Calavar self-propelled condor models 3238, 4248, 4248LC Operation/maintenance and illustrated parts manual ! (SN

CORPORATION OPERATION/MAINTENANCE AND ILLUSTRATED PARTS MANUAL FOR CALAVAR SELF-PROPELLED CONDOR MODELS 3238, 4248, 4248LC, 4248T Calavar Corporation provides this Manual for the guidance of all owners, operators, and servicing personnel in order to obtain the longest possible trouble-free service. It contains general data; specifications; operating instructions; recommended lubrication procedures; vendor information and specifications; illustrated parts breakdown and a special section on safety. Model Serial No. Date Delivered CUSTOMER Note: Additional copies of this Manual (Part No. 92152) may be obtained through the Parts Department at Calavar. Series IV (Serial Nos. 2392-2544)

INTRODUCTION The primary purpose of this manual is to provide the user with a thorough understanding of the proper operating procedures necessary to comply with the intended use of the CONDOR®, and to provide the information necessary to maintain and service the CONDOR®. THE OPERATOR'S MANUAL MUST BE RETAINED ON THE CONDOR® AT ALL TIMES. Do not attempt to operate or service the CONDOR® until you have read and understood all information provided in this manual. Familiarize yourself with the functions and operations of the upper and lower controls. A good understanding of the controls, their limitations, and their capabilities will maximize operating efficiency. The various decals attached to this CONDOR® also contain vital operational instructions. Read the decals before operating this CONDOR®. It is YOUR RESPONSIBILITY to follow procedures while operating the CONDOR®. The manufacturer of this CONDOR® cannot control the wide range of applications that may be used in carrying out a variety of jobs. Therefore, it is THE USER'S RESPONSIBILITY to consider all personnel when making decisions regarding the C OND OR@ ' s intended use. It is also YOUR RESPONSIBILITY to understand and obey all federal, state, and local regulations regarding the operation and use of aerial work platforms. A copy ofthe ANSI/SIA Manual of Responsibilities is attached for your use: ANSI/SIA A92.5-1992 is provided for Boom-Supported Elevating Work Platforms, and ANSI/ SIA A92.6-1990 is provided for Self-Propelled Elevating Work Platforms. TIME CONDOR Corporation reserves the rightto modify, improve, add, and/or delete certain design features of its products without any obligation to incorporate new features into products previously sold. Our manuals are continually updated to reflect these changes. DO NOT ALTER OR MODIFY THIS CONDOR® WITHOUT PRIOR WRIT1LN APPROVAL FROM THE MANAGEMENT OF THE TIME CONDOR Corporation. SERVICE & MAINTENANCE Many ofthe parts used in the manufacture of the CONDOR® have specific properties, and the manufacturer recommends that replacement parts be purchased through -the TIME CONDOR Corporation in orderto ensure the original integrity of the product. Repairs and adjustments should only be made by trained and qualified personnel. Please referto the maintenance and parts sections ofthe TIME CONDOR Corporation Operation, Maintenance, & Parts Manual for information on service and maintenance of the CONDOR®. NOTE: Please refer to the TIME CONDOR Corporation Parts section of the Operation, Maintenance, & Parts Manual for information pertaining to your CONDOR®.

CONDOR OPERATION AND SAFETY MANUAL It shall be the responsibility of all users to read and comply with the following common sense rules that are designed to promote safety and aid in better understanding the operation of the Self-Propelled Condor. These rules do not purport to be all inclusive, nor to supplant or replace other additional safety and precautionary measures to cover usual or unusual conditions. If these rules conflict in any way with any state, local or federal statute or regulations, said statute or regulation shall supersede these rules and it shall be the responsibility of each user to comply therewith. UNLOADING 011111•••■•■■••■••■■•■••■•■■•■■■■•■•••■•■ 1) If the use of a loading ramp is necessary to unload the Condor, select a sturdy ramp. The Condor Model 4248 weighs approximately 15,000 lbs..and the Condor Model 6066 weighs approximately 21,200 lbs. 2) If the work platform was removed for shipment, it must be replaced prior to unloading. Do not unload unit by standing on fork assembly. OPERATING 1) Operating instructions are located on a placard on the ground control side of counter weight. Before operating unit, check out items as instructed on the placard and in this booklet. 2) Start unit and allow engine to warm up. If it is necessary to reposition boom, this can be done from the ground control station. Switch Aerial/Ground Selector Switch to Ground, and by activating toggle switches, the boom can be placed in a position that would be safe for unloading. If possible unload the Condor boom first. 3) By switching Aerial/Ground Selector Switch to the Aerial Position, ground position controls are inoperative. Unit can now be operated from Aerial Position. 4) Aerial Controllers are proportional, except for steering, platform tilt and platform rotation, which are bi-directional toggle switches. Each controller has a deadman lock-out mechanism that must be depressed before the controller can be activated. By depressing the deadman button not only is the controller free to be activated, but also will bring the pump from a stand-by position to a working position, while increasing engine R.P.M. from idle to operating R.P.M. 5) Normal driving position for the Condor is with the counterweight over the driving wheels. Controller movement is based on this configuration. With counterweight over steering, the drive and steering control will react reversed. 6) Try each controller momentarily to orient yourself on its operation. The controller should always be moved gradually to obtain the smoothest possible operation;

7) Before unloading Condor, test the automatic braking system by moving forward and reverse to see that the brakes apply when the drive controller returns to the neutral position. 8) Located between the drive motors is the two speed valve. Handle up indicates high speed, minimum torque. Handle down indicates minimum speed, maximum torque. Unit should be loaded and unloaded in low---handle down. INSPECTION •1•111•011•■• 41■1.111110 •MMIP .11=01 .1111•M 1) Once unit has been unloaded, give the unit a visual inspection paying special attention to items listed below. This inspection should become part of a daily inspection performed at the beginning of a work shift by the assigned operator. A) Check tire pressure B) Check for cut or damaged tires C) Check electrolyte level D) Check engine oil E) Check hydraulic oil level (use A ,T.F. oil only) F) Check oil cooler for damage and cleanliness G) Check air cleaner oil level and cleanliness H) Check stop and start circuit from ground and aerial position I) Visual inspection for hydraulic leaks NOTE: Condor models equipped with 54 to 1 torque hubs. Check operation of slope sensor device. If possible, place unit on slope of 5° or more, indicator light should come on and all boom functions will be inoperative. The Condor Model 6066 is also equipped with limit switches. One located inside the boom and another located outside of boom at the boom to turret hinge pin. When either switch is activated, they automatically shift drive to low speed when boom is extended or raised to horizontal. OPERATOR TRAINING 1) In order for an operator to thoroughly understand the operation of a Condor and to become a qualified operator, it is recommended that after having been checked out by a trained, qualified operator, the trainee operator should move the unit to an area free of any overhead obstruction. The surface upon which the unit will be operated should be level with no hazardous irregularities or accumulation of debris. Models equipped with manual two-speed shift---shift to high speed (handle up), drive unit to become familiar with the speed and braking characteristics. Shift unit to low speed (handle down) and repeat driving exercise, NOTE: Condors equipped with automatic shift---this is done automatically when boom is extended or reaches horizontal,

3) Elevate boom to approximately 60°, at this angle the operator will have a clear field of vision over the area below. Repeat low speed driving exercise. 4) With boom at 60°, extend boom approximately half way and repeat driving exercise. 5) With boom at 60° and half extension, rotate counterweight between drive wheels and repeat driving unit. 6) Extend boom to maximum and raise boom to 75°, rotate turret. Turret rotation is continuous. By gradually operating rotation controller giving full signal to rotation, and by gradually returning controller to neutral, the operator will learn how the rotation can be controlled to place unit along side a building smoothly. 7) Place counterweight over drive wheels, with unit at 75° and maximum extension. Repeat driving exercise. NOTE: Extreme care must be taken when driving in this position, as ground vision has been reduced. The operator must watch for objects or personnel that may be in the area. 8) At the end of this exercise, the operator will have driven the Condor in both high speed and low speed; with extended and retracted boom; and will have driven the Condor with boom off to the side, and will have practiced placing Condor in imaginary work positions. SAFETY Listed below are items pertaining to safety that the operator must know and follow. 1) The Calavar Self-Propelled Condor is a personnel lifting device and it is essential that it is properly maintained and operated to perform all functions with maximum safety and efficiency. 2) The operation of any new and unfamiliar equipment can be hazardous in the hands of untrained operators. Only trained operators should be assigned to operate the Condor. 3) It is the responsibility of the operator to be familiar with the manufacturer's manual and to follow all recommendations made. Never exceed mamufacturer's recommended load. 4) It is the reponsibility of the owner to instruct the operator with the safety requirements made not only by Calavar, but by various safety boards in your area, as well as requirements set down by OSHA and ANSI. (Note: See ANSI 92.2-6.1.1 and 6.1.2 1969 Appendix A2.1 and A2.2.)

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Calavar self-propelled condor models 3238, 4248, 4248LC Operation/maintenance and illustrated parts manual ! (SN

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