRIPTION QUANTITY
1 234 5
1 33369 Assembly, Speed Reducer Ref
2 AQC01095 Gasket, Motor 1
3 AQC01057
4 AQC01096 Screw, Cap (attaching parts) 2
5 BOW36840 Plate, Bearing Container Tapped
Screw, Flat Head (attaching parts)
R1ng, A11gnment
1
4
6 AQC01097 1
7 AQC01098
Plate, Bear1ng Container 1
8
9
AQC01099
AQC11454 Gasket, Bracket Hous1ng
Ring, Snap
2
1
10 AQC01100 Coupling 1
11 AQC01101 1
12 AQC01682 Container, Bearing
13 AQC01681 Gasket, Bearing Container 2
14 AQC01016 Gasket, Bearing Container 4
15 AQC01644 Cup, Bearing 2
2
16 AQC01055 Cone, Bearing
AQC01102 Spacer, Worm 2
17
18 AQC01056 Assembly, Hous1ng 1
2
19 AQC01103 Bushing, Housing
1
Hous1ng
20
21
AQC01035
AQC01104 Worm, Left Hand
Shaft, Worm
1
1
22
23
AQC01051
Aij(;Ulbtsts
Key
~t:.Y, ..unn
1
1
~
24 AQC01052 Container, 8earin~ 1

25 BOW36727 Washer, SPL Lock attaching parts) 4
26 BOW36057 Screw, Cap (attaching parts) 4
27 AQC01685 Seal, Grease 1
28 AQC01105 Shaft, Output 1
29 AQC01006 Key, We1gh 2
30 AQC01106 Seal, Grease 1
31 BOW13373 P1 ug, Soli d 2
32 AQC01107 Race, Thrust 1
33 AQC01108 Gear, Left-Hand Worm 1
34 AQC01109 Ring, Snap 1
35 AQC01110 Gasket, Worm Housing Cover 2
36 AQCO 11 11 Assembly, Hous1ng Cover 1
37 AQC01061 Washer, SPL Lock (attaching parts) 6
38 AQC01060 Screw, Cap (attach1ng parts) 6
39 AQC01564 Valve, Relief 1
"vnn
,... 11 ~ ..." E I AS5II", .
CO~PORATlO"

_
FROM SERIAL NO. 6'"0
-60-11 '-02
(817) 666-4545 Fax (817) 666-4544 " ISSUED'" 1_
--------'
- RING-GEAR UP
PARTS SECTION
,
DASH(-) ITEM NOT :LLUSTRATED
5----
eiiiilL.-ps---- 5
--~
9
, 9
11
nUl CALAWAI DESCII,nCII QUMTI
IlUMEIt PART NUMBER 1 234
-1 46N-60-I2 Assembly, Rotary Coupling Ref

2 00466 Connector, STR (B5, B6) 2
3 02298 Elbow, 90 (B5, B6) 2
4 04009 Plug, (B4, P4) 2
5 02525 Connector, STR {P5, P6, P7} 3
6 00266 Connector, STR (PI, P2) 2
7 01160 Connector, STR (P3) 1
8 21569 Bushing, O-Ring (P3) 1
9 02677 Elbow, 90 (BI, B2, B3) 3
10 02236 El bow, 90 {B7} 1
11 32554 Coupling, 7 Port Rotary 1
(See 46N-60-I3 for DET)
II _. .III.Y

~ -60~j~I-Ol
In~""\ 000 A.c::At:: 1:'....." 10""7\ Q:Q.'LAI:AA
RING-GEAR UP
PARTS SECTION
DASH(j ITEM NOT ILLUSTRATED
.....- - - 3
!4
13
~~~---2
5
115--~
14 1----6
i13
I
CALAYAR DESCRIPTION
PA RT NtJIIItE R 1 2 345
-1 32554 Assembly, 7-Port Rotary Coupling Ref

2 KVQ01003 Spool 1
3 KVQOI0I0 Screw, Cap 1
4 KVQOI011 Plug, Flush Pipe 1
5 KVQ01006 Plate, Mounting 1
6 KVQ01004 Spacer, Updated 1
7 KVQOI002 Housing 1
8 KVQOI012 Plug, Flush Pipe 1
9 KVQ01005 Plate, Keeper 1
10 KVQOI008 Washer, SPL Lock (attaching parts) 4
11 KVQ01007 Screw, Cap (attaching parts) 4
-12 92079 Kit, Seal 1
13 KVQ01001 . O-Ring 8
14 KVQ01013 . O-Ring 2
15 KVQ01009 . Ri ng, Seal 1
FlIIIi: 1~ t-lIJfIiTMi C8IIIPU.'

CORPORATION

(817) 666-4545 - Fax (817) 666-4544
46M -60- 1~:-01
FROM SERIAL NO. 6270 I SSUED .DIE 1990
RING-GEAR UP
PARTS SECTION
DASH() rTEM HOT ; LLUSTRArEO
2--_ _ _.....
"A-----l
14 5
12 -~6
13
9 11
7
7
~~~-~
10
na CALAYAI DSCIIPTIOI QUMTIT"!

_I PAIT "':1 1 2 345.
-1 32659 Assembly, Slip Ring Ref

2 TMP01009 Assembly, Center Harness 1
3 TMPOI01O Weldment, Tube 1
4 Base, Aluminum (with O-Ring) 1
5 Assembly, Brush and Holder 1
6 Screw, Set 2
7 TMP01005 Connector 3
8 Cover, Spun Aluminum 1
9 TMP91708 Assembly, Core 1
10 TMP01706 Core, Brush and Holder 10
11 TMP01707 Spring 10
12 TMPOI003 Terminal 10
13 TMPOI004 Sleeve, Plastic 10
14 TMP01008 Stud 2
15 Connector, 90 1
16 Assembly, Brush Harness 1
'- - -_~ ~_~

__ ________
(817) 666-4545 Fax (817) 666.4544
'_J~~46M:--60~ 14 -01
RING-GEAR UP
GatH PARTS SECTION
:JASH( -) :rEM .~or rLLUSTRftTED
s CONDOR 461 RING-GEAR parts

BASE PLATE AND RING-GEAR INSTALLATION as:
46N-10-00
-01 1 -ion
o
o
Avnn
CORPQRATiON
8300 Imperial Dr., P.O. Box 21447. Waco, TX 76702-1447

(817) 666-4545 Fax (817) 666-4544 . FROM SERI~.L NO 6270 ISSUEC JUNE 1990
RING-GEAR UP
PARTS SECTION
OASH(-) [TEM NOT :LLUSiRATEO
1-----3
2-----cI
ITDI CAUYM DESCII'TI ..

r..eE1 'AIT ..eEl I 2 l 4
1 46N-70-01 Installation, Base Plate and Ring Gear Ref

BOW7595-1 Fitting, Grease 4
2
3 21922 Gea r, Ro 11 i x Ri ng . 1
Weldment, Base Plate 1
4 30704 Strip, Lock 9
5
6
58237
BOW33564 Washer, SPL Lock (attachin~ parts)
Bolt, 18
7 BOW36111 Hex (attaching parts 18
8300 Imperial Dr., P.O. Box 21447, Waco, TX 76702-1447 FROM SERIAL NO. 6270
-!7P- 01-01
ISSUED ME 1990
(817)666-4545 - Fax(817)66~
RING-GEAR UP
BaNI PARTS SECTION
Thh (III. . . . . IIIIG-GEAI UP parts section GROUP 80

OPTIONAL INSTALLATION is illustrated as:
-01 Optional Installation
-02 Platform Work Light Installation
-03 Air Line to Platform Installation
-04 Safety Light Installation
-05 Remote Control Box Assembly
-06 110 VAC to Platform Installation
... TaI . . . . .S.!

""'lin
CORPORA TlON
4M~I8() - 001- 01
(817) 666-4545 - Fax (817) 666-4544
FROM SERIAL NO. 6270 ISSUED'" 1990
RING-GEAR UP
BaNI PARTS SECTl~
' ...
n.
-1
CAU'AI
'AiT . . . .
46N-80-01
1
Installation, Optional
DlSC.I'TU.
Ref
1
2 21062 Assembly, Platform Work Light
Installation, Air Line to Platform 1
3 46N-80-03 (See 46N-80-03 for DET) i
4 35769 Installation, Safety Light 1
Assembly, Remote Control Box 1
-5 36464 (See 46N-80-05 for DET)
i
Installation, 110 VAC to Platform (Tip-Mtd) 1

6 35049 (See 46N-80-06 for DET)
1
7 35064 Installation, 110 VAC to Platform (Top-Mtd)
i

- 8\0- 01-01
ISSUED DE 1990
(817) 666-4545 - Fax (817) 666-4544
RING-GEAR UP
BaNI PARTS SECTION
DASH() ITEM NOT :LLUSTRATED
3~;:-- _ _ _~
2
5
7
~-----'I
II
11
.....--::.~
..
ITO CAUWAI DSCltl,ntJI

. .It 'ART '-:1 QUANTIT'!
12 l 4 5
!.
-1 21062 Installation, Platform Work Light Ref
2 67260-027 Assembly, Work Light 1
3 67260-030 Bulb, Replacement (Only) 1
4 BOW31212 Nut, Hex (attaching parts) 3 i

6 BOW30209 Bolt, Hex (attaching parts 3
7 32596 Socket 1
8 32593 Receptac 1e , Female 1
9 32594 Plug, Male 1
10 32595 Pin 1
11 Cable, Wire 1
13 40880 Guard, Switch 1
PUll B.I . . u ... IIIDUIn

(817) 666-4545 Fax (817) 666-4544
. 4&4 -180 - 02r 0 1
.~
;:/\:'N''''"~'',,,
,.~Ul ~" :
RING-GEAR
,.! UP
PARTS SECTION
t!!r~ l!!J \'.J JASH( -) i~EM ~OT :_LUS;~ATEC
4
I
8
9
u:1t
8300 imperial Dr., P.O. Box 21447, Waco, TX 76702-1447

(817) 666-4545 - Fax (817) 666-4544
46N -80 - 03- 0 1
FROM SERIAL NO. 6270 ISSUED JUNE 1990
RING-GEAR UP
PARTS SECTION
DASH(-) ITEM NOT :LLuSTRA~ED
13
!
16
11
I
19
18
ITEM CAUWAR DESCRIPTION

NUMBER PART NUMBER 1 234 5
-1 Pl
1
2 67 ...
:3 67100-010 1
JI. 21394 1
5 1
6 4
7 k ( ) 4
8 Roller 3.,
9 Hose Roller J.
(attachi
11 . Washer, Lock ( )
. Nut, Hex (attachi
;ng. Quick 3
, 45 3
Sui 1
(attaching ) 2'
) 2
],
e 1
1
'J,1

- 03- 02
:ssuED JUlIE 1990
(817) 666-4545 - Fax (817) 666-4544 FROM SER:AL NO 6Z10
GBNI \46M RING-GEAR UP
PARTS SECTION
DASH( -) ITEM NOT :LLUSTRA TED
1---_ ,
; I tALA'AR DESCRIPTION QUANTITY;

i~R PART NUMBER 1 2 3 4
-1 35769 Installation, Safety Light Ref

2 Cable, Wire 1
3 BOW26921 Ty-Rap (attaching parts) AIR
4 35771 Assembly, Rotating Beacon 1
5 KHF01015 Bul b, Amber 1
6 21344 Beacon, Rotating 1
7 35770 Assembly, Strobe Light 1
8 68459 Bulb, 12VDC Strobe Light 1
9 BOW31144 Bolt, Hex (attaching parts) AIR
10 1OW31323 Washer, SPL Lock (attaching parts) AIR
CORPORATION

FROM SERIAL NO. 6270 ISSUED JIIIE 1990
(817) 666-4545 - Fax (817) 666-4544
RING-GEAR UP
BaNI PARTS SECTION
(lASH( -) ITEM NOT : LL~SiRA TED
19
ITEM CALAVAR
ffUMBR PART NUMBR DSCRIPTION
1 234 5
-1
2 Machi ng 1
3 , Control Box . 1
4 . Potenti 1
5 . Knob, Potenti 1
6 4
7 Lock 1
8 1.
9 1
1
1
1.
,==~:::--""""''''''''''_'''''''''''''''_~_~~~~~;''~-'If'l,_~~,- I, '.'.''i ~ji"@il~~'-~~'i;'$-;:it'!i~~~-&-:k:;Hl:filf_iil-t:i~ii-i;l_~ af"--" ... ~l~V!';I;_'_ - J

(817) 666-4545 - Fax (817) 666-4544
Ii
~
..1~" -:80 - 05- 0 1
RDIIli:
FROM SERIAL NO. iVO

,alB. ASSDSll
ISSUEr JUlIE 1990

(46~N.~
__ U ~ ~ING-GEAR UP
PARTS SECTION
DASH() rTEM NOT :LLUSTRA TED
3
4
11

. (817) 666-4545 - Fax (817) 666-4544 SERIAL NO. 6270 ISSUED ME 1990
RING-GEAR UP
PARTS SECTION
DASH ( -) I TEM NOT ll.l.UST~ TEO
10
12
---~~
14-
13~\
-v--
11

CAlAVAI DESCIU'TICII
'ART '-:R 1Zl 4 5
-1 35049 Installation, 100 VAC to Platform (Tip-Mtd) Ref

-2 35064 Installation, 110 VAC to Platform (Top-Mtd) Ref
3 35062-001 Assembly, Wire Cable 1
(Used On 35049 Tip-Mounted)
4 35062-002 Assembly, Wire Cable 1
(Used On 35064 Top-Mounted)
5 15376-024 Decal, 110 VAC 1
6 29163 Breaker, 15 AMPS Circuit 1
7 40956 Box, Bell 2
8 29160 Outlet, 125 VAC - 15 AMPS 1
9 29161 Plate, Weatherproof 1
10 80333 Receptacle, 110 VAC Twist Lock 1
11 35618 Bracket, Universal Mounting 2
14 1OW31146 Screw, SLT (attaching parts) 16
15 67114-003 Connector, Strain Relief 2
_ iac" .....lIlirfr 1iIrraLm.1

I\.vnn
CORPORATION

(817) 666-4545 - Fax (817) 666-4544
~------~
46M: \8_0- Olt 021
FROM SERIAL NO. 6270 ISSUED . . 1990
RING-GEAR UP
BaNJ PARTS SECTION
OASH() rTEM NOT ; LLUSTRA TED
100 Pound Unrestricted CAPACITY: 500 lb. (227 kg) ut'lrestricted platform load
capacity in any boom position with or without 1800 platform
Platform Capacity rotation.
4& Foot Working Height PLATFORM: Welded tubular steel construction with
expanded metql floor, and continuous top railing. Protected
Zero Tail Swing opening for easy access. Self-leveling with power adjust-
ment. Control console for all functions.
BOOM & ELEVATING SYSTEM: Activated by double
....nt State-of-the-Art acting hydraulic cylinders with built-in load holding valves.
Adwances Boom elevation from -15 0 to + 75 above horizontal. Two
section steel, telescoping dry-type boom. Inner section slides
Clllawr engineers are continually advanc- on low friction, high density polyethylene adjustable wear
IRe . , state-of-the-art in design of aerial pads. Hoses and wiring are contained in plastic track inside
boom, eliminating all mechanical moving parts.
W8I'Il platforms. This Condor model incor-
......s these advances: TURRET: Heavy plate steel welded construction, mounted
on sealed bearing internal-tooth ring gear. Driven hydrauli-
cally. Self-locking worm gear speed reducer. 360 0 continuous
rotation in;either direction. Two section removable fiberglass
8IIIIIed controllers with qulck-dlsconnects cover with access doors for easy maintenance.
o-tant-rate load-sensing CHASSIS: Rigid welded steel plate frame houses: Engine-
. . . .ullcsystem pump assembly: hydraulic and fuel tanks. Removable top
TM
.....rsal symbols on control consoles

......ted boom design PLATFORM CONTROL CONSOLE: Sealed, propor-
...... patent 4,506,480) tional spring-loaded controllers, with deadman feature for
drive, turret rotation, boom extension/retraction and elevation.
Toggle switches for steering, platform tilt and rotation, emer
gency power functions, high-low speed and dual fuel. Slope
sensor light and engine start-stop button. All functions marked
with permanent-type universal symbols. Flip top box allows fast
entry to all components and connections.
GROUND CONTROL: Permits ground operation of boom
functions, turret rotation, engine stop/start, aerial/ground
selector switch, power switch, and emergency power func-
OIJI8nal tions. Variable speed control for boom functions. FunctioflS
'-tionBoom marked with permanent universal symbols .
. . .ated STEERING: Tru-Trak 8 power steering for short turning
radius and improved tire life.
ELECTRICAL SYSTEM: 12 volt DC, 140 A.H. rated stor-
age battery with externally driven 37 Amp alternator.
HYDRAULIC SYSTEM: Closed-center system using
pressure-compensated, load-sensing, piston pump, directly
driven by engine. Pump delivers 18 gpm (68 Lpm) at 2400
rpm. Operating pressure 2500 psi (172 bars).
WHEEL DRIVE: Two speed drive for high gradeability or
high speed. Torque hubs on rear wheels driven by reversible
hydraulic motors. Disc brakes are automatically spring
applied and hydraulically released.
ENGINE: Wisconsin air cooled Model VH4D, 30 hp gas-
oline, oil bath air filter.
MFETY rUTUMS! 5 ~ 5en$Of wttn werning.1Ilt
OriwtIdesceflt hom. E~ power system for ~
tton, rotatiofl and ~ Meets or elCCeeds aM ANa
Ae2.5-1 180 and OSHA requirement&
CORPORATlII!t
1m "PROP"" ED AERIALWOM. PLATPOMi.
(817)666~ - Fax(817)666-4544 ISSUED ME 1990
RING-GEAR UP
PARTS SECTION
DASH(-) ITEM HOT ILLUSTRATED
This CONDOR 461 RII6 GEAR-UP parts section 6ROUP 90

POWER PACK IISTALLATION is illustrated as:
-01 Power Pack Installation
-02 Hydraulic Tank Assembly
-03 Hydraulic Pump Assembly
-04 Emergency System Installation
,1tIII" fIiii~if _'iiti:

CORPORATION

_~'D- 00)-01
(817) 666-4545 - Fax (817) 666-4544
RING-GEAR UP
PARTS SECTION
DASH(-) [TEM NOT :LLUSTRATEO
11
19'--

- \910 - 0 1- 0 1
ISSUED dillE 1990
(817) 666-4545 - Fax (817) 666-4544
RING-GEAR UP
PARTS SECTION
OASH(-) ,TEl'! NOT .
'LLUSTIlA~EO

1 2 345
-1 46N-90-01 Installation, Power Pack Ref
1
2
3
32818-001
BOW219 Weldment, Power Pack Base
J-Bolt 2
Battery, 12V 1
4
5
32614
32726 Bracket, Battery Hold Down
Nut, 1
6 BOW34324 Wing (attaching parts) 2
7 Washer, Flat (attaching parts) 2
8
BOW36751
Assembly, Hydraulic Tank 1
21742
9
10
BOW36056
BOW36727 Washer, SPL Lock (attaching parts) 4
Assembly, Electric Control 1
11
12
36345
Bracket, Alternator 1
13
32214
40166 Bracket, Alternator Mounting 1
14 32218 Assembly, Alternator 1
15 32874 Arm, Alternator Belt Tension 1
16 32818-009 1
17 V-Belt
Connector, STR 1
18
00370
02679 Elbow, 90
Connector, 1
19 02582 STR 1
20 02236 Elbow, 90
Elbow, 90 1
1
21
.,.,
-- --- -
02671
~?~7? L-ll0
~nllnlinn 1
Screw,SOCHead (attaching parts) 2
---- 23 80W4Q531 Assembly, Sheave
24 32871
Assembly, Electric Motor 1 .
1
25
26
32851
32895 Support, Pump 1
27 Assembly, Hydraulic Motor 1
32524
29 BOW36104 Bolt, 2
30 BOW36729 Washer,HexSPL(attaching parts)
Lock (attaching parts)
10
Assembly, Emergency Motor 1
32 46N-90-04
21368 Valve, Check 1
33

" l - ei . . . . NCI _ l A T . 1-
~vnR
CORPORATlO"

(817) 666-4545 - Fax (817) 666-4544 FROM SERIAL NO. 6270 ISSUED . . . 1990
RING-GEAR UP
PARTS SECTION
23
25,

'----------~ 4i'~~o
(817) 666-4545 - Fax (817) 666-4544
.
-012\-01
ISSUED .JlIIE 1990
RING-GEAR UP
BaNI DASH(.)
PARTS SECTION
:m~ NOT :LLUSTR,IEO
ITEM CALAVAR
NUMBER PART NUMBER DESCRIPTION QUANTITY
1 234 5
-1 21742 Assembly, Hydraulic Tank Ref
2 67053 Cover, Quick Disconnector 1
3 67051 Disconnector, Quick 1
4 BOW13196 Nipple, Steel Close 2
5 BOW13503 Elbow, 90 1
6 21192 Stick, Dip 1
7 02697 Tee, Run 1
8 00388 Reducer, STR 1
11 32522 Filter, Return 1
12 67408 . Element, Filter (Only) 1
15 21799-007 Assembly, Tube 1
16 02681 Elbow, 90 1
17 BOW13237 Nipple, Steel Close 2
18 BOW13507 El bow, 90 1
19 67489-004 Valve, Gate 1
20 02326 Reducer, STR 1
21 02679 El bow, 90 1
22 21237 Assembly, Tank 1
?~
24
AnQ"A
21473
.
Rw-o::llt-how-
Strainer, Sump
J:';llow- 1
1
25 BOW13237 . Nipple, Steel Close 1
26 00417 Plug 2
27 21237-014 Weldment, Tank 1
28 21237-015 Gasket, Tank 1
29 21237-016 Cover, Tank 1
30 BOW31834 Screw, Self-Topping (attaching parts) 18
- ... -~vnR
CORPORATlO,,"

(817) 666-4545 - Fax (817) 6664544
.-1910- 02~02
FROM SER:AL NO. 6270 ISSUED . . . 1190
BaN]
2
AI-----l
13
14
16
11
ita. "93 tmIIWlit: PuMP AssBliJ

..........,IL..AvnR
CORPOR ATlON
8300 Imperial Dr., P.O. Box 21447. Waco, TX 767021447

(817) 6664545 - Fax (817) 6664544
46N -90 - 03,- 0 1
, FROM SERIAL NO. 6270 ISSUED JUNE 1990
RING-GEAR UP
PARTS SECTION
!lASH( -) '''EM NOT " LUSTIO\EO
.' .~
ITEM CALAVAR DESCRI PTI ON

1 234 5
-1 32524 Assembly, Variable DISP Pump Ref
Kit, Control Valve 1
2
3
RTN01826
RTNOI024 .Plug 2
1
4
5
RTN01023
RTN01025 .
Spool
Spool ",
1
1
6 RTN01827
Housing, Control Valve
4
7 RTNOI021
Screw, Cap (attaching parts)
1
8
9
RTN01022
RTNOI020 .
O-Ring
Gasket, Control Valve 1
1
10 RTNO 10 11

Plug, Special
1
11 RTN01026

Orifice
12
13
RTN01027
RTN01828
Retainer, Spring
Spring, FC (400 PSI)
2
1
1
14
15
RTN01006
RTN01029 .
Pin, Spring
Spring, PC (3,000 PSI) 1
2
16 RTN01030
O-Ring
17 RTN01031

Screw, Adjusting 2
2
18
19
RTNOI032
RTN01024
Nut, Lock (attaching parts)
Plug
Cap, End 1
20 RTNOI047 Screw, Cap (attaching parts) 1
4
21 RTNOI043
Cap ..,1
22
23
RTN01034
RTN01005 P;n ..
24 RTNOI004 Pin 1
25 RTN01829 Screw, Adjustment 1
26 RTN01035 O-Ring 1
27 RTN01038 Cylinder, Control 1
28 RTNO 10 37 Gasket, End Cap 1
29 RTN01830 Shim 2
30 RTN01831 Bearing, Rear 1
31 RTN01832 Plate, Valve 1
32 RTNO 10 13 Kit, Cylinder Block 1
33 Barrel 1
34
35
. Pin
Washer
3
1
36 Sl ipper 1
37 Retainer, Slipper 1
38 Pi ston 9
39 RTNOlO15 Plate, Thrust 1
40 RTN01833 Plate, Swash 1
41 RTNOI046 Shaft, Drive 1
42 RTN01834 Bearing, Front 1
43 RTNOI040 Retainer, Spring 1
44 RTN01041 Spring 1
45 RTNOlO07 Plug 1
46 RTNOI008 O-Ring 1
47 RTN18036 Bearing, Journal 2
49 Shim 2
50 RTN01838 Trunnion, 2
_,.. _Avnn
'1- U ".TILIC"" ASslIILI
CORPORA TIO ....

(817) 666-4545 - Fax (817) 666-4544 FROM SER:AL NO. 6270 ISSUED .DIE 1990
RING-GEAR UP
PARTS SECTION
28

CORPORATION
'I.~.. .4&4-1910:
. 1.'"1' ...... lIT,
O~i O~
8300 Imperial Dr., P.O. Box 21447, Waco, TX 76702-1447 I SSUED ME 1990
_ .~. (817) 666-4545 - Fax (817) 666~
RING-GEAR UP
BaNI PARTS SECTION
:lASH(.) :rM NOT :LLUSTAAEO

1 2 345
19 RTND1024 Plug 1
20 RTN01047 Cap, End 1
21 RTNOI043 Screw, Cap (attaching parts) 4
22 RTN01034 Cap 1
23 RTNOI005 Pin 2
24 RTN01004 Pin 1
25 RTN01829 Screw, Adjustment 1
26 RTNOI035 O-Ri ng 1
27 RTN01038 Cylinder, Control 1
28 RTNO 10 37 Gasket, End Cap 1
29 RTN01830 Shim 2
30 RTN01831 Bearing, Rear 1
31 RTN01832 Plate, Valve 1
32 RTN01013 Kit, Cylinder Block 1
33 Barrel 1
34 Pin 3
35 Washer 1
36 Sl ipper 1
37 Retainer, Slipper 1
38 Pi stan 9
39 RTN01015 Plate, Thrust 1
40 RTN01833 Plate, Swash 1
41 RTN01046 Shaft, Drive 1
42 RTN01834 Bearina Front 1
43 RTN01040 Retainer, Spring 1
44 RTNOI041 -Spring 1
45 RTNOlO07 Plug 1
47 RTN18036 Bearing, Journal 2
49 Shim 2
50 RTN01838 Trunnion 2
51 Washer, Ring (attaching parts) 6
52 RTN01839 Bolt, SOC HD (attaching parts) 6
53 RTN01835 Housing 1
54 RTN01044 Seal, Lip 1
55 RTN01840 Ring, Retaining 1

(817) 666-4545 Fax (817) 666-4544 FROM SER:AL NO. 6270 ISSUED'" 1190
RING-GEAR UP
PARTS SECTION
TED
----I
11
10,-....-_ _ _- J
t----,
7 11/
12
n.
'-111
CALA-
,All _I .SCII,n. ",11"
-1 46N-90-04 Installation, Emergency System Ref

Elbow, 90 1
3
4
04097
50148
Fi 1Element,
ter, Inline 1
Inline Filter (Only) 1
5 51634 Elbow, 90 1
6 04155 Assembly, Emergency Motor and pum) 1
7 35659
,
8 BOW36727
BOW36059
Washer, SPL Lock (attachin~ parts
Bolt, Hex {attaching parts
Solenoid
2
2
1
10
11
AZPOI005
35245 Pump, Emergency ,1
12 35244 Motor, Emergency 12V 1
----~--~- --

04 01
FROM SERIAL NO. 617n

Condor 36N - 46N - 60N - 92260

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Condor 36N - 46N - 60N - 92260

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What safety precautions are outlined in the manual?

What safety precautions are outlined in the manual?

What are the specifications of the different models discussed (36N, 46N, 60N)?

What are the specifications of the different models discussed (36N, 46N, 60N)?

OPERATION AND SAFETY MANUAL

For Your Own Safety and Protection

SPECIFICATIONS MODEL 36N MODEL 46N MODEL 60N

Tires (Foam Filled) 11x15LT 31/11.5x16.5 14x17.5

ZERO TAIL SWING

MOL 36N - 5 FT. 9 IN.

6' 11.83m) wor~'ng height

20'6" 16.2Sm) ~ 30'

2'Section Boom with

1. DESCRIPTION OF INDUSTRIAL CONDOR

KNOW and FOLLOW all cautions, warnings and operating

YOUR SAFETY IS OUR UTMOST CONCERN AND

CIINIIW. OPIRATING INSTRUCTIONS-

YOU MUST NOT OPERATE THIS MACHINE

CAUTION - CAUTION - CAUTION

1. LOADING AND UNLOADING

The CONDITION of the unit prior to start up is a very IMPORTANT factor, as it

1. OVERALL MACHINE CONDITION

Defective components, structural damage, misSing parts or equipment malfunctions

u..;;::,....,..-- SAFETY LI6IfT

GROUIID COIITROI. BOX

:.-_ _ _ _ _ _ THRUST LOCKING PIN

~~)".-_ _- - - - LIMIT SWITCH

},..-_ _ _ _ TOPPING CYLINDER

rm--~---~ KEY SIIITCH

GROUND CONTROL BOX IDENTIFICATION

PLATFORM CONTROL BOX IDENTIFICATION

~r" KEY SWITCH

V STEER TRAVEL SPEED

2. OPERATION FROM PLATFORM CONTROLS

FORWARD/REVERSE and LEFT/RIGHT steering movement directions indicated on the

lIP - HEAVY DUTY OPEN GEAR:

D 100 HOURS or IOITHL Y

o 500 HOURS or AllllAlLY

1. PRESSURE GUN LUBE POINTS

4. ROTATION GEAR TEETH AND PINION

6. DRIVE TORQUE HUBS

7. HYDRAULIC SYSTEM - KEEP SYSTEM CLEAN

'" ,. iI u.. X'OW60A II !'""6QASlC.

...... EMf:R6fNCY "'''' ,.., )II ,.,

"" 02 P " SIAtI PI 10 ~.m~l:

" ,,-,,~f,,:L.-; . " tIl'UtIlll'UUl

~.l:2A~:r, ~--~. ~86.

"fIR 'L_ [-1... U_ .. _

SLOPE rm'HSlON IT' C/)

~ " G!L-I!\... 42 R6 P!HSO P~_ ~II

.,." 6 .~.:.!:. :lr"

I': r .. L .. i(c: _.i I r~

~" r-/ 23,.> 23 .J3 _ _ ~1

CONDOR JlJDEL 361 AID 461 HYDRAULIC SCIIEMTIC

COftDOR MODEL 6011 HYDRAULIC SCHEMATIC

WHEN PROPERLY MAINTAINED AND OPERATED

You are required by ANSI/SIA A92.5-2006 to read and understand YOUR

The USER and OPERATOR MUST MAKE DECISIONS on the operation

Refer to the manufacturer's operation and USE of the aerial