Calavar self-propelled condor models 86 Operation/maintenance and illustrated parts manual ! (Part No.92238)

92238 OPERATION/MAINTENANCE AND ILLUSTRATED PARTS MANUAL FOR YOUR CALAVAR SELF-PROPELLED CONDOR MODEL 86 HAVING PLATFORM CAPACITY = 600 LBS. 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. CORPORATION Serial No. ------------------- Date Delivered ---------------- ______________ _ Note: Additional copies of this manual (Calavar Part No. 92238) can be obtained through the Parts Department at Calavar Corporation, Santa Fe Springs, California 90670

( , 2/84 OPERATION/MAINTENANCE AND ILLUSTRATED PARTS MANUAL FOR YOUR CALAVAR SELF-PROPELLED CONDOR MODEL 86 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 p·rocedures, vendor information arid specifications, illustrated parts breakdown and a special section on safety. CORPORATION Serial No. --------------------- Date Delivered ------------------ CUSTOMER ----------------------- Note: Additional copies of this manual (Calavar Part No. 92181) can be obtained through the Parts Department at Calavar. SERIES III COMMENCING WITH SERIAL #5100

CALAVAR SELF-PROPELLED CONDOR MODEL 86 INDEX Introduction ••.•••• Unloading Instructions. Factory Recommended Transporting Diagram. Check-Out Instructions. Calavar Warranty ••••• • Conversion Tables, Degrees to Percentage .• General Information: , General Specifications . , Hydraulic System ••. , Electrical System ••. , Presetting Proportional Controllers •. Lubrication Charts. • . . Oil Specification Sheet. Tightening Torque Valves. Wire Rope Cable Adjustment. Troubleshooting Guide , Engine. · · · , El ectri ca 1 System' • " Hydraulic System • Drive . · · · , Boom Operation • , Turret . · · · Preventative Maintenance .• Recommended Spare Parts List i · 1 · 2 · 3 · 5 · 8 · 9 · .10 · .12 . . . . . .14 .16 . •. 17,18 .19 . . . . .20 · .20a · .21 . . . .22 · .22 · .23 · .23 · .24 · .25 . ••• 40

CALAVAR SELF-PROPELLED CONDOR MODEL 86 INDEX (Cont'd.) Vendor Section • Engine (Ford Gasoline or Ford Diesel or Duetz Diesel) • Racine Solenoid Control Valves • W.S.I. Drive Motor • Fairfield Torq-Hubs • H.P.I. Proportional Valve • Sundstrand Load-Sensing Pump • Sundstrand/Honeywell Control Consoles • Sundstrand/Honeywell Multi-Axis Slope Sensor • Return Line Spin-A-Filter • High Pressure Filter • 180 0 Rotary Actuator • Hydraulic Rotary Coupling • Synchro-Start D.C. Solenoids • • Counterbalance Valve Cartridge • Waterproof Limit Switches Parts Section • Parts Breakdown • Hydraulic Schematic • Electrical Schematic Condor Operation and Safety Section ii

SELF-PROPELLED CONDOR MODEL 86 PARTS AND MAINTENANCE MANUAL INTRODUCTION The function of the Parts and Maintenance Manual is to first provide the customer with a complete and up-to-date Parts Manual covering models presently in production and second, to aid in ordering correct parts. If used properly, it will provide the customer with a source of information that will aid in solving quickly and inexpensively the bulk of maintenance problems. Under the various sections called out in the index, Calavar has included all of the specifications sheets from the manufacturers of component parts that make up the CONDOR, as well as a general trouble-shooting guide directed solely to the CONDOR as a completed unit. Throughout this manual reference is made to unit serial numbers, and the use of this number when ordering parts will assist our Parts Department in giving you plfompt and accurate service. The use of correct serial numbers and part numbers will also expedite completion of warranty claims sent to Calavar. Serial numbers should also be used at all times in phone conversations to Calavar service personnel. This manual has been produced as a valuable tool for our customers. It is in your best ineterest that time be spent to read and understand all the sections in the manual. Calavar has included a special section that deals with the safe operation of the Self-Propelled Condor, as well as information about certain items that must be inspected periodically to ensure a safe operating unit. SP86/11-81 1

SELF-PROPELLED CONDOR MODEL 86 INTRODUCTION The two primary functions of this Manual (covering Condor Model 86 machine in current production) are to assist in the safety/training of operators and maintenance personnel, and to provide a complete and up-to-date Parts Section for replacement parts. This Manual has been produced as a valuable tool for our customers. It is in the best interest of everyone involved with the use, operation, and maintenance of the machine to read and thoroughly understand all sections of this Manual. Calavar has included in this Manual the specification/parts/ maintenance sheets for various critical components. A vendor Section is also included together with a general Trouble-Shooting Guide for the Condor unit. . Throughout this Manual, reference may be made to serial numbers of Condor units. When ordering parts, use of this serial number will assist our Parts Department in giving prompt and accurate service. Serial numbers should be used at all times in phone conversations with Calavar Service personnel. Also, the use of correct serial numbers and part numbers will expedite completion of warranty claims sent to Calavar. All product descriptions and illustrations contained in this Man- ual are valid at the time of publication for the given series of production machines. Calavar Corporation reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obligations upon itself to in- stall them on its products previously manufactured. Calavar has included a special section that deals with the safe operation of the Condor 8b as well as information about certain items that must be inspected periodically to ensure a safe operating unit. The operation of any AERIAL WORK PLATFORM is subject to certain hazards that can be protected against only by the exercise of in- telligence, care, and common sense and not by mechanical means. It is essential to have competent, careful personnel trained in the intended use, safe operation, maintenance and service of this type of equipment. Condor Models are designed and built to conform to Calavar1s understanding and interpretation of all applicable OSHA Rules and Regulations and ANSI Standards: • OSHA Title 29, Paragraph 1910.67 -Vehicle-Mounted Elevating and Rotating Work Platforms-Labor

• OSHA Title 29, Paragraph 1926.556 • ANSI Standard A92.5-1980 -Aerial Lifts- Construction -Boom-Supported Elevating Work Pl atforms It is imperative that all owners and operators of the Condor read, understand and conform to these regulations. Ultimate com- pliance to prevailing OSHA regulations is the responsibility of the employer utilizing the equipment.

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CHECK-OUT INSTRUCTIONS , The following instructions are a step-by-step procedure for checking out the Self-Propelled Condor Model 86 while, at the same time, acquainting operating personnel with its operation. The procedure will not take over an hour and is time well spent to give both operator and maintenance personnel a better understanding of the operation of the Condor, and also to provide an opportunity to acquire experience in the operation of the Self-Propelled Condor. Prior to placing the Self-Propelled Condor Model 86 into service, a full check-out of the unit should be made and the Installation Inspection Report completed and returned to the factory. Each unit has undergone a thorough Quality Control Inspection and each unit leaves Calavar in a first class condition. Unfortunately, in transportation damages may occur, and you should be aware of such damage and make a note on the consignee copy of the freight bill. Calavar Corporation is not responsible for damage to units in transit. 1. Visually inspect all parts of the CONDOR that are exposed. Check for loose nuts, bolts, damaged hydraulic lines, broken wires or structural damage. 2. IMPORTANT! Check tires for cuts, etc. They were foam filled by the vendor. 3. Check hydraulic oil level---add Dexron II A.T.F. oil, if required. 4. Fill gas tank, use regular gasol ine only/or diesel. 5. Check battery with a hydrometer. Battery must have a full charge. 6. All hydraulic valves are located inside turret cover and are exposed by opening the turret L.H. door. Close this door, after visual inspection of turret compartment, before placing unit in service. 7. Turn on master key switch to start at ground station located on turret junction box inside the turret door. Allow engine to warm up at idle. (The choke is electric.) After unit has warmed up and with Ground/Aerial Selector Switch in ground position, unit can now be operated from hand held control box on 20' of electric cable by activating switches marked BOOM UP, BOOM DOWN, TURRET ROT., LEFT OR RIGHT, and BOOM EXTEND or RETRACT. Wheel drive is not available from ground station. Master switch must be left on during all aerial operations. Engine can be shut off and restarted from either ground control or platform control. 8. With Master Switch ON, switch to AERIAL POSITION. Condor can be started or stopped from AERIAL POSITION. Position unit in an area that is free from any overhead obstruction. Lift bottom of Controller Knob' for boom function, push slowly to the UP position and raise boom about six (6) feet. When released, the controller will return to neutral position automatically. Learn to operate controller slowly to obtain the smoothest possible operation. SP86/11-81 5

9. The Self-Propelled Condor Model 86 has been designed to drive with the counterweight over the drive wheels. This configuration will provide the best traction and a familiar driving position. 10. A modular valve is located on the base between drive wheels. It contains several features---a flow divider cartridge, two diverter cartridges, a two-speed solenoid cartridge, a flow control and check valve cartridge, and an additional counterbalance valve is in the pressure lines to the modular valve. This modular valve performs the necessary functions of dividing the oil for slow speed travel with adjustable differential action to round corners, as well as diverting the oil flow for high speed travel. The counterbalance valve softens the brake re- lease and application efficiently without an accumulator. 11. The wheel drive has the following features: A. There is a HIGH/LOW speed selection (toggle switch) on the aerial control box. B. In HIGH speed mode, the boom in stowed position, the vehicle has a 0 - 2.5 mph speed capability (fully proportional). HIGH speed is available only when boom is in cradled position. C. In HIGH speed mode, no aerial functions can be operated (even if operator activates the controllers for aerial functions). When boom is elevated up out of cradle, HIGH speed is canceled and boom functions become available. D. In LOW speed mode, the vehicle has a 0 - 1.25 mph speed capability (fully proportional). In creep speed mode, the vehicle as .65 mph speed capability (FP). E. All aerial .functions can be operated only in LOW and creep speed modes. F. At no time can the operator shift from HIGH to LOW on-the-go. (i.e.: HIGH/LOW toggle switch can only be functional when controller for drive function is in the neutral position.) 12. Operate boom at HORIZONTAL position until you have familiarized yourself with the operation and how the controllers feel. The smoother you are with the controller, the smoother the unit will respond. 13. Gradually operate unit up to maximum elevation and extension. 14. The Self-Propelled Condor Model 86 is equipped with slope sensing device which has been incorporated into the system to sense a 5° out-of-level condition. This safety system is operational only when the boom is above horizontal or at minimum extension. This device will automatically cancel all boom functions at both control stations when unit subjected to an out-of-plumb condition of 5° or more. An indicator light located SP86/11-81 6

Calavar self-propelled condor models 86 Operation/maintenance and illustrated parts manual ! (Part No.92238)

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