V2648XL 92357

TIME CONDOR Corporation
SELF-PROPELLED
ELEVATING WORK PLATFORM
MODEL V2648XL, V2648

Serial Number X5159700 1

Serial Number X53597001
OPERATOR'S, MAINTENANCE.
ILLUSTRATED PARTS MANUAL
SHIPPING ADDRESS MAILING ADDRESS
CONDOR® CONDOR®
TIME CONDOR Corporation TIME CONDOR Corporation
8300 IMPERIAL DRIVE P.O. Box 21447
VVAco,TEXAS76712 VVACO, TEXAS 76702-1447
(254) 420-5200 (254) 420-5200
MANUAL 92357'()()3
JUNE 1997
SELF-PROPELLED


OPERATOR'S MANUAL
SIDPPING ADDRESS MAILING ADDRESS
CONDOR® CONDOR®
WACO, TEXAS 76712 WAco,TEXAS76702-1447
(254) 420-5200 (254) 420-5200
MANUAL 92357-003
JUNE 1997
i
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®.
THIS MANUAL MUST BE RETAINED ON THE CONDOR® AT ALL TIMES.
Do not attempt to operate this CONDOR® until you have read and under-
stood 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 capabili-
ties will maximize operating efficiency. The various decals attached to this
CONDOR® contain vital information. Read all decals before operating this
CONDOR®.
It is YOUR RESPONSIBILITY to follow procedures while operating this 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 of the personnel when
making decisions regarding the intended use of this CONDOR®.
It is also YOUR RESPONSIBILITY to understand and obey all federal, state, and local regulations
regarding the operation and use of aerial work platforms. A copy of the ANSIISIA A92.6-l990 Manual of
Responsibilities is attached for your use.
TIME CONDOR Corporation reserves the right to modify, improve, add, and/or delete certain design
features of its products without any obligation to incorporate new features into products previously sold.
Manuals are continually updated to reflect these changes.
DO NOT ALTER OR MODIFY THIS CONDOR® WITHOUT PRIOR WRITTEN

APPROVAL FROM THE MANAGEMENT OF TIME CONDOR CORPORATION.
SERVICE & MAINTENANCE
Many of the parts used in the manufacture of this CONDOR® have specific properties, and the manufac-
turer recommends that replacement parts be purchased through TIME CONDOR Corporation in order to
ensure the original integrity ofthe product. Repairs and adjustments should only be made by trained and
qualified personnel. Please refer to the maintenance and parts sections of the TIME CONDOR Corporation
Operation, Parts & Maintenance Manual for information on service and maintenance of this CONDOR®.
MANUAL 92357-001
JUNE 1997
ii

CONDOR® SERVICE INFORMATION
1. Ifyou need assistance or have any service or maintenance questions, TIME CONDOR
Corporation service and parts personnel are always available by phone or fax. The
telephone numbers are:
(254) 420-5200 Telephone

(254) 420-5298 Voice Mail
(800) 443-5803 FAX
2. There are numerous written Maintenance Procedures available for this CONDOR®.
These procedures are available through the TIME CONDOR Corporation Service
Departmentto anyone who requests them.
3. Service and maintenance are not a substitute fortrained, qualified service technicians.
TIME CONDOR Corporation conducts service schools onacontinuing basis. Call any
ofour service or sales persons for a schedule. Remember, training ofmechanics is the
responsibility oftheir employer, but TIME CONDOR Corporation Service Schools help
you provide this training.
4. TIME CONDOR Corporation Service School Training Manuals are available for
purchase through the parts department. The part numbers for these manuals are: #92333
for self-propelled models; and #92334 for truck-mounted models.
8300 OOERIALDIuVE,P.O. Box21447, WACO, TEXAS 76702-1447- 254-420-5200, 254-443-5803 FAX
MANUAL 92357-001
JUNE 1997
iii
TABLE OF CONTENTS
IN'TRODUCTION ••••••••••••••••••••••••••••••.•••••.••••••••••••••••••••••••••••••••••••.••••••.••••••••••.•••••••••••••••.•••••••••••.••••••.•••.•••• ,
SERVICE IN'FORMATION •••••••••••••••••••••••••••••••••••••••••••••••••.•..••••••••••••••••.••••••••••.••.•••.•••••••••••••.•••••••••..••••. ii
TABLE OF CONTENTS ._...................................................................................................................... iii
I. PREPARATION, INSPECTION, AND MAINTENANCE •••••••••••••••••••••••.••••••.••••••••••••••••••••••.••.••••• 1
A. Overall Machine Condition ....................................................................................................... 1

B. Lower Control Station ............................................................................................................... 1
C. Emergency Lowering ................................................................................................................ 1
D. Platform and Upper Control Station .......................................................................................... 2
E. Hydraulic System ...................................................................................................................... 2
F. Batteries ..................................................................................................................................... 2
II. MACmNE OPERATION •••••••••••••••••••••••••••••••••.•••••••••••••.•..••••••.•••••••••••••••••••••••••••••••••••••••••••..•••••••••••• 2
A. Rated Work Load ...................................................................................................................... 2

B. LowerControls .......................................................................................................................... 2
C. Upper Controls .......................................................................................................................... 3
D. Emergency Lowering ................................................................................................................ 3
E. Lift-up Entry Gate ..................................................................................................................... 3
F. Deck Extension ......................................................................................................................... 5
G. Removable Upper Control Box ................................................................................................. 5
ill. MOVING FR.OM JOB--SITE TO JOB-SITE •••••••••.••••••••••••••••••••••••••.•.••••••.••••••..•..••••.•••.••..•••••.•.••••••• 5
A. Loading and Unloading ............................................................................................................. 5

B. Ramp Method ............................................................................................................................ 5
C. Forklift Loading and Unloading Method .................................................................................. 5
D. Transporting ...................................•.......................................................................................... 6
E. Freewheel Operation ................................................................................................................. 6
IV. STORAGE •••••••••••••••••••.•••••••.•••••.••••.••••••••••••••••••••.•••••••••.•...•••_•••.•••••••••••••••••••••••••.••••••.••••••••••••.•••••.••.•• 6
APPENDIX: DECALS ILLUSTRATION ••••••••••••••••••••••••••••.•..••.••...•••.••••••••••••.•••••••..•••••.••••••••.•...••....••.•. 8
ANSI/SIA A92.6 -1990 MANUAL OF RESPONSmILITIES
MANUAL 92357-001
JUNE 1997
48
IMPORTANT: A COPY OF THE ANSIISIA A92.6 - 1990 MANUAL OF RESPONSmILITIES IS
ATTACHED TO THIS OPERATOR'S MANUAL. IT CONTAINS IMPORTANT OPERATING
INFORMATION FOR THIS CONDOR®. READ IT BEFORE OPERATING THIS CONDOR®.
I. PREPARATION. INSPECTION, AND

MAINTENANCE STEERING:
The condition of this CONDOR® is very

important, as it directly affects the operator as D Check steering link to knuckle
connections and steering cylinder for
well as others. The operator must perform a proper and secure mounting.
thorough walk-around inspection each day prior to
operating the CONDOR®. Any damage or faulty BRAKES:
operation should be reported immediately.
A DO NOT OPERATE tag outlining the
problem should be attached to the lower control D Check for abnormal wear between
deadbolts and hubs, and for loose or
station and any discrepancies should be corrected missing bolts, nuts, and pins.
before operating this CONDOR®.
DECALS:
KNOW THIS CONDOR® AND ITS
CAPABILITIES. REPORT ANY UNUSUAL
OPERATION,SUCHAS ERRATIC SWAY OR D Check that all decals and warning
signs are in place and are clearly
MOTION OF THE ARMS OR PLATFORM. legible.
Some major areas to check daily are:

CAUTION
A.OVERALLMAC~CONDITION Defective components, structural damage,
missing parts, and equipment malfunction
MISSING, BROKEN, OR DAMAGED jeopardize the operator and other
PARTS: personnel and may cause excessive
damage to the unit. A poorly maintained
D Check cylinder mounting pins, pivot pins,

pin retainers, bearing pads, bolts, and nuts.
CONDOR® could become the greatest
operational hazard you may encounter.
STRUCTURAL:
D Check for damaged or cracked welds

on structural components-arms, platform,
B. LOWER CONTROLS
chassis.
D Check that all functions operate
properly, that switches return freely
TIRES AND WHEELS: to neutral position. Do not operate
the CONDOR® with sticking controls
D Check for cracks, tears, cuts, or missing or

loose lug nuts (a rust line running down the
rim from the lug nut indicates a loose lug C. EMERGENCY LOWERING
nut).
D Check emergency lowering
function by pulling red T -handle.
MANUAL 92357-001
JUNE 1997
..
. D. PLATFORM AND UPPER
CONTROL STATION
D Keep battery tops clean and dry.
Check that lift-up entry gate is functional
D and that chain is secure. D Keep vent caps tightly in place.
D Re-check the structural condition of the D Check that battery cable connections are
tight and clean and free of corrosion.
platform-pins, railings, and floor.
D Check for missing bolts & nuts - Replace D Make sure the battery charger and the
before operating. indicator lights and meter are not dam-
aged.
D Check that extension deck is locked in

place.
D
----~~-.-.-.-. ---
Check function of red button. It disconnects , y
power to the controls and, when pushed, CAUTION
stops all powered functions. CONDOR® MUST BE OPERATED
ONFIRM, LEVEL GROUND ONLY.
D Check that drive control lever returns freely

to neutral. . A. RATED WORK LOAD
The platform will support a combined weight equal

E. HYDRAULIC SYSTEM to the unit's rated work load-including personnel,
tools, and equipment-throughoutthe working
D Check the hydraulic tank fluid level with envelope of the CONDOR®.
the platform all the way down. Fluid must
be visible in sight glass. Add Shell Tellus Rated work load, on extension deck only, is not to
T-32 Hydraulic Fluid if required. Ensure exceed 250 Ibs. (113 kg) including one occupant.
that the breather cap is clean and in place Total rated work load is not to exceed 1,000 Ibs.
on the tank. (454 kg) including two occupants.
D Check for hydraulic leaks at all fittings B. LOWER CONTROLS

and valves.
CAUTION
D Check all hydraulic hoses and tubes for
damage and kinks.
ARM STAND MUST BE USED WHE
MAINTENANCE PERFORMED ON
CONDOR® REQUIRES SCISSOR
F. BATTERIES ARM'S TO BE RAISED.
CAUTION 1. To engage arm stand, raise platform,

Keep flame, sparks and metal away then rotate stand until it hangs vertically.
from the batteries. Lower the platform until the arm stand rests
on the cross tube on the frame. Maintenance
D Check Electrolyte level daily in each cell.
If necessary, add clear, odorless, mineral
can now begin.
free water to bring the level to 1/2 " above

the top ofthe separators, or to the Level
Indicator (if equipped), in each cell. Only
add water after charging cycle is complete.
MANUAL 92357-001
JUNE 1997
2. To store ann stand, raise platform so that
ann stand can be rotated until it rests on the
Select desired drive speed with the "high/low!
creep" switch. (A limit switch automatically cuts
•
stop provided on the scissor anns. drive speed to "creep"as the platform is raised.)
Tum "controls" switch to "lower" position, to To drive forward or reverse, squeeze lever switch
operate from ground. on handle, and push or pull handle in the intended
direction of travel. Release lever switch to stop
In an emergency, push red button. To operate, movement. Letting go of handle also will stop
button must be pulled out. (Also, if applic- movement.
able, battery disconnect switch must be "on" to
operate.) Brakes are automatically released whenever the
drive handle is moved. Let go of the handle to
Push "raise" or "lower" switches to move automatically set the brakes.
platform.
To improve drive traction, depress and hold
Tum switch to "upper" position, to operate "positraction" switch. (This will automatically
from platform. cut-out high drive speed.)
To steer left or right, squeeze lever switch on

C. UPPER CONTROLS handle, and depress rocker switches on top of
handle in the intended direction of travel. Steering
Tum "controls" switch, on lower control panel, to is not automatically self-centering. Be sure the
"upper" position to operate from platform. steering wheels point in the direction you want
before letting go of the steer switch.
NOTE:
Chain should be snapped in place across entry. D. EMERGENCY LOWERiNG
Gate should be lowered and closed when operating
CONDOR® from upper controls. For emergency lowering, grasp the
Tee-handle located below the rear bumper.
In an emergency, push red button. To operate from Gently pull to lower the platform. Release
platform, both red buttons, on lower and upper handle to stop lowering.
controls, must be pulled out.
To raise and lower platform, push and hold the E. LIFT-UP ENTRY GATE
green "power" button, and push the "raise" or
"lower" button. Release buttons to stop movement. To load 4' wide sheets, lift entry gate up until
lockpins snap in place. After loading, pull at
both lockpins, to let gate fall into place. Keep
gate down, except for loading and unloading.
MANUAL 92357-001
JUNE 1997
.. LOWER CONTROLS
REDEMERGENCY_____
STOP BUTTON
t-____________~~~~
RAISEILOWER
BUTTONS
OPERATING -------4_--+
INSTRUCTIONS
CONTROL STATION
SELECTOR SWITCH
~~~~---CONTROL
CIRCUIT
BREAKER
UPPER CONTROLS
RIGHTILEFT
LEVER STEER
SWITCH ROCKER
SWITCH
r-------------_ DRIVE
CONTROL
HANDLE
REDEMERGENCY ------r
STOP BUTTON
RAISEILOWER
BUTTONS
HIGHILOW/CREEP
DRIVE SPEED
SELECTOR POWER
SWITCH BUTTON
MANUAL 92357-001
JUNE 1997
F. DECK EXTENSION B. RAMP METHOD
.,
Lift lockpin, at right side of deck, and push exten- Ensure that the ramp is sufficiently strong to
sion deck forward (or out). When fully extended, support the weight of the CONDOR®.
lockpin will automatically lock. To retract, lift
lockpin and pull extension deck all the way back The ramp should be set, not steeper than this
untillockpinautomatically locks CONDOR®'s rated gradeability, which for Model
extension deck in place. V2648/531XL is 140 or 25%, or a rise ono inches
in a run of 10 feet.
CAUTION
Do not lower extension deck on Before driving the CONDOR® on a ramp, lower
people or any objects! the platform completely, test the drive/steer
controls and the brake system.
G. 'REMOVABLE' UPPER CONTROL CAUTION

BOX Select "low" drive speed,
not "high" and not "creep".
Unsnap overcenter latch at bottom of upper control
box and pull plug out of receptacle. Bend cable so The front of the CONDOR® should be uphill,
that plug faces down. Snap cover onto receptacle meaning: Drive forward uphill and reverse
at bottom of box. Lift box and store it in a secure down.
place to prevent unauthorized use of the
CONDOR®. Keep CONDOR® in alignment with the ramp
during loading and unloading procedures.
III.MOVING FROM JOB-SITE TO

JOB-SITE C. FORKLIFT LOADING AND
UNLOADING METHOD
A. LOADING AND UNLOADING
Ensure that the forklift has sufficient capacity to
Although this CONDOR® is somewhat small handle the weight of this CONDOR®.
compared with larger construction equipment, it (SEE III. A. )
requires the same care and attention in loading,
transporting, and unloading. At no time should its This CONDOR® can be lifted from the rear,
size,or weight be under estimated. Before using the forklift pockets provided.
loading or unloading, inspect the CONDOR® for
any physical damage or defects. NOTE THAT THE CENTER OF GRAVITY
IS 50 INCHES FROM THE END OF THE
The means by which you load or unload the CONDOR®.
CONDOR® should be of sufficient strength to
withstand its weight. The CONDOR® should only be raised to a height
sufficient to clear any obstructions.
MODEL WEIGHT(#) WEIGHT(KG)
V2648 44001bs. 1860kg Keep forklift travel to a minimum, carry
V2648XL 45001bs. 1905 kg CONDOR® as close as possible to the ground,
V2653 46001bs. 1950 kg and set it down gently.
V2653XL 47001bs. 1996 kg
MANUtu. 92357-001
JUNE 1997
• D. TRANSPORTING
This CONDOR® can be easily transported

between job-sites if the following rules and
procedures are followed:
Block all wheels to prevent forward and reverse

motion.
Tie down the CONDOR® with chains or cables,

running them through the tie-down holes only. Do
not tie down over the guardrails or entry steps.
Always tum the power off at the lower control

station.
E. FREEWHEEL OPERATION
CAUTION
This CONDOR® must be on firm, level
ground when releasing the parking brakes.
To put the CONDOR® into freewheel mode,
use the brake release handles on the rear axle.
One handle is on the front side of the axle and
the other is on the rear side of the axle. Tum
each release handle 90° and at the same time,
slightly rotate it. The brakes are now released.
(Released brakes will automatically reset the
next time forward or reverse drive is used,
then will engage when drive is stopped.)
Never exceed 5 mph when moving the

CONDOR® in the freewheel mode.
IV. STORAGE
When you get out ofthe platform, leave it all the

way down.
CAUTION
Never park the CONDOR®
with platform raised.
MANUAL 92357..001
JUNE 1997
NOTES •
MANUAL 92357-001
JUNE 1997
APPENDIX: DECALS ILLUSTRATION
,.
.
0
r">
l:
8
~ ~
~ l
'----- '--
PARTIAL SECTION A
APPLIES TO ALL MODELS
MANUAL 92357-001
JUNE 1997
ITEM PARTNUMBER
APPENDIX: DECALS ILLUSTRAnON
DESCRIPTION QTY
•
Ref 55999-005 ..................... Decal Installation V2648 ................................................................. Ref.
55999-006 ..................... Decal Installation V2648XL ............................................................ Ref.
55999-007 ..................... Decal Installation V2653 ................................................................. Ref.
55999-008 ..................... Decal Installation V2653 XL ............................................................ Ref.
*1 55890 ............................ Decal, V Upper Operator's Instructions (V2648/53) ............................ 1
55889 ............................ Decal, V XL Upper Operator's Instructions (V2648/53XL) ................ 1
*2 55894 ............................ Decal, V General Caution ..................................................................... 1
*3 54652-003 ..................... Decal, GuardraiVChain Caution ............................................................ 1
*4 55963-1200 ................... Decal, 1200 Rated WorkLoad (V2648/53XL) .................................... 2
*5 55944 ............................ Decal, 250 RWL On Ext. (V2648/53XL) ............................................. 1
*6 55480-001 ..................... Decal, Lower Controls .......................................................................... 1
*7 55480-002 ..................... Decal, Lower Operator Instructions ...................................................... 1
*8 54652-002 ..................... Decal, Arm Stand Caution ..................................................................... 1
*9 54984-005 ..................... Decal, Rear Bumper .............................................................................. 1
*10 66973 ............................ Decal, Electrocution Hazard .................................................................. 2
*11 55871-001 ..................... Decal, V XL Upper Electrical Box Top ................................................ 1
55856-001 ..................... Decal, V Upper Electrical Box Top ...................................................... 1
*12 55871-002 ..................... Decal, V Upper Electrical Box Front .................................................... 1
55856-002 ..................... Decal, V XL Upper Electrical Box Front .............................................. 1
13 54984-007 ..................... Decal, Hydraulic Fluid .......................................................................... 1
14 55940-023 ..................... Decal, CONDOR 3.45 X 23 .................................................................. 2
15 56004-006 ..................... Decal, V20481XL .................................................................................. 2
56004-008 ..................... Decal, V26531XL .................................................................................. 2
16 55941-017 ..................... Decal, Condor "Bird" ............................................................................ 2
17 53259 ............................ Tape, Non-Skid Jet Black ............................................................ 1.50LF
18 66921 ............................ Coating, Non-Skid Jet Black .........................................................25GL
19 55999 ............................ Dwg., Decal Installation ........................................................................ 1
20 54984-006 ..................... Decal, 110 Volt Ext. To Platform (V2648/53XL) ................................ 1
31 ...................................... Nameplate Scissors Indentification .................................................. Ref.
* 55999-101 ..................... Decal Kit, V2648 Essential .............................................................. Ref.

* 55999-102 ..................... Decal Kit, V2648XL Essential ......................................................... Ref.
- Indicates Items Not Shown

*Indicates Included Iu Essential Decals
,.
..... ..
·......
····.......
OJ • " ••••••
"
•
.......
...... ....
" •••••• 0
·· ......
......
· ..........
'II
•
o ••••••••
• 0 ••••••
••••• CI 0_
2 1/4 MARGIN
NO NON-SUP
COATING
I
PLANVI(W OF
MODELS V20/2648/5J PARTIAL REAR VIEW OF
MANUAL 92351-001 MODELS 1/20/2648/53
JUNE 1997
1
OPERA TING INSTRUCTIONS
o TURN SWITCH, ON LOWER CONTROL BOX, TO "UPPER" POSITION, TO OPERATE FROM PLATFORM.
o IN AN EMERGENCY, PUSH RED BUTTON. TO OPERATE FROM PLATFORM, BOTH RED BUTTONS,
ON LOWER AND ON UPPER CONTROLS, MUST BE PULLED OUT.
o TO RAISE AND LOWER PLATFORM, PUT AND KEEP FOOT ON SWITCH, AND
PUSH TOGGLE SWITCH IN "UP" OR "DOWN" DIRECTION.
RELEASE SWITCH OR TAKE FOOT OFF SWITCH TO STOP MOVEMENT.
o SELECT DRIVE SPEED WITH "FAST/SLOW/CREEP" SWITCH.
A LIMIT SWITCH AUTOMA TICALL Y REDUCES DRIVE SPEED AS THE PLATFORM IS RAISED.
o TO DRIVE FORWARD OR REVERSE, PUT AND KEEP FOOT ON SWITCH, AND
PUSH OR PULL TOGGLE SWITCH IN INTENDED DIRECTION OF TRAVEL.
RELEASE SWITCH, OR TAKE FOOT OFF SWITCH TO STOP MOVEMENT.
o BRAKES ARE AUTOMA TICALL Y RELEASED WHENEVER DRIVE MOVES.
RELEASE SWITCH OR TAKE FOOT OFF SWITCH TO AUTOMATICALLY SET BRAKES.
o TO STEER LEFT OR RIGHT, PUT AND KEEP FOOT ON SWITCH, AND
MOVE "STEERING" SWITCH IN INTENDED DIRECTION OF TRAVEL.
STEERING IS NOT AUTOMA TICALL Y SELF-CENTERING. BE SURE STEERING WHEELS POINT
IN DIRECTION YOU WANT BEFORE LETTING GO OF SWITCH.
OPERA TING INSTRUCTIONS

o TURN SWITCH, ON LOWER CONTROL BOX, TO "UPPER" POSITION, TO OPERATE FROM PLATFORM.
o IN AN EMERGENCY, PUSH RED BUTTON. TO OPERATE FROM PLATFORM,
BOTH RED BUTTONS, ON LOWER AND ON UPPER CONTROLS, MUST BE PULLED OUT.
o TO RAISE AND LOWER PLATFORM. PUSH AND HOLD THE GREEN "ENABLE" BUTTON. AND
PUSH THE "UP" OR "DOWN" BUTTON.
RELEASE BUTTONS TO STOP MOVEMENT.
• SELECT DRIVE SPEED WITH "FAST/SLOW/CREEP" SWITCH.
A LIMIT SWITCH AUTOMATICALLY REDUCES DRIVE SPEED AS THE PLATFORM IS RAISED.
o TO DRIVE FORWARD OR REVERSE, SQUEEZE GRIP SWITCH ON HANDLE, AND
PUSH OR PULL HANDLE IN INTENDED DIRECTION OF TRAVEL.
RELEASE GRIP SWITCH OR LET GO OF HANDLE TO STOP MOVEMENT.
o BRAKES ARE AUTOMA TICALL Y RELEASED WHENEVER DRIVE MOVES.
RELEASE GRIP SWITCH OR LET GO OF HANDLE TO AUTOMA TICALL Y SET BRAKES .
• TO STEER LEFT OR RIGHT, SQUEEZE GRIP SWITCH ON HANDLE, AND
DEPRESS ROCKER SWITCHES ON TOP OF HANDLE IN INTENDED DIRECTION OF TRAVEL.
STEERING IS NOT AUTOMA TICALL Y SELF -CENTERING. BE SURE STEERING WHEELS POINT
IN DIRECTION YOU WANT BEFORE LETTING GO OF SWITCHES.
55889
MANUAL 923S7-OO1
JUNE 1997
2
ILh CAUT~O~ I
• DO NOT OPERATE THIS CONDOR'" UNTIL YOU HAVE BEEN PROPERLY TRAINED AND HAVE
COMPLETEL Y READ AND UNDERSTOOD THE OPERA TOR'S MANUAL LOCATED ON THIS CONDOR~
• THIS CONDOR'" IS NOT ELECTRICALLY INSULATED.
SEE OPERATOR'S MANUAL FOR SAFE APPROACH DISTANCES TO ENERGIZED POWER LINES.
• PRIOR TO EACH DAY'S USE, CHECK TO MAKE SURE ALL FUNCTIONS ARE OPERA TING PROPERLY.
PERFORM ALL INSPECTIONS REQUIRED BY SECTION 6 OF THE ANSI 92.6 STANDARD.
• DO NOT USE THE CONDOR'", IF IT IS MALFUNCTIONING OR DAMAGED IN ANY WAY,
OR IF THE WIND BLOWS OVER 15 MPH.
• RAISE PLATFORM ONLY WHEN CONDOR'"IS ON FIRM, LEVEL GROUND.
• DO NOT DRIVE ON A SLOPE UNLESS THE PLATFORM IS FULLY LOWERED.
• ALWAYS LOOK IN THE DIRECTION IN WHICH THE PLATFORM IS MOVING.
WATCH FOR, AND AVOID, OVERHEAD OBSTRUCTIONS AND ANYTHING ELSE THAT MAY STRIKE
PLA TFORM, PERSONNEL, CONTROLS, OR CONDOR'".
• FOLLOW INSTRUCTIONS IN OPERA TOR'S MANUAL WHEN SERVICING BATTERIES.
EACH REPLACEMENT BATTERY MUST WEIGH AT LEAST AS MUCH AS ORIGINAL EQUIPMENT.
• REPLACEMENT TIRES MUS, BE SAME AS ORIGINAL EQUIPMENT.
• IN CASE OF EMERGENCY, PUSH RED "EMERGENCY STOP" BUTTON.
55894
ILh Cfo\Ur~O[N I
GUARDRAILS AND SAFETY
CHAINS MUST BE SECURED
AND USED AT ALL TIMES
54652-003
RA TED WORK LOAD

1000 LBS INCLUDING
TWO OCCUPANTS 55963-1000
RA TED WORK LOAD

ON DECK EXTENSION
250 LBS 55944
MANUAL 92357-001
JUNE 1997
6 7
OPERATING
INSTRUCTIONS
• TO OPERATE FROM GROUND,
UP TURN SWITCH TO "LOWER" POSITION.
• IN AN EMERGENCY, PUSH RED BUTTON.
$ TO OPERATE, BUTTON MUST BE PULLED OUT.

• PUSH TOGGLE SWITCH TO MOVE PLATFORM.
• TURN SWITCH TO "UPPER" POSITION,
$
DOWN
TO OPERATE FROM PLATFORM.
55480-002
PPER
+ OFF
LOWER
8
l~cAul~oNl
STAND CLEAR
UNLESS ARM STAND
IS IN PLACE
54652-002
[ FORKLIFT
POCKET
J EMERGENCY LOWERING
PULL T-HANDLE. TO LOWER PLATFORM.
BRAKE RELEASE
ONLY ON FIRM, LEVEL GROUND.
I[ FORKLIFT
POCKET
1
RELEASE HANDLE TO STOP MOVEMENT. ROTATE BOTH LEVERS TO RELEASE BRAKES.
10
ELECTROCUTION HAZAR
DEATH OR SERIOUS INJURY WILL RESULT
FROM CONTACT WITH THIS MACHINE IF IT
SHOULD BECOME ELECTRICALLY CHARGED.
KEEP C EAR
MANUAL 92357-OO(
JUNE 1997
APPENDIX: DECALS ILLUSTRAnON
11-"V"
FORWARD
~ 11-"XL"
O
EMERGENCY
STOP FAST REVERSE
SLOW
EMERGENCY
STOP
G L@R
FORWARD
CREEP
SSI!71-CCt
AST
SLOW
CREEP REVERSE
DRIVE SPEED 55856-001
12-"V"
12-"XL"
ENABLE UP
o
UP
DOWN
PLATFORM
55871-002
o
55856-002
DOWN
13 HYDRAULIC
FLUID 54984-00
MANUAL 92357-001
JUNE 1997
20 110 VOLT
EXTENSION TO
PLATFORM
'4QR4-006
31
8300 IMPERIAL DRIVE 0

WACO, TEXAS 76712
~IM=A=N=U=F=A=C=TU=R=E=D==IN==U=.S=.A=.==~I ~IS=E=R=IA=L=N=O=.============~
I CONDOR MODEL V2648 II RATED WORK LOAD 1000 LBS
~==============~
I PLATFORM HEIGHT 26' .0· II HYD. PRESSURE 2700 PSI
~IS=YS=T=EM==V=OL=T=AG=E=2=4=V==D=.C=.==~1 ~I__________________~
THIS UNIT IS NOT ELECTRICALLY INSULATED.
THIS SELF-PROPELLED ELEVATING WORK PLATFORM CONFORMS
o TO ALL APPLICABLE REQUIREMENTS OF ANSI A92.6-1990 0
51340
31

WACO, TEXAS 76712
~IM=A=N=U=F=AC=T=U=R=E=D=I=N=U=.=S.=A=.===;I ~IS=E=R=IA=L=N=O=.============~
I CONDOR MODEL V2648XL I I RATED WORK LOAD 1000 LBS
I~P::=:LA=T=F::::OR:::M=HE:=:::IG:=:::H=T===2:::6='.:,::0="==~II HYD. PRESSURE 2700 PSI
~IS_Y_ST_E_M_V_0_L_TA_G_E~2~4_V~D~.C=.__~1 I~__________________~
THIS UNIT IS NOT ELECTRICALLY INSULATED.
THIS SELF -PROPELLED ELEVATING WORK PLATFORM CONFORMS
51340
MANUAL 92357-001
JUNE 1997
--.
31

WACO, TEXAS 76712
IMANUFACTURED IN U.S.A. II SERIAL NO.

~==============~
ICONDOR MODEL V2653 II RATED WORK LOAD 1000 lBS
~==============~
IPLATFORM HEIGHT 26'.0· II HYD. PRESSURE 2700 PSI
~IS=Y=ST=E=M=V=O=LT=A=GE=2=4==V=D=.=c=.==~1 ~I__________________~
THIS UNIT IS NOT ELECTRICALLY INSULA TED.
51.340
31

WACO, TEXAS 76712
~IM=A=N=U=FA=C=T=U=RE=D~IN~U~.S~.A~·~~I~ls=E=R=IA=L=N=O=.============~
I CONDOR MODEL V2653Xl II RATED WORK LOAD 1000 lBS
I PLATFORM HEIGHT 26'.0· II HYD. PRESSURE 2700 PSI
~IS=Y=ST=E=M=V=0=LT=A=GE=2=4==V=D=.=c=.==~1 I~________________~
THIS UNIT IS NOT ELECTRICALLY INSULA TED.
51340
MANUAL 92357-001
IDNE 1997
SELF-PROPELLED


MAINTENANCE MANUAL
CONDOR® CONDOR®
(254) 420-5200 (254) 420-5200
MANUAL 92357'()(}2
JUNE 1997
i
INTRODUCTION
The primary purpose ofthis manual is to provide the user with a thorough understanding ofthe 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 under-
standing 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 manufac-
turer of this CONDOR® cannot control the wide range of applications that may be used in carrying out
a variety of jobs. Therefore, it is THE USER'S RESPONSIBILITY to consider all personnel when
making decisions regarding the CONDOR®'s intended use.
regarding the operation and use of aerial work platforms. A copy of the ANSIISIA Manual of
Responsibilities is attached for your use: ANSIISIA A92.5-1992 is provided for Boom-Supported
Elevating Work Platforms, and ANSIISIA A92.6-1990 is provided for Self-Propelled Elevating Work
Platforms.
TIME CONDOR Corporation reserves the right to modify, improve, add, and/or delete certain design
features of its products without any obligation to incorporate new features into products previously sold.
Our manuals are continually updated to reflect these changes.
DO NOT ALTER OR MODIFY THIS CONDOR® WITHOUT PRIOR WRITTEN APPROVAL

FROM THE MANAGEMENT OF TIME CONDOR CORPORATION
Many of the parts used in the manufacture of the CONDOR® have specific properties, and the
manufacturer recommends that replacement parts be purchased through TIME CONDOR Corporation
in order to ensure the original integrity of the product. Repairs and adjustments should only be made by
trained and qualified personnel. Please refer to the maintenance and parts sections of the TIME
CONDOR Corporation Operation, Maintenance, & Parts Manual for information on service and
maintenance of the CONDOR®.
NOTE: Please refer to the TIME CONDOR Corporation section of the Operation, Maintenance, &
Parts Manual for information pertaining to your CONDOR®.
ii
1. If you need assistance or have any service or maintenance questions, TIME CONDOR
Corporation service and parts personnel are always available by phone or fax. The telephone
numbers are:
(254) 420-5200 Telephone

(254) 420-5299 Voice Mail
(800) 443-5803 FAX
These procedures are available through the TIME CONDOR Corporation Service Depart
ment to anyone who requests them.
3. Service and maintenance are not a substitute for trained, qualified service technicians.
TIME CONDOR Corporation conducts service schools on a continuing basis. Call any of
our service or sales persons for a schedule. Remember, training of mechanics is the responsi
bility of their employer, but TIME CONDOR Corporation Service Schools help you provide
this training.
4. TIME CONDOR Corporation Service School Training Manuals are available for purchase
through the parts department. The part numbers for these manuals are: #92333 for self-
propelled models; and #92334 for truck-mounted models.
8300 IMPERIAL DRIVE, P.O. Box21447, WAco,TEXAS 76702-1447-254-420-5200,254-666-4544 FAX

iii
Condor® Self-Propelled Booms and Scissors

WARRANTY
TIME CONDOR Corporation warrants to the purchaser that each new aerial work platform made by TIME
CONDOR Corporation is free from defects in material and workmanship arising under normal use and
service-in the case of major weldments, (chassis, turret, and booms), for a period of five (5) years after the
original shipment of the aerial work platform fromTiME CONDOR Corporation's plant; and in the case of
all other parts. for a period of one (1) year after the aerial work platform is placed in service or two (2) years
after the original shipment ofthe aerial work platform from TIME CONDOR Corporation's plant, whichever
comes first.
The obligation and liability under this Warranty is expressly limited to repairing or, at TIME CONDOR
Corporation's option. replacing free of charge at its facto!)' in Waco, Texas or at an authorized repair facility
designated by TIME CONDOR Corporation, the defective part. In no event shall TIME CONDOR
Corporation or its suppliers be liable to the purchaser or any other person for transportation charges or for
any incidental, collateral, special, or consequential damages, including without limitation damages for loss
ofprofits, loss ofcustomers, loss ofgoodwill or work stoppage, claims by any party other than the purchaser,
or any other similar damage or loss even ifTIME CONDOR Corporation, its suppliers, or its representatives
have been advised of the possibility of such damages.
Parts claimed to be defective and for which repair or replacement is desired shall be returned transportation
prepaid to TIME CONDOR Corporation's facto!), for inspection. This Warranty applies to replacement
partS provided under the terms of this Warranty only for the remainder of the Warranty period applicable to
the original purchase.
Any operation of the equipment beyond rated capacity, improper use or application of the equipment,
substitution upon it of parts not approved by TIME CONDOR Corporation or alteration or repair of the
equipment by any person not authorized by TIME CONDOR Corporation shall, at TIME CONDOR
Corporation's option. void this Warranty. TIME CONDOR Corporation n shall have no liability or
responsibility for damages resulting from accident or the malfunction of equipment and components not
supplied byTIME CONDOR Corporation.
No agent, employee, distributor, dealer, or other representative of TIME CONDOR Corporation is

authorized to modify this Warranty in any way. Accordingly, additional statements or presentations by any
such representative, whether oral or written, do not constitute warranties by TIME CONDOR Corporation
and should not be relied upon as limited warranties of TIME CONDOR Corporation, and no attempt, effort,
or promise to repair equipment by TIME CONDOR Corporation or any such representative at any time shall
modify or extend this Warranty in any way. If the purchaser has used its own order form. no additional or
different warranty terms contained in the purchaser's form will be honored by TIME CONDOR Corporation.
This Warranty covers only new and unused aerial work platforms manufactured by TIME CONDOR
Corporation. Products or parts manufactured by others are covered only by such warranties as are extended
to the purchaser by TIME CONDOR Corporation's suppliers.
This Warranty is in lieu of all other warranties, expressed or implied, including but not limited to warranties
of merchantibility and fitness for a particular purpose. Any applicable implied warranty shall be limited in
duration to the warranty period.
&300 imperial Drive, P.O. Box 21447, Waco, Texas 76702-1447-254-420-5200,254-666-4544 FAX
Fonn No.513-3M-392 Effective Date 9/1190

Printed in U.S.A.
Effectiye January 1, 1993
WARRANTy PROGRAM
Warranty is a function of a manufacturing company to back up the product it manufactures. It is a
guarantee against defects in design and workmanship ofcomponents utilized in the product, and is offered
for a fixed period oftime following the purchase of the product by a customer.
TIME CONDOR Corporation Warranty states, in general, that TIME CONDOR Corporation will replace
free ofcharge any components found to be defective within the time frame ofthe warranty period. There
are exceptions to some components which are not the responsibility of TIME CONDOR Corporation.
These will be outlined in subsequent paragraphs.
A. ~PERIOD
1. The Self-Propelled Boom and Scissor Warranty is one (1) year from placing the
CONDOR® in service or two (2) years following shipment from TIME CONDOR
Corporation, whichever comes first. In the case ofmajorweldments (chassis, turret, and
booms), the Warranty Period is five (5) years following shipment from TIME CONDOR
Corporation.
2. The Truck-Mounted CONDOR® Warranty Period is one (1) year from shipment ofthe
CONDOR® from TIME CONDOR Corporation's plant.
3. For parts sold through the Parts Department, the Warranty Period is six (6) months from
utilizing the component or placing it in service, or twelve (12) months following
shipment from TIME CONDOR Corporation, whichever comes first, unless the part is
furnished to correct a defective part on the original shipment still under Warranty.
4. Replacement parts provided under the terms ofthe Warranty are for the Warranty Period
applicable to the unit in which they were installed as if such parts were original
components ofthe aerial work platform.
5. During the Warranty Perio9, in addition to covering the parts replaced under Warranty,
TIME CONDOR Corporation will pay a Dealer Warranty Labor Rate which is based on
a percentage of your standard shop labor rate.
NOTE:
The term "IN SERVICE" means that the Warranty starts at the time the CONDOR® is
first used for any purpose. An example: The dealer may have purchased a CONDOR®
to have in stock, but may not use it. After three months, the CONDOR® is sold or the
dealer decides to put the CONDOR® into its rental fleet. In this situation, the Warranty
Period begins the day the dealer puts the CONDOR® into the fleet or when the
CONDOR® is delivered to the end user.
The submittal of a warranty claim against a stock machine constitutes it as being "in
service," initiating the warranty period.
B. PRE-DELIVERY INSPECTION SHEET (p.D.I.)
1. Each Self-Propelled Boom or Scissor CONDOR® shipped from TIME CONDOR

Corporation facility will have a Pre-Delivery Inspection (P.D.I.) sheet enclosed in the
Safety Manual holder tube.
2. It will be the responsibility of the original recipient ofthe CONDOR® from whether it
will be the dealer or the end user, to complete this form and return it to TIME CONDOR
Corporation's facility within 45 days from the date of receipt to set up the Warranty
Account.
3. Failure to complete the P .0.1. sheet and return it to TIME CONDOR Corporation within
the time frame given will result in voiding the Warranty on the CONDOR® .
NOTE:
The form must be filled out completely, giving the name of the dealer, address, model
number, serial number, person inspecting the CONDOR® IS, signature, and date of
inspection. (The date of inspection does not constitute the "In Service" date.)
C. ITEMS NOT COVERED UNDER WARRANTY
Some components are used on the CONDOR® which are not warranted by TIME CONDOR
Corporatioin. However, these are warranted by the component manufacturer. Some ofthese are:
1. Tires and Batteries: These are normal wear items and are considered normal
maintenance items. However, ifthey are found to be defective, contact can be made with
the manufacturer's local dealer.
2. Hydraulic Filters and Fluid: These are considered general maintenance and service
items, and are not covered by warranty.
3. Other components: Products or parts manufactured by others are covered only by such
warranties as are extended to TIME CONDOR Corporation by its suppliers.
4. Freight and Charges: The warranty does not include any transportation, other charges,
or the cost of installation or any liability for direct, indirect, or consequential damages or
delay resulting from the defect.
5. Travel Time/Mileage: Travel time and the mileage to and from dealer facilities to
CONDOR® location are not covered or reimbursable.
6. Troubleshooting: Troubleshooting is not covered or reimbursable. However, TIME

CONDOR Corporation Warranty will cover reasonable labor charges for the removal and
replacement of defective components.
D. PROCESSING OF WARRANTY CLAIM
During the Warranty Period, should a component failure be encountered within the guidelines of
the TIME CONDOR Corporation Warranty Policy, the following procedure is to be followed:
1. Upon identifying the defective component, the replacement can be obtained by:
a. Issuing an order to our Parts Department through normal channels, which

entails your being invoiced.
b. You may have previously purchased the part from TIME CONDOR Corporation
for your stock and will utilize it for this replacement.
The above two methods will enable you to indicate on the claim the TIME CONDOR
Corporation invoice number to substantiate the parts purchase and the amount to be
credited.
c. Although not recommended, you may purchase the part locally. When this is
done, a copy ofthe purchase order or receipt MUST accompany the claim. TIME
CONDOR Corporation has the option to ship a replacement part at no charge if
the local cost would be greater, in lieu ofissuing credit for locally purchased parts.
d. When parts arepuchased from TIME CONDOR Corporation, part numbers with
invoice numbers MUST be referenced in the appropriate section ofthe claim
form.
2. Complete the Warranty Claim as noted in the "Warranty Claim Procedure" section.
Provide as much information as possible to enable TIME CONDOR Corporation to
thoroughly evaluate the claim and process it in the shortest amount of time possible.
NOTE:
WARRANTY CLAIMS WILL NOT BE ACCEPTED BY TIME CONDOR COR-
PORATION AFTER 45 DAYS AFTER FAILURE
3. Provided no return parts are required and all the information has been verified, the claim
will be processed and credit will be issued against your account.
E. RETURNAUTHORIZATIQN
1. If a component is found to be defective within the normal guidelines of the Warranty, a

Warranty Claim Form must be completed.
2. It will be necessary for you to call the TIME CONDOR Corporation Service Department
and ask to be issued a Return Authorization (R/A) number. You will be asked for a Dealer
Claim Number. As noted in Section 2, Item A, ofthe Warranty Claim Procedure, this is
a number assigned by the dealer for the purpose of tracking the claim, as there may be
more than one claim for the same CONDOR®. The R/A number issued must be logged
in the appropriate section ofthe claim form, and the gold copy (RIA) ofthe form must
be returned with the parts being returned.
NOTE:
DO NOT SHIP ANY RETURN PARTS WITHOUT
A RETURN AUTHORIZATION (RIA) NUMBER
Doing so may result in parts getting lost in the system and may delay processing the claim,
or may cause denial due to the time element of the claim.
3. All RIA parts must be received at TIME CONDOR Corporation within 45 days from the
date the RIA number was issued. Failure to do so will cause the claim to be denied.
4. All parts claimed under Warranty will be required to be shipped back to TIME CONDOR
Corporation FREIGHT PREPAID. No freight collect shipments will be accepted.
CONDOR® Model V2648/53XL. V2648/53
MAINTENANCE MANUAL
•
TABLE OF CONTENTS
INTRODUCTION ..................................................................................................................... i
CONDOR® SERVICE INFORMATION .............................................................................. ii
SELF-PROPELLED WARRANTY ........................................................................................ iii
Table of Contents ...................................................................................................................... 1
Specifications ............................................................................................................................ 3
Recommended Tool List ........................................................................................................... 4
Serial Nwnber Location ............................................................................................................ 5
Serial Nwnber To Model Designation ...................................................................................... 6
Hydraulic System Description .................................................................................................. 7
Pressure Adjustment Procedures ............................................................................................ 11
Electrical System Description ................................................................................................. 15
Machine Options Description .............. ............................. ..................... ... ........ ...................... 19
Assembly Diagrams Section ................................................................................................... 23
Battery Service ........................................................................................................................ 45
Preventive Maintenance .......................................................................................................... 53
Hydraulic Fluid Specifications ............................................................................................... 63
Battery Charger Troubleshooting Guide ................................................................................ 65
Bolt Torque Chart ................................................................................................................... 75
MANUAL 92357-002
lUNEl997
• NOTES
MANUAL 923S7-OO2
JUNE 1997
SPECIFICATIONS
.,
SPECIFICATIONS V26481XL V26531XL
Maximum Working Height 32ft. 32ft.

PlatfonnHeight 26ft. 26ft.
StowedPlatfonnHeight 44.5" 46.5"
Overall Length 93" 93"
Overall Width 48" 53"
Overall Height 79" 81"
Overall Height With Rails Removed 44 1/2" 46 1/t
Platfonn Size 92.5"x44" 92.5"x44"
Platfonn Capacity (Rated WorkLoad) 10OOlbs. IOOOlbs.
Gross Weight 4500lbs 47001bs.
4400 lbs. (XL) 400 Ibs.(XL)
Power System 24 volt DC 24 volt DC
Battery Capacity 235 amp hour 235 amp hour
Number ofBatteries 4 4
Battery Voltage 6 volt 6 volt
Battery Charger 25 amp 25 amp
WheelBase 75" 75"
Tires (non marking) solid rib 16x5 18x9.58
Inside Turning Radius 38" 40"
Drive Speed 611.212.4 mph .7511.5/2.4 mph
Gradeability 250/0114° 250/0114°
LiftlLowerTime 48/40 sec 48/40 sec
OPTIONS
* Battery Condition Indicator * MotionIMovementAlarm

* Strobe Light * DescendAlann
* 250 Amp Hour Deep Cycle Batteries * 5° SlopeAlann
* Hour Meter * Low Volt Warning/InterruptBattery
* TravelAlarm Protection System
* KeySwitch
TheCONDOR® Model V2648/531XL is designed and built to confonnto TIME CONDOR Corporation
understanding and interpretation ofall applicable OSHA rules and regulations as well as ANSI standards:
ANSI Standard A92.6 - 1990 ................... SelfPropelled Elevating Work Platfonn
CAUTION
It is imperative that all owners and operators ofthe CONDOR® read, understand and confonn to these
regulations. Ultimate compliance to prevailing OSHA regulations is the RESPONSIBILITY of the
employer utilizing the equipment
MANUAL 92357-002
JUNE 1997
• RECOMMENDED TOOL LIST
The following is a list of tools that you will fmd helpful when performing service, maintenance
or troubleshooting the CONDOR® equipment.
leach Volt/Ohm Test Meter

leach Hydraulic Flow Meter, 0-10 GPM
1 each Hydraulic Flow Meter, 0-50 GPM
1 each Hydraulic Quad Meter Pressure Gauge
1 each Battery Hydrometer
1 each Battery Load Tester
1 each 112" Drive Torque Wrench, 0-250 ftIlbs
1 each Pry Bar
1 each Strap Type Filter Wrench
1 each Grease Gun
1 each Hammer, 24 oz.
1 each Vice Grip Pliers
1 each Combination Wrench Set, 1// to 1- 1/2"
1 each 3/s" Drive Socket Set, 1// to 31/
1 each 112" Drive Socket Set, 3/s" to 1- 1/2"
1 each Hex Key (allen wrench) Set, up to lit
1 each Screwdriver Set, Phillips Tip & Slot Tip
1 each Punch Set; Drift, Lineup and Straight
1 pair Wire Stripping Pliers
1 pair Wire Crimping Pliers
1 pair Wire Cutting Pliers
1 pair Needle Nose Pliers
2 pair Jumper Wires with Alligator Clips
NOTE: This list is not intended to be all inclusive ofthe tools required to perform every maintenance
function that may be required on this specific CONDOR® model. However, these tools will greatly
assist in troubleshooting problems and conducting routine maintenance on the equipment.
MANUAL 92357-002
JUNE 1997
Serial Number Location •
1
2
The CONDOR® Model V2648/531XL Serial Number is stamped in two locations on the machine.
1. The first place to find the serial number is on the data plate affixed to the
chassis, at the rear between fork lift pockets.
2. The second place to fmd the serial number is at the front steering knuckle
kingpin.
MANUAL 92357-002
JUNE 1997
..
MANUAL 92357-002
JUNE 1997
HYDRAULIC SYSTEM DESCRIPTION •
The following is a detailed description ofthe hydraulic system usedon the CONDOR® model V26481
53IXL scissor, and how it is designed to operate. To assist in understanding the system, this description should
be used in conjunction with the hydraulic schematics found atthe end ofthis section.
GENERAL
The hydraulic system on the CONDOR® model V26481531XL consists primarily ofa singIe manifold
assembly, used to control all the hydraulic functions through the use ofhydraulic cylinders and motors. The
system is electric over hydraulic, meaning that the hydraulic valve assembly is activated by electrical signals
from the function controls. The system is also ofthe open-centervalve type, meaning that the hydraulic fluid
circulates back to the tank when the pump is running and no functions are being operated. All lift and drive
functions can be performed from the platform console, while ONLY lift functions are available from the lower
control console.
HYDRAULIC TANK
The hydraulic tank is an "L" shaped

weldment having a fluid capacity of 7 US gal-
lons. The main portion of the tank is located
between the batteries in the belly pan, with the
smaller portion extending outward to the right
side ofthe unit (See FIG. 1) next to the hydraulic
pump. A filler neck and cap, and a sight glass are
provided at the extended section of the tank for
checking and maintaining the fluid level. Filtra-
tion ofthe hydraulic oil is provided through a 10 Ball
micron spin-on return filter, and a 100 mesh, 10 Valve
GPM, tank-mounted strainer. The filter, and
strainer are located at the end of the tank, just
behind the pump. The use of a tank strainer and
shut-off valve (ball valve) for the tank has been
discontinued. Although the tank configurations
differ between models, the attaching compo-
FIG. 1
nents are identical.
NOTE: Only check the tank fluid level when the unit is in its stowed position to ensure the level will
be at its highest. The hydraulic fluid used is Shell Tellus T-32 and only this fluid, or its equivalent should
be used.
DO NOT MIX HYDRAULIC FLUIDS.
MANUAL 92357-002
JUNE 1997
.,
PUMPIMOTOR
The pump and motor assembly is lo- HYDRAULIC TANK

cated in the right side of the belly pan, between ELECTRIC MOTOR
the tank and the fixed axle (See FIG. 2). A 24

volt DC motor drives a tandem pump, which
consists of two separate pumps driven from the
same shaft. Both sections have a size of .194
cubic inch per revolution, which equals to 2.7
GPM of hydraulic flow at 3600 rpm. One
section ofthe pump is only used for drive, while
PUMP/MOTOR CONTACTOR
the other pump section supplies fluid for steer-
ing, lift, or to increase the drive speed when FIG. 2
directed to the drive circuit.
MAIN VALVE ASSEMBLY
Located in the left side of the belly pan Batteries Ground Controls
between the batteries and battery charger is the
main valve assembly which performs all of the
hydraulic functionsofthe machine (See FIG. 3).
This assembly includes three directional control
valves and a variety ofcartridge valves to achieve
the operation ofthe cylinders and motors for the Main Valve Battery Charger
machine functions. These individual functions Assembly
are described in detail below. FIG. 3
MACHINE FUNCTIONS
The hydraulic functions of the CONDOR® model V2648/53IXL includes: forward and reverse
drive with three selectable speeds at limited height, spring applied/hydraulically released brake cylinders,
left and right steering, and platform raising or lowering. Each of these functions are performed by the
main valve assembly via electrical control signals. A detailed description of the electrical controls and
their circuits can be found in the Electrical System Description of this maintenance section.
DRIVE FUNCTION
The drive function is only available at the platform controls. Movement of the drive control
handle l3 0 from its center position in either direction will tum the pump motor on and energize the
respective forward/reverse electrical circuit. The forward/reverse electrical circuits consist solely of
the drive controller and the drive directional control valve located on top ofthe main valve assembly (see
FIG. 4).
MANUAL 92357-002
JUNE 1997
----------------------------------------~~
Drive Directional
Control Valve
Creep Speed
Solenoid Valve
Flow Divider/Combiner Creep Speed

Needle Valve
FIG. 4
DRIVE FUNCTION (cont'd)
Pump flow circulates through the main valve assembly and back to tank if no functions are
activated when the pump is running. Once the directional control valve shifts, fluid is directed to one
of the load control valves in its free-flow direction, and then to the normally open positraction valve.
Fluid flows through the positraction valve cartridge, then to both drive motors which each have an 11.9
cubic inch per revolution displacement and are located on the steer axle. When the positraction button
is depressed at the upper control box, the 4-way normally open positraction valve closes, blocking the
flow of fluid through it, but forcing the fluid through the flow divider/combiner to enhance tire traction.
The deceleration valve is utilized to cushion the braking action of the drive circuit. This is
accomplished by letting fluid by-pass between the two drive motors. Since the deceleration valve is a
2-way normally open spool valve, it allows fluid to flow through it at all times. When the drive control
handle is actuated, energizing the drive circuit, the deceleration valve becomes energized and closes,
blocking the flow of fluid through it. When the drive handle is released (circuit de-energized), the
deceleration valve opens, and lets the drive pressure by-pass to the opposite drive motor, allowing the
two drive motors to continue to roll momentarily without creating a hydrostatic lock in the circuit. A
0.040 dia. orifice, located under the deceleration valve, is used to control the amount of by-pass that
occurs which affects the deceleration of the machine.
The V2648/531XL has a creep speed which is either automatically activated at platform heights
above seven feet by a limit switch, or is operator selectable at heights below seven feet. Creep speed is
a situation in the drive circuit whereas when the creep speed solenoid valve is energized, someofthe drive
flow is diverted back to the tank. The speed at which the machine travels when in creep, is controlled
by the creep speed needle valve (See FIG. 4). The creep speed is factory set to obtain a travel speed of
80-lO0 sec/88 feet, on firm, level ground; (Ref..75/.6 mph), (see note #2 on schematic at end ofhydraulic
section).
MANUAL 92357-002
JUNE 1997
• DRIVE FUNCTION (cont'd)
When the speed selector switch is in the

high position, the drive speed increases by the
Select Directional Steer Directional
Control Valve Control Valve
addition of the P2 pump's fluid displacement (between drive and steer)
(steer/lift pump) being diverted to the drive
circuit. This is accomplished by activation of
the select directional control valve. The hydrau-
lic pump contains two individual pump sections,
one of which is used solely for the drive circuit.
The other pump section supplies fluid for the
operation of lift and steer, and will supply fluid
to the drive circuit when the machine is in high
speed. A check valve cartridge is used to isolate Check Valve
the drive-only pump flow for use in the drive Cartridge
Creep Valve
circuit (See FIG. 5).
FIG.S
STEERING FUNCTION
Steering is accomplished with a cylin-

der, knuckle, and connecting arm arrangement,
which in its configuration provides a tight turn-
ing radius. The drive motors are mounted to the
steering knuckles, thus enhancing driveability.
The steering cylinder, located just behind the
front bumper plate of the chassis, is controlled
by the steer directional control valve on top of
the manifold assembly (See FIG. 5&6).
Steer Cylinder
FIG. 6
LIFT FUNCTION
Lifting of the platform is accomplished

by energizing the select directional control valve.
This will direct fluid from the P2 pump to the Cylinder
base end ofthe lift cylinder, with the rod end of
Manifold
the lift cylinder being vented back to the tank.
Coil
Located on the cylinder body (See FIG. 7), is the
holding valve, which consists of a manifold Cable
body, a 2-way normally closed cartridge with a
manual override, and an electric coil. Attached
to the cartridge is a cable assembly used for
FIG. 7
manually lowering the platform via aT-handle
located at the rear ofthe machine, under the rear
bumper plate. Descent speed is controlled by a flow control valve (See FIG. 3), in which clockwise
rotation decreases descent speed, while counterclockwise rotation increases the descent speed.
MANUAL 92357-002
JUNE 1997
PRESSURE ADJUSTMENT PROCEDURES
NOTES: All pressure adjustments are to be made with the pump motor running, and with the hydraulic
•
fluid at operating temperature. Ensure that the tank is filled to its recommended level, and that the
batteries are fully charged. To simplify the adjustment procedure, install a pressure gauge at the "G 1"
port, and install another pressure gauge at the "G2" port, which are both located at the creep valve end
of the main valve assembly. All relief valves adjust in the same manner: clockwise increases pressure
setting, and counterclockwise decreases pressure setting. All flow control cartridges adjust in the same
manner: clockwise decreases flow, and counterclockwise increases flow. Refer to FIG. 8 for
adjustments.
Drive Pressure Adjustment
1. Chock both drive wheels to prevent them from spinning in the forward drive direction.
2. With the drive speed selector in the low position, activate forward drive with the drive controller.
3. While drive is activated, adjust "RVI" to 2700 psi while observing the gauge reading from the
"GI" port.
4. After setting, lock the adjustment screw with the jam nut.
Higb Drive Pressure Adjustment
1. Select high speed at upper control box.

2. Observe the pressure reading at the "G 1" port while climbing a grade, and note pressure reading
at which the high drive shifts to low.
3. Adjust the "SEQ" valve until the pressure reading is 1100 psi when high drive shifts to low.
4. After setting, lock the adjustment screw with the jam nut.
NOTE: The load control valves, "CB I " and "CB2", are factory set. Ifthey are not functioning properly,
they must be replaced; DO NOT ATTEMPT ADJUSTMENT.
Lift PressurelDescent Speed Adjustment
1. With pump running, and platform raised completely (cylinder bottomed out), observe the
pressure reading on the gauge connected to the "G2" port. Adjust "RV2" to 2700 psi.
2. Adjust "FCI" to obtain a 25-35 second descent from a fully raised position.
MANUAL 92357-002
JUNE 1997
To aid troubleshooting, some of the valves and cartridges are identical to others and can be swapped to
help determine faulty components:
l. "RV3" and "RV4" steer reliefs are identical with same pressure settings.
2. "FCI" and "FC2" brake and descend flow control valves are identical while settings may differ.
3. "CBI" and "CB2" are identical-- DO NOT ADJUST!
4. "RVl" and "RV2" are identical with the same pressure settings.
5. "CREEP" and "DECEL" solenoid cartridge valves are identical.
"G2" Gauge Port

- t t - t - - - - (Reads Steer/Lift!
High Drive Pressure)
"G1" Gauge Port

(Reads Drive Only
Pressure)
"FC1" - Controls Platform

Descent Speed
"RV2" Relief For Steer/Lift

("G2" Gauge Port)
"RV5" Secondary
Lift Relief
Creep Speed
Adjustment
"SEQ" (Sequence) Valve "RV1" Relief For Drive Only

Controls High Drive Shifting ("G1" Gauge Port)
"CB1" and "CB2" Load

Control Valves
(DO NOT ADJUST)
FIG. 8
MANUAL 92357-002
JUNEJ997
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MANUAL 92357-002
JUNE 1997
ELECTRICAL SYSTEM DESCRIPTION
The following is a detailed description of the electrical system used on the CONDOR® model
V2648/53IXL scissor, and how it designed to operate. To assist in understanding the system, this
description should be used in conjunction with the electrical schematics found at the end ofthis section.
GENERAL
The CONDOR® model V2648/531XL uses a 24 volt direct current (DC) electrical system
consisting of four, 6 volt DC batteries, an electric motor to drive the hydraulic pump, and various
electrical controls to operate the system. Included in this system description is a Machine Options
section, describing options which are available on the model V2648/531XL. All ofthe options contained
in this description are electrical only, and do not affect the hydraulic performance of the machine.
BATTERIES
The model V2648/531XL scissor uses four, 6 volt DC batteries, each having a 235 amp hour
capacity. There are two batteries on each side of the belly pan nearest the steer axle. The four batteries
are connected in series, combining their voltage, to make up the 24 volt DC system. The batteries are
of the wet-cell type, and when filled with electrolyte, each battery weighs 661bs. More information on
batteries in general can be found in the Battery Service Section beginning on page 47.
BATTERY CHARGER
The battery charger has a 25 amp @ 24

Main Manifold Ground Controls
volt DC nominal rating, and operates offof aIlS Assembly
volt alternating current (AC), 160 Hz, 8 amp
input. The charger features contains an ammeter
for reading the DC amp output, and two LED
status indicator lights; a red LED indicates the
charger is on, charging, while a green LED indi-
cates the charging is complete. The charger is
located on the left side of the belly pan, between
the main valve assembly and the fixed axle (See
FIG. 9). More detailed information ofthe charger
can be found in the Battery Charger Trouble-
shooting Guide beginning on page 67. .
cmcmT BREAKERIFUSE
Located below the control selector switch on the lower control box (see FIG. 11), is a 15 amp
fuse. This circuit fuse protects all the machine control circuits.
MANUAL 92357-002
JUNE 1997
• PUMP MOTOR
The CONDOR® model V2648/53XL PumplMotorContactor

utilizes a pump motor which is a 24 volt DC unit,
rated 6 hp @ 3600 rpm. Since the model V26481
53XL utilizes a gravity lowering system, the
motor does not run while the lowering function is
activated.
FIG. 10
LOWER CONTROL FUNCTIONS
Located above the left rear wheel is the

lower control box, which provides a junction
Emergency Stop Button
connection through the use oftwo terminal strips,
for the limit switch cable, the hydraulic valve
cable, the pump motor contactor cable, and the Platform Lift Control ---";I!+--L....L
cable to the upper controls. At the lower controls
are switches (see FIG. 11), to provide operation
of the lift function only; drive is not available Control Selector Switch ---jft-+-+-~., J
OFF :
from this control box. The lower control box """--------':

_-l!IH--@ :
15 Amp Circuit BreakerlFuse"
contains an emergency stop button which must be ~ ___________ J,
pulled out to supply power to both control boxes.
The control selector switch is a 3-position main-
FIG. 11
tained rotary switch that directs power to either
control box for operation of the machine,
while the box not selected, will not have power. The platform lift control consists of two pushbuttons,
which, through the use of contact blocks, energize the pump motor and selector valve for raising, or the
holding valve for lowering. The pump motor does not run during lowering.
UPPER CONTROL FUNCTIONS
The upper control box, located at the right hand forward comer of the platform, is a fiberglass
enclosure which contains two slip-fit inserts on its underside that allow the box to press onto two pins
which are part of the platform weldment. The control box is removeable by disconnecting the cable
harness plug underneath, and lifting upward on the box assembly. The feature allows for disabling the
machine, storage of the box, or ease of repair to the controls. Some of the controls used are identical to
the those found at the lower control box (See FIG. 12), primarily the emergency stop button and the lift
controls. The platform lift control buttons operate similar to the lower control pushbuttons. However,
at this control box, the green "POWERff pushbutton must be depressed to supply power to either the raise
or lower lift button. To provide electrical power to the upper control box, both emergency stop buttons
must be in the "out" position, the control selector switch must be in the "UPPER" position.
MANUAL 92357-002
JUNE 1997
UPPER CONTROL FUNCTIONS (cont'd) •
Cut-Away View
of Slip-Fit Insert
(-----------------------------,
Lift Controls r: ',J
Drive Controller
w/SteerRocker
Switch
Power Button
(green)
/"
Cable Harness
Plug Hidden View of
Slip-FitInsert
FIG. 15
Integrated in the forward edge ofthe drive handle is a grip lever which is a substitute forthe footswitch
commonly used on other machines. The grip lever must be squeezed to perform drive (movement ofthe
handle), or steer (activation of the rocker switch) functions. This lever, however, does not affect the lift
controls. Movement ofthe drive handle 13 0 in either direction will turn the pump motor on, and energize the
drive directional control valve, thus initiating drive motion. Drive speeds are selectable from the drive speed
selector switch. Selecting "fast" will energize the select directional control valve and increase drive speed by
adding the second pump's flowtothe drive hydraulic circuit. Selecting "low" will de-energizethe select valve,
and drive speed will then rely on the single pump output. When in "fast" or "low", the creep valve is always
energized because it is a normally open valve. When "creep" speed is selected, or when the platform is above
six to seven feet, it is de-energized, thereby letting fluid by-pass to tank through an adjustable needle valve.
MANUAL 92357-002
JUNE 1997
NOTES
MANUAL 92357-002
JUNE 1997
MACHINE OPTIONS DESCRIPTION
The following descriptions are intended to be used with wiring diagrams at the end of this
electrical section.
STROBE LIGHT (OPTION)
This option is to indicate that the machine is on or ready to operate. The strobe has: a plug-in
flash tube for easy replacement, an energy output of 2 joules, a power output of 3 watts, and a flash rate .
of 60 + 10 flashes per minute. The strobe is energized whenever the control selector switch is in the
ItUPPERIt or "LOWER" position and the lower control emergency stop button is pulled out.
5°SLOPE ALARM (OPTION)
This option sounds an alarm when the V2648/53IXL is 50 or more out of level. A 50 omni-
directional sensor is mounted in the belly pan to sense a 50 out-of-Ievel condition. In this situation, a fast
pulse/loud tone alarm at the upper control box (See FIG. 13), is activated until the machine is returned
to a less than 50 condition. This serves as a warning, and does not inhibit any functions. The sensor is
mounted on a spring loaded base which is adjustable to allow leveling. Testing of the system is
accomplished by manually tilting the sensor against its spring tension mount, to physically put the sensor
in a 50 out-of-Ievel condition, causing the alarm to sound. Power is supplied to the sensor, and the alarm,
only when the machine is in the ItUPPER" control position. When the sensor is activated (50 or greater),
the sensor's white wire (connected to the alarm), becomes grounded after a few second delay, through
circuits inside the sensor.
BATTERY CONDITION INDICATOR (OPTION)
This option is to monitor the batteries' Slope Alarm

state-of-charge, (See FIG. 13). The indicator is Battery
Condition
wired directly to the batteries with the 15 amp Indicator
circuit breaker, or fuse, included in the circuit.
Consisting of an analog 10-LED bar display, the
indicator provides a visual reference for reading
properly charged batteries (top LED lit), batteries
at 70% depth-of-discharge (second from bottom
LED flashes), and when the batteries have reached
an 80% depth-of-discharge (bottom two LED's
flash alternately).
FIG. 13
SIGNAL HORN (OPTION)
This option consists of a 133 db automotive type hom mounted in the chassis, and a white
pushbutton on the side ofthe uppercontrol box (See FIG. 14). The hom is only operable when the control
selector switch is in the ItUPPER" position.
MANUAL 92351-002
JUNE 1991
• LOW VOLTAGE BATTERY
PROTECTION SYSTEM (OPTION)
This option prevents operation when the

batteries are in a low voltage condition. It be- Low Volt Override Pushbutton ignal Hom
comes energized whenever the control selector (w/Amber Indicator Lamp) Pushbutton
switch is in either "UPPER" or "LOWER" posi- (white)
tion (lower emergency stop button must be pulled

out). While energized, the module monitors the
batteries' voltage level, and will prevent the pump
motor contactor from being activated once the
battery voltage reaches 12.5% undervoltage, or
approximately 21 volts. This condition must be Slope ~~~- Cable Harness Plug
Alarm
present for 21 seconds to activate the interrupt FIG. 14
system. Terminals 3 & 4 of the module are
normally closed contacts which complete the
pump motor contactor circuit, and it is these contacts which are opened during a low voltage condition.
Terminal 7 of the module is the battery input voltage, while terminal 6 is machine ground. Terminals 1
& 2 are normally open contacts which close during a low voltage condition and turns on an amber
indicator light (pushbutton) at the upper control box. The system can be overridden by pressing the
pushbutton on the side ofthe upper control box (See FIG. 14), which energizes terminalS ofthe module.
However, the override will only allow three repeated by-pass cycles of2 minutes 30 seconds each. The
LVI module will reset when the battery voltage reaches approximately 25.5 volts during re-charging.
Once the batteries have been properly charged and the L VI module has automatically reset, the
CONDOR® can be operated once again.
TRAVEL ALARM (OPTION)
This option indicates forward or reverse drive (travel) of the machine. The alarm signal is
activated by the deceleration valve circuit since the deceleration valve is always energized during both
forward and reverse drive.
DESCEND ALARM (OPTION)
This option indicates descent (lowering) of the platform. The alarm signal is activated by the
holding valve circuit, which is energized when lowering the platform.
MOTION ALARM (OPTION)
This option indicates forward or reverse drive, and raising or lowering ofthe platform. The alarm
signal is activated from two different circuits; one energizes the pump motor contactor, and the other
energizes the holding valve for platform lowering (pump not running). A diode is used in each circuit
to prevent unintended feedback.
HOUR METER (OPTION)
This option is to record the "run time" of the machine for maintenance scheduling, rental usage,
etc.. The meter runs only when the pump motor contactor is energized (pump running); therefore, the
meter does not run when the machine is sitting idle, or when the platform is being lowered.
MANUAL 92357-002
JUNE 1997
L66I3Nill
<:QO-LSt<:6 "IVllNVN
5' SLOPE SENSOR OPTION
3 14 WHT
HORN SLOPE ALARM OPTION
.i. ""TE BUT, SEE NOTE 3

~
o 12,
SIGNAL OPTION
A STROBE LIGHT opnON
5D
7 ® LOW VOLT OPTION (SENSOR)
3-POS BATTERY CONDITION

SELECTOR INDICATOR OPTION
M[ (
UPPER
RED SA TlERY CHARGER BLK ~ SA TTERY DISCONNECT
...J... 5D KEY S'tYITCH OPTION
15A
FUSE 58
pas FOUR 6VOC SA TTERl(S
.. PlAlFORM
8 UP
8A
58
PUMP MOTOR
PUMP MOTOR CONTACTOR

5C
•
PLATFORM HOUR METER OPTION
DO""
Be
MOTION ALARM OPTJON
9
VALVE ON un CYL
DESCEND ALARM OPTION

8A
!·----i?
RIGHT
(STEER VAlV£)
LEFT
EMERGENCY
..... STOP
2 FORWARD
3A (DRIVE VALVE)
, I
REVERSE
3B
GREEN
.i. ..r:. PLA~':: TRAVEL ALARM OPTION
3A 3C •
ENAB~..r:.
8D
DECELERATION VALVE
PLATFORM
3C B UP
ufT PLATFORM
(SELECTOR VALVE)
I.
FAST DRIVE SPEED
foe' CR2
"A
" SEE JlfOTE 1
CREEP DRIVE SPEED VALVE
12
POSITRACTION VALVE
38
3A
® lDW VOLT OPTION (OVERRiDE)
I.
~ lOW VOLT OPTION (WARNING)
SEE NOTE 2
~'T
!'lQlES:.
1. UMIT SIMTCH SHO\\N WITH PLATFORM BELOW 7'.
2. C!)THRu0REPRESENT TERMINALS OF OPTIONAL LOW VOLTAGE UNIT IN LOWER CONTROL BOX.
3. FOR SIGNAL HORN, PLUS ~ OTHER OPTIONS, ADD RELAY, AND DELETE "NC" CONTACT AT 3 POS SWITCH.
.... 4. THIS SCHEMATIC SUPERCEDES 55866 .
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This Page Intentionally
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MANUAL 92357-002
JUNE 1997
BATTERY SERVICE
BATTERY SERVICING TOOLS
Use proper tools when performing battery service to prevent damage to battery, cables, terminals
and hold-downs, and to save time and energy.
Suggested battery tools and their use are described below.
FILLING DEVICES
One of the most important routine battery service for conventional batteries is to maintain the
correct electrolyte level. Two devices are available for this purpose, a self-leveling filler which fills the
battery to a predetermined level automatically, and the syringe type. Battery cells should never be filled
above the level indicator. Do not squeeze the syringe so hard that the water splashes acid from the
cell opening.
SCRAPER AND WIRE BRUSH
The scraper and wire brush can be used for removing dirt, corrosion and rust from various parts
such as the battery posts, battery tray, the hold-down and the hold-down bolts.
BATTERY CARRIER
A battery carrier should not place any undue strain on the battery terminals or the container. An
excellent carrier for plastic cased batteries is a clamp ("ice tong") type carrier with rubber pads which grip
the SIDE WALLS of the container just below the lip of the cover. It is used on the side walls rather than
the end walls, since the side walls have additional strength from the inner cell partitions. Gripping the
flexible end walls of plastic containers could cause electrolyte to spew from some of the cells.
SERVICE PROCEDURES
The user should realize that the battery is a perishable item and requires periodic attention. With a
reasonable amount of care, the life of the battery can be appreciably extended. Neglect and abuse will
invariably cause shorter life.
CAUTION
Low battery voltage (discharged) requires higher current draw to dothe same
work. This high current draw WILL DAMAGE the electric motor, relay
contacts and the batteries. DO NOT OPERATE the CONDOR® with a
battery DISCHARGED or that has a specific gravity of 1.130 or LESS.
Routine servicing of the battery should proceed as follows:
First, make a visual inspection for defective cables, loose connections, corrosion, cracked cases
or covers, loose hold-downs and deformed or loose terminal posts. Ifany parts such as cables, hold-downs
or the battery appear to be unserviceable, it is recommended that they be replaced.
When there is corrosion on the terminal posts or hold-down, the tray or hold-down parts are rusty,
or the battery is very dirty, it is recommended that time be taken to clean the parts. A wire brush can be
used to remove dirt, corrosion or rust from parts. Clean dirt from the battery top with a cloth wetted with
ammonia or baking soda in water.
MANUAL 92357-002
JUNE 1997
Next, wipe with a cloth with clear water. After rust is removed from a part with a wire brush,
rinse with clear water, dry and paint with an acid-resistant paint.
If corrosion is found on the terminal posts, remove the cable terminals from the battery (ground
cable first), using the proper end wrench. A wire cleaning brush can be used to clean the posts and the
mating surfaces of the cable clamps. Connect the cables to the terminal posts (ground cable last). Coat
the terminal connections with a spray corrosion inhibitor or high temperature grease.
The second item in routine servicing ofconventional batteries is to check the electrolyte level in
all cells. Ifnecessary, add clear, odorless, mineral free water to bring the liquid level to the level indicator
in all cells. If the battery does not have a level indicator, bring the level to 1/2 " (13mm) above the tops
of the separators. Do not overfill any cell. When a cell is overfilled, the excess electrolyte may be
forced from the cell by the gas formed in the battery. This will cause excessive corrosion of adjacent
metal parts, reduced performance and shorter life.
BATTERY TESTING
Battery testing should be considered an integral part of periodic equipment maintenance and should be
performed whether or not a starting problem has occurred. Servicing the battery in the equipment as
described will help prevent premature battery failure from external causes and periodic battery failure
from both external and internal causes or merely from the battery reaching the end of its useful life.
STEP 1 - VISUAL INSPECTION
For protection, wear a face shield. First, visually inspect the battery. Check for container,
cover or terminal damage that might cause leakage of electrolyte or internal damage. If serious damage
is found, replace the battery. Check the electrolyte level in each cell. Ifbelow the tops of the plates in
any cells, fill all cells with water to just above the tops of the separators and charge for 15 minutes at 15-
25 amps to mix the water with the electrolyte. If electrolyte levels are above the tops of the plates,
continue to Step 2.
STEP 2 - HYDROMETER TEST
Using the hydrometer, measure and record the specific gravity (sp. gr.), corrected to 80 degrees
F (26.7 C) ofthe electrolyte in each cell. Ifthe range (highest-lowest) is 50 points (0.050 sp. gr.) or greater
orthe lowest is less than 1.225 SP'gr" charge the battery at the recommended rate or until all cells are 1.225
SP'gr' or greater and the range is less than 50 points. If no amount of charging will achieve these
conditions, replace the battery. If these conditions are achieved, apply a 150 amp load for 15 seconds
to remove the surface charge on the battery and continue to Step 3.
DANGER
Lead acid batteries generate highly explosive hydrogen gas especially during the
charging cycle. To AVOID the possibility of an explosion, charge batteries ONLY
in a well VENTILATED AREA. Keep fire, sparks, and burning material away from
the charging area. Do Not smoke near a battery, and always shield the eyes when
working near a battery.
MANUAL 92357-002
JUNE 1997
The average state ofcharge ofthe cells in a battery can be determined by measuring the stabilized
voltage of the battery. The voltage is stabilized ifthe battery has been on open circuit overnight or for
a period of several hours. A voltage reading of 12.4 (6.2 on a 6 volt battery) is equivalent to a specific
gravity of 1.225. The disadvantage of measuring the open circuit voltage is that a lower voltage cell can
--
be masked by the remaining cells. Ifthe cell connectors are accessible for voltage measurements, a range
of 0.05 volts between the highest and lowest cells corresponds to a 50 point variation in specific gravity.
A cell voltage of 2.07 is equivalent to a specific gravity of 1.225.
STEP 3 - ADJUSTABLE LOAD TEST
The following instructions are intended as guidelines. When available, the instrument
manufacturer's instructions should be followed. Follow all precautions.
A. Disconnect battery cables starting with ground cable.
B. Measure temperature of a center cell. If instrument has an integral temperature

compensator, use attached probe.
C. Connect voltmeter and load test leads to appropriate battery terminals, make certain
terminals are free of corrosion.
D. Connect current transducer (if necessary) to appropriate lead.
E. Apply test load equivalent to 50% of Cranking Performance rating of battery for 15
seconds. If Cranking Performance is unavailable, use 3 times the 20 ampere-hour
capacity.
F. Read the voltage at 15 seconds, then remove the load.
G. Determine minimum voltage required at electrolyte test temperature from chart in

Figure X.
H. If test voltage is above minimum, return battery to service.
I. If test voltage is below minimum, replace battery.
TESTING WITH FIXED LOAD TESTER AND OPEN CIRCUIT
For testing batteries with a fixed load tester and an open circuit voltmeter, referto "Battery Testing Chart"
Figure Y.
STEP 1 - VISUAL INSPECTION
First, visually inspect the battery and check the electrolyte levels as described in Step 1 of"Testing
with Adjustable Load Tester and Hydrometer"; take the same corrective actions. Continue to Step 2.
MANUAL 92357-002
JUNE 1997
• STEP2-FIXEDLOADTEST
Some commercial battery testers do not have an adjustable load but measure the battery voltage
under a heavy fixed load. The tester should include a selector switch or meter scale to choose among a
variety of battery sizes. It should include some means of correcting for the battery temperature, either
in automatic sensing circuit or a manually selectable one.
The following instructions are intended as guidelines. When available, the instrument manufac-
turers instructions should be followed.
A. Disconnect battery cables starting with ground cable.
B. Measure temperature of a center cell and set temperature dial on tester or insert
automatic temperature corrector probe in center cell. Cover battery with a damp cloth.
C. Set battery size selector to a range or select range on meter which will include 50%
ofthe Cranking Performance rating or 3 times to 20 ampere-hour capacity ofthe battery.
D. Connect voltmeter and load test leads to appropriate battery terminals, make certain
terminals are free of corrosion.
E. Apply test load for 15 seconds.
F. Read battery performance from instrument meter at 15 seconds, then remove the load.
G. If the battery passed the load test, return it to service.
H. If the battery failed the load test, continue to Step 3.
STEP 3 - OPEN CIRCUIT VOLTAGE TEST
If the battery failed the load test, the state of charge must be checked. If a hydrometer is not
available, the stabilized open circuit voltage can be used to indicate the state of charge. Allow at least
10 minutes after the load test for the voltage to stabilize, then measure and record the open circuit voltage.
Determine the approximate state ofcharge from the following chart (Battery temperature 60-1 00 degrees
F.)
OPEN CIRCUIT VOLTS PERCENT CHARGE

12.6 or greater 100%
12.4 - 12.6 75-100%
12.2 - 12.4 50-75%
12.0 - 12.2 25-50%
11.7 - 12.0 0-25%
11.70rless 0%
The change of voltage with state of charge is small and must be measured accurately using a
digital meter or an analog meter ",ith an expanded scale. If the state of charge is 75% or greater and the
battery failed the load test, it should be replaced. If the state ofcharge is less than 75%, the battery should
be charged at the recommended rate and time, and the load test repeated. If the battery passes the load
test, return it to service. If it fails the load test again, replace it and refer to the next chapter to determine
the cause of failure.
MANUAL 92357-002
JUNE 1997
DETERMINING CAUSES OF BATTERY FAILURE
Whether the battery passes or fails either of the above tests, the results must be believed. If the battery
passed the load test only after a recharge, the cause of the discharge condition should be determined.
Ifthe battery has been returned previously or is otherwise still questionable, one final test should be made.
Fully charge the battery and place it on open circuit stand for three days. If the loss in specific gravity
of any cell is greater than 35 points or the open circuit voltage drops by more than 0.20 volts, replace the
battery. If not, return the battery to service and determine the cause for the discharged condition.
The following should be checked:
1. Corroded Battery Terminals or Connectors
A corrosion layer between the battery terminals and the cable connectors can prevent good
electrical contact even when the connectors are tight. The cables should always be removed
before testing a battery and any corrosion cleaned from the terminals.
2. Electrical Circuit Leakage
There may be a fault in the equipment's electrical system that can discharge the battery even when
all the accessories are turned off. To check for such leakage, tum off all accessories in the equipment..
Check for leakage using one of the following methods.
A. Ammeter - Cover battery with a damp cloth. Disconnect the ground cable. Using a DC
ammeter with a resolution of at least 0.1 amp, measure the current between the
disconnected cable and the battery terminal. (DO NOT CONNECT AMMETER
ACROSS BATTERY TERMINALS!) A leakage current measurement of 0.1 amp or
more indicates the equipment electrical system should be tested and repaired.
B. Ohmmeter - Disconnect the positive cable at the battery. Connect an ohmmetertothe

disconnected cable end and to the chassis. A resistance measurement of under 100 ohm
indicates a load of 0.1 amp or more and indicates the equipment electrical system should
be tested and repaired.
C. Voltmeter - Disconnect the ground cable (negative) at the battery. Connect a low
resistance voltmeter (l00 ohms - see Note 1) between the disconnected battery post
and the chassis. A voltage measurement of 6 volts or more indicates a leak of 0.1 amp
or more and the equipment electrical system should be tested and repaired.
Note 1: The voltmeter test cannot be made with high resistance voltmeters.
3. Charging System
To complete the determination of the cause for the battery's discharged condition, check the
equipment's charging system.
MANUAL 92357-002
JUNE 1997
FIGURE: X
BATTERY TESTING CHART
STEP 1 VISUAL INSPECTION

CHECK FOR OBVIOUS DAMAGE SUCH AS
CRACKED OR BROKEN CASE THAT SHOWS
LOSS OFELECTROLYTE. ALSO CHECK FOR
TERMINAL DAMAGE.
IOBVIOUS DAMAGE I I NO OBVIOUS DAMAGE I

I
IREPLACE BATTERY I I CHECK ELECTROLYTE LEVEL I
BELOW TOP OF PLATES IN ONE OR I
MORE CELLS
I ELECTROLYTE LEVEL ABOVE TOP OF
PLATES IN ALL CELLS - PROCED TO
ADD WATER TO JUST ABOVE SEPA- STEP 2
RATORS. CHARGE FOR 15 MINUTES
AT1~25AMPS.PROCEEDTOSTEP2
STEP2 I HYDROMETER TEST I

. I I
SPECIFIC GRAVITY LESS THAN 1.225 SPECIFIC GRAVITY 1.225 OR GREATER
OR CELL VARIATION 50 POINTS OR OR CELL VARIATION LESS THAN 50
GREATER. POINTS.
I
I RECHARGE,
I
I I
DISCHARGE AT 150 AMPS FOR 151
SECONDS
SPECIFIC GRAVITY LESS THAN 1.225 1

OR CELL VARIATION 50 POINTS OR
GREATER.
ICONTINUE TO STEP 3 I
I
IREPLACE BATTERY I
STEP 3 I LOAD TEST I
I
1. PLACE THERMOMETER IN CENTER CELL.
COVER BATTERY WITH A DAMP CLOTH.
2. CONNECT VOLTMETERAND AMPERE LOAD
EQUAL TO 112THE COLD CRANKING AMPERES
AT OaF (-18°C) RATING OF THE BATTERY FOR
15 SECONDS.
3. OBSERVE VOLTAGE AT 15 SECONDS WITH
LOAD ON.
4. REFER TO VOLTAGE CHART BELOW.
I
I
IVOLTAGE BELOW CHART VALUE I
I
I I
VOLTAGE EQUAL TO OR ABOVE CHART
VALUE - RETURN TO SERVICE
I
IREPLACE BATTERY I
VOLTAGE CHART
ESTIMATED ELECTROLYTE TEMPERATURE MINIMUM REQUIRED VOLTAGE UNDER 15 SEC. LOAD

(USE 112 THESE VALVES FOR 6-VOLT BATTERIES)
70°F (21°C) & ABOVE 9.6

60°F (16°C) 9.5
50°F (10°C) 9.4
40°F (4°C) 9.3
30°F (-1°C) 9.1
20°F1-7°C) 8.9
10°F (-12°C) 8.7
oaF (-18°C) 8.5
MANUAL 92357-002
JUNE 1997
FIGURE: Y
SATTERY TESTING CHART
STEP 1 VISUAL INSPECTION

CHECK FOR OBVIOUS DAMAGE SUCH AS
CRACKEDORBROKENCASETHATSHOWS
LOSS OF ELECTROLYTE. ALSO CHECK
FOR TERMINAL DAMAGE.
I
I I
IOBVIOUS DAMAGE I NO OBVIOUS DAMAGE I
I I
IREPLACE BATTERY I CHECK ELECTROLYTE LEVEL. ADD
WATER IF NECESSARY. PROCEED
TO STEP 2.
STEP 2 I FIXED LOAD TEST I

I
1. ATTACH TESTER CLAMPS TO BATTERY TERMINALS IN CORRECT
POLAITY - USUALLY RED TO POSITIVE (+) AND BLACK TO NEGATIVE (-).
2. SET SELECTOR SWITCH ON LOAD TESTER TO 112 CRANKING AMPERAGE
RATING OF BATTERY (AT O'F, -1S'C).
3. IF TESTER DOES NOT HAVE AN AUTOMATIC BATTERY TEMPERATURE
COMPENSATOR, PLACE A THERMOMETER IN CELL, READ AND SET TEMP-
ERATURE DIAL ON TESTER. WITHOUT ANY TEMPERATURE CORRECTION,
MAKE LOAD TESTS ONLY ON BATTERIES ABOVE 60"F (16'C).
4. APPLY LOAD FOR 15 SECONDS AND READ LOAD TESTER JUST BEFORE
RELEASING THE LOAD.
I
I I
IBATTERY FAILS LOAD TEST I
I
IBATTERY PASSES LOAD TEST
RETURN TO SERVICE.
I
I
IPROCEED TO STEP 3 I
STEP 3 IOPEN CIRCUIT VOLTAGE TEST I

I
1. ALLOW 10 MINUTES FOR BATTERY VOLTAGE TO STABILIZE
AFTER LOAD TEXT.
2. READ OPEN CIRUITVOLTAGE.
I
UNDER 12.4 VOLTS-BATTERY SHOULD 12.4 VOLTS OR ABOVE -IF BATTERY

BE CHARGED AND LOAD TESTED AGAIN DID NOT PASS THE LOAD TEST, IT
(REPEAT STEP2). IF BATTERY AGAIN SHOULD BE REPLACED - THEN PRO-
FAILS THE LOAD TEST, REPLACE IT. IF IT CEED TO STEP 4.
PASSES, RETURN TO SERVICE AFTER
PROCEEDING TO STEP 4.
STEP 4 CAUSES OF BATTERY FAILURE:

1. CORRODED BATTERY POSTS OR CONNECTORS -ALWAYS CLEAN THE BATTERY POSTS OR
SIDE TERMINALS AND THE BATTERY CABLE CONNECTIONS WHEN CHARGING OR REPLACING
A BATTERY.
2. ELECTRICAL LEAKAGE - CHECK FOR ELECTRICAL LEAKAGE WITH ALL ACCESORIES TURNED
OFF:
A) DISCONNECT THE BATTERY GROUND CABLE AND CONNECT A SUITABLE VOLTMETER
BETWEEN DISCONNECTED BATTERY POST AND GROUND (A READING OVER 6 VOLTS
INDICATES AN EXCESSIVE LEAK).
OR
B) DISCONNECT THE BATTERY CABLE THAT GOES TO THE STARTER AND CONNECT AN
OHMMETER BETWEEN THE CABLE AND THE GOUND (A RESISTANCE OF UNDER 100 OHMS
WILL DRAIN THE BATTERY).
3. CHARGING SYSTEM SHOULD ALWAYS BE CHECKED AFTER CHARGING OR REPLACING A
BATTERY.
MANUAL 92357"()()2
JUNE 1997
NOTES
MANUAL 92357"()02
JUNE 1997
PREVENTIVE MAINTENANCE
In conjunction with the pre-operation inspection, a good preventive maintenance program will ensure
a properly operating CONDOR®. This section is directed toward those items of maintenance which
the operator should be aware of, and which may be accomplished prior to the operation ofthe equip-
ment. Refer to the "Preventive Maintenance Daily Inspection" and the "Preventive Maintenance 50
Hour Inspection" for detailed inspection procedures. Included in this section are checklists, for the
Daily and 50 Hour Inspections, to assist in maintaining the CONDOR®. Please note that on the 50
Hour Inspection, some items may be stated as 500 Hours, where applicable.
LUBRICATION
NOTE: Recommended lubrication intervals are based on normal use in

normal environmental conditions. The operator is cautioned to
adjust the lubricating interval accordingly to meet each individual
condition and usage. The recommended lubricants are generally
the best choice. Should these lubricants be unavailable in your area,
consult your local supplier for an equivalent.
1. Wheel Bearings
Lubricant: Wheel bearing grease.
Time Interval: Every 500 hours of operation or yearly, whichever comes first
--or upon disassembly.
Procedure: Raise chassis and support. Remove fixed axle wheels. Remove
outer dust cap, spindle nut, and washer. Remove outer cone
bearing, hub, dust seal and inner cone bearing. Clean cone
bearings and races, and inspect both for physical damage
(pitting, etc). Inspect spindle for bending, cracked welds, or
other physical damage.
IMPORTANT: If damage is evident, remove the CONDOR®

from service until the spindle assembly is replaced, and contact
the Condor Div. Service Department to report the damage.
Repack cone bearings using fresh wheel bearing grease, install

new dust seal, then reassemble components in reverse order of
disassembly. Tighten spindle nut until hub will not tum, tum
spindle nut counterclockwise one castellation, or until cotter
pin will pass through spindle and spindle nut. Secure cotter
pin, ensure that hub will rotate. Reinstall wheel assembly;
torque wheel nuts to 120 ft lbs.
MANUAL 92357-002
JUNE 1997
• 2. Hydraulic System
Fluid Level: Check level daily. Maintain fluid level so that it is visible
between the marks on the sight glass with platform all the
way down.
Return Filter: Replace filter element after ftrst 50 hours of operation. There-
after, replace filter element every 500 hours of operation.
Tank Breather: Clean every 50 hours of operation. Remove from tank and clean
with solvent; air blow-dry.
Hydraulic Tank: Drain fluid from tank and replace annually. Add hydraulic fluid
to required level using only Shell Tellus T-32 or equivalent.
Suction Strainer- Drain oil from tank and replace strainer annually. If operating
in dusty or harsh conditions, inspect filter more frequently and
replace if necessary.
DO NOT MIX DIFFERENT HYDRAULIC FLUIDS
3. Battery Servicing
FOR PROTECTION WHEN SERVICING BATTERIES,

ALWAYS WEAR A FACE SHIELD AND DO NOT SMOKE!
Visual Inspection: Inspect for defective cables, loose connections, corrosion,

cracked or swelling cases or covers, loose hold downs, and loose
or deformed terminal posts.
Cleaning: When needed, a wire brush can be used to remove rust, corro
sion, or dirt from terminal ends or posts. The battery top can be
cleaned with a cloth wetted with ammonia, or baking soda with
water, then wiped with a cloth and clear water.
Electrolyte Level: Check electrolyte level daily in each cell. If necessary, add clear,
odorless, mineral free water to bring the level to 1/2" above the
top of the separators, or to the level indicator (if equipped), in
each cell. Only add water after the charging cycle is complete.
MANUAL 92357-002
JUNE 1997
PREVENTIVE MAINTENANCE INSPECTION
This field inspection list provides for a systematic inspection of the CONDOR®. The items listed to be
inspected or checked daily will ensure proper unit performance prior to operation. By following the daily inspec-
tion procedure on a regular basis, any potential malfunction will be identified before it can become a major
problem. The 50 Hour Inspection will detect any defective, damaged, or improperly secured part. The 50 hour
Inspection also includes items requiring attention at 500 hours or yearly which, are indicated where applicable.
The time interval of 50 hours applies to normal operation under normal conditions. Should the unit be subjected
to extensive use or abnormal environmental conditions, the inspections should be made more frequently. TIME
CONDOR Corporation recommends that a maintenance log be maintained, and that abnormal conditions of any
kind be recorded. To help assist in starting a maintenance log, there are inspection checklists included after each
inspection list. These are intended to be used with the field inspection lists to help gain familiarity with the
repetitive tasks.
DAILY INSPECTION
A. VISUAL INSPECTION
Overall Condition: Inspect platform, armstack, and carriage to make certain that no physical
damage is evident. Look for missing components and hardware, loose
components, etc.
Tire Condition: Inspect tires for wear, cuts, and abrasions.
Battery Cable
Connections: For protection, wear a faceshield. Inspect for swelling of battery sides,
tightness and corrosion of terminals. If corrosion is present, remove cables
from the battery (ground cable first). Clean terminals and posts with a wire
brush and reconnect to battery (ground cable last). Coat the terminal
connections with a spray corrosion inhibiter, or high temperature grease.
Hydraulic Fluid
Leaks: Inspect to ensure that there is no evidence of leaking hoses or fittings.
Decals and Placards: Verify that all decals and placards are in place and are legible. It is recom
mended that any decals or placards which are torn, damaged, missing, or
painted over, be replaced. Essential decals must be legible, or must be
replaced.
B. FLUID LEVEL CHECK
Hydraulic Tank
Level: Check level daily. Maintain fluid level so that it is visible between the
marks on the sight glass with platform all the way down.
Battery Electrolyte
Level: For protection, wear a faceshield. Check electrolyte level in each cell.
If necessary add electrolyte or clear, odorless, mineral free water as required
to bring the level to 1/2" above the tops of the separators or to the level
indicators (if equipped), in each cell. Add only after the charging cycle is
complete.
MANUAL 92357-002
JUNE 1997
• C. OPERATIONAL TEST
Instrument Check
Hour Meter: Ensure that meter is recording properly.
Battery Condition Indicator: Ensure that indicator is monitoring the batteries state-of-
charge properly.
Lower Controls
Operation Check
Emergency Stop Button: Ensure that machine will not operate with button pushed in.
Check that button maintains its in or out position.
Control Selector Switch: Ensure that switch controls the selection of "UPPER or
LOWER" properly. Make certain that machine will not
operate with switch in its center position.
Lift Control Buttons: Check that buttons and toggle switch return to their normal
position when released, and that buttons and toggle switch
properly operate the lift function.
Upper Controls
Operation Check
Emergency Stop Button: Ensure that machine will not operate from upper controls with
button pushed in. Check that button maintains its in or out
position.
Lift Control Buttons: Check that buttons return to their normal position when
released, and that buttons properly operate the lift function.
Make certain that lift function does not operate unless green
power button is depressed.
Drive/Steer Functions: Squeeze handle grip and operate drive and steer functions.
Drive Speed Selector: Ensure that each speed selection works properly while driving.
Positraction Button: Ensure that speed shifts to low when button is depressed
(platform below seven feet), regardless of speed selector
position.
Slope Alarm: Tilt sensor more than 5° (located in belly pan), and check for
audible alarm at platform control box. Selector switch must be
in "UPPER" position.
MANUAL 923S7"()()2
JUNE 1997
PREVENTIVENUUNTENANCE
DAILY INSPECTION
MON TUBS WED THURS FRI SAT SUN
ITEM I
VISUAL INSPECTION
rz /
HOURS V / 1// V !/
Overall Condition
Tire Condition
Battery Cable Connections
Hydraulic Fluid Leaks
Battery Electrolyte Level

Verify Legibility of Decals & Placards
OPERATIONAL TEST
Hour Meter
Battery Condition Indicator
LOWER CONTROLS
Control Selector Switch
Lift Control Buttons

UPPER CONTROLS
Lift Control Buttons
Drive/Steer Functions
Drive Speed Selector Switch
Positraction Button
Slope Alarm
MANUAL 92357-002
JUNE 1997
• PREVENTIVE MAINTENANCE INSPECTION
50 HOUR INSPECTION
A. CHASSIS
Visual Inspection: Inspect for cracks in welds, dents or bends in material.
Steering Cylinder: Check cylinder, pins, and cotter pins holding cylinder in place
for proper installation.
Steering Connecting Arm: Check pins and retaining rings for proper installation. Ensure
that arm does not bind or contact chassis throughout range of
steering travel.
Steering Knuckles: Inspect thrust washer for wear, and make certain that both pivot
pin retainers are installed properly. Ensure there is no binding
through out range of travel.
Wheels: Check for loose or missing lug nuts, loose hub assemblies (fixed
axle), and damaged or cracked rims.
Drive Motors: Check motor hydraulic lines for leakage. Check wheel hub
retaining nut and cotter pin for proper installation.
Brake Cylinders: Check hydraulic lines for leakage. Check for proper brake
operation. Check for proper brake release lever operation.
Inspect cylinders and retaining bolts for damage and proper
installation.
Hydraulic Hoses
and Fittings: Inspect for leaks, cuts, and abrasions. Check fittings for tightness.
Tires: Inspect for excessive or abnormal wear, cuts and abrasions.
Belly Pan: Check belly pan to chassis weldment bolts for tightness and
proper installation. Check for security of components.
Battery Charger: Inspect for damage. Verify proper charging operation.
Wiring and Electrical

Connections: Inspect for damage, defective cables, fraying or cracked insula
tion, tightness ofterminal ends, loose connections, corrosion,
cracked or swelling cases, or covers, loose hold downs or
deformed terminal posts on batteries.
Electric Motor and Pump: Inpect motor and pump mounting hardware for tightness, cable
connections for tightness, corrosion, fraying, or damage.
MANUAL 92357"()()2
JUNE 1997
B. ARMSTACK
Lift Cylinder Hoses

and Fittings: Inspect for leaks, cuts, and abrasions. Check for tightness and
proper routing.
Electrical Cable: Inspect for fraying or cracked insulation. Check for proper
slack throughout range of movement.
Lift Cylinder: Inspect for damage to chrome on lift cylinder rod, damage
to cylinder body, and all welds for cracks. Inspect holding
valve bolts for tightness.
Lift Cylinder Pins and

Retaining Bolts: Inspect cylinder pins and retaining bolts for security.
Limit Switch: Inspect for damage to switch housing, or to arm lever. Inspect
for security of internal wiring, proper strain relief sealing, and
security of switch mounting.
UpperlLower Electrical
Junction: Remove terminal strip cover and inspect wiring for corrosion
and tightness. If rust or corrosion are present, clean with a
wire brush and coat terminal connections with a spray corro-
sion inhibiter or high temperature grease.
Armstack Bearing Pads

(chassis): Inspect for binding, cracking, pitting, or abnormal wear. Clean
any dirt or debris from pad slide area. If binding or chatter is
present during movement, lubricate sliding surfaces with anti-
sieze compound.
C. PLATFORM
Platform Pivot Shafts and

Retaining Bolts: Inspect security of retaining bolts and pin.
Platform Bearing Pads: Inspect for binding, cracking, pitting, or abnormal wear. Clean
any dirt or debris from pad slide area. If binding or chatter is
present during movement, lubricate sliding surfaces with anti-
sieze compound.
Platform Entrance Lift Gate

and Latch Assemblies: Inspect for damage. Ensure that gate slides (operates) freely
MANUAL 92357-002
JUNE 1997
.,
C. PLATFORM (cont'd)
Extension Deck and Latch

Assembly: Inspect for damage. Ensure that deck slides freely and latch
assembly functions properly.
Electrical Cable: Inspect for damage, fraying or cracked insulation, and proper
routing.
D. LOWER CONTROL BOX
Visual Inspection
External: Inspect for proper mounting, damage to enclosure or controls,

Ensure that enclosure lid seals watertight and that controls are
secure.
Internal: Inspect for tightness of terminal strip mounting, all wire ends,
and cable strain reliefs. Ensure that no corrosion is present and
that box drain holes are open.
Manual Tube Holder: Inspect for damage and security. Ensure that end caps provide
a watertight seal and that the operator's manual is inside.
E. UPPER CONTROL BOX
Visual Inspection
External: Inspect for proper operation of electrical cable quick discon-

nect plug. Inspect for damage to enclosure or controls. Ensure
that box fits snugly onto mounting posts and that controls are
secure.
Internal: Inspect for tightness of wire ends at all locations. Ensure that
enclosure lid seals water tight, and lid hinges are not damaged.
MANUAL 92357-002
JUNE 1997
PREVENTIVE MAINTENANCE
50 HOUR INSPECTION
MON TOES WED THURS FRI SAT SUN
ITEM I
CHASSIS
1:2::' /1/1/[7[71/V
HOURS
Visual Inspection
Steering Cylinder
Steering Connecting Arm
Steering Knuckles
Wheels
Drive Motors
Brake Cylinders
Hydraulic Hoses and Fittings
Tires
Belly Pan
Battery Charger
Wiring and Electrical Connections
Electric Motor and Pump
ARMSTACK
Visual Inspection
Lift Cylinder Hoses and Fitting
Electrical Cable
Lift Cylinder
Lift Cylinder Pins and Retaining Bolts
Limit Switch
UpperlLower Electrical Junction

Armstack Bearing Pads (chassis)
PLATFORM
Visual Inspection
MANUAL 92357-002
JUNE 1997
• PREVENTIVE MAINTENANCE
50 HOUR INSPECTION
(cont'd)
MON TUES WED THURS FRI SAT SUN
ITEM I
PLATFORM (cont'd)
Z / / / / / / //1
HOURS
Platfonn Pivot ShaftslRetaining Bolts
Platfonn Bearing Pads
Platfonn Entrance Lift GatelLatches
Extension Deck and Latch Assembly
Electrical Cable
Manual Storage Container
LOWER CONTROL BOX

Visual Inspection--Extemal
Visual Inspection--Intemal
Manual Tube Holder
UPPER CONTROL BOX

Visual Inspection--Extemal
,
Visual Inspection--Intemal
MANUAL 92357-002
JUNE 1997
HYDRAULIC FLUID SPECIFICATIONS
FOR
CONDOR® AERIAL WORK PLATFORMS
Shell Tellus - T32 Hydraulic Fluid
Viscosity
SUS@ 100°F 155
SUS@210°F 47
Viscosity Index 154
Flash Point OF 3250
Pour Point OF -540
COLD TEMPERATURE OPERATION
For continuous operation in sub-zero temperatures, a fluid change is required. One of the
following should be used:
A) Conoco DN-600 Antiwear Hydraulic Fluid

Manufacturer: Continental Oil Co., Houston, Texas
B) Sun Low Temperature No.3 Hydraulic Fluid

Manufacturer: Sunoco, Inc., Toronto, Ontario, M5S 2S4, Canada
C) Fluids Conforming to MIL-H-5606C Specifications.

Examples: Chevron Aviation Hydraulic Fluid-C
Shell L.O. Hydraulic #23
CAUTION
DO NOT MIX DIFFERENT FLUIDS
MANUAL 92357-002
1UNE1997
NOTES
MANUAL 923S7"()()2
JUNE 1997
115 VAC BATTERY CHARGER
TROUBLESHOOTING GUIDE
To be able to use the troubleshooting guide effectively, it is important to read this guide
completely before beginning any tests.
I CAUTION
_. REPAIRS BY QUALIFIED PERSONNEL ONLY. II
NOTE: Modifying this charger for use other than that for which it was intended, repairs by persons
not qualified, or not using original equipment replacement parts will void the warranty and Lester
liability. •
CAUTION
DO NOT DISASSEMBLE THE CHARGER. TAKE IT TO A
QUALIFIED SERVICEMAN WHEN SERVICE OR REPAIR IS
REQUIRED. Incorrect assembly may result in a risk of electric shock or fire.
SECTION 1 - CHARGER DOES NOT TURN ON
In normal operation the charger DC output must be connected to the batteries in order to tum the
charger on. A time delay of2 to 5 seconds is provided to allow adequate time to make a secure connection
before the charger turns on. After this time delay the power relay closes and an audible "click" should
be heard. When the relay closes, AC power is supplied to the transformer primary coil. If operating
properly, the transformer should hum and the ammeter should indicate the charge rate. If the charger
does not turn on properly, refer to Part A, B, or C for specific test procedures.
WARNING
Do not operate the charger if it is malfunctioning. Personal injury or
property damage could result.
MANUAL 92357-002
JUNE 1997
.,
PART A- RELAY DOES NOT CLOSE, NO TRANSFORMER HUM AND AMMETER
DOES NOT REGISTER.
Check to be sure the power supply cord is securely connected to a live outlet. Check the
DC output connector and the battery connector for damage, dirt or corrosion that would prevent a
good electrical connection.
WARNING
If the plug or receptacle is broken, twisted, bent or loose and does not make
good electrical contact, have it replaced by a qualified serviceman immediately.
DO NOT USE THE CHARGER IN THIS CONDITION AS FIRE OR
PERSONAL INJURY CAN RESULT.
Disconnect the power supply cord from its outlet. With the DC output connector still connected
to the battery connector, measure the voltage at the battery connector using a suitable DC voltmeter. The
voltage reading should be the same as the battery terminal voltage and must be between 24 and 50 volts
DC in order to close the relay. If the DC voltage is within the above limits, remove the charger cover and
verify that the charger is properly wired and you read the same voltage (24 to 50 volts DC) inside the
charger where the white and black wires ofthe DC cord attach. lethe battery DC voltage measured inside
the charger is now below the above limits or not present, the DC plug or cordset has an internal break and
must be replaced. Ifthe charger is wired correctly and a satisfactory battery DC voltage is measured inside
the charger, a malfunction in the Electronic Timer Kit has probably occurred. Due to its complexity, do
not attempt to make field repairs to any part of the Electronic Timer Kit. If a malfunction exists, simply
remove the entire Electronic Timer Kit and replace it with a new one. Refer to Part D - "Electronic Timer
Kit Replacement" - for correct procedure.
CAUTION
ALWAYS UNPLUG THE ELECTRICAL CORDS FROM THE AC
OUTLET AND THE BATTERIES BEFORE ATTEMPTING ANY
REPAIRS TO THE CHARGER.
The Electronic Timer Kit may be bypassed in order to verify that a malfunction exists. First
disconnect the charger power supply cord from its outlet and the DC output from the battery. Place a
jumper wire between terminals # 1 and #3 to bypass the Electronic Timer Kit.
The power supply cord is now connected directly to the primary transformer coil and the
transformer should hum when the power supply cord is connected to a live outlet. The charger operation
may be checked by first connecting the DC output connector to the battery connector, and then connecting
the power supply cord to an outlet. If normal charging current is indicated on the ammeter the Electronic
Timer Kit is defective and must be replaced.
MANUAL 92357'()()2
JUNE 1997
CAUTION
DO NOT charge batteries with the Electronic Timer Kit bypassed. The charger
will remain on as long as the power supply cord is connected to an outlet.
Severe overcharging and eventual damage to batteries will result.
If the transformer does not hum and the ammeter still does not register with the Electronic Timer
Kit by-passed, a continuity check of the charger AC circuit is necessary. Disconnect the power supply
from its outlet and the DC output connector from the battery connector and, with a suitable continuity
tester, check the circuit across the power supply cord prongs. With the Electronic Timer Kit bypassed, the
CIRCUIT SHOULD BE COMPLETE. If the circuit is not complete, individually check the continuity of
the power supply cord, primary transformer coil and all connections.
PART B-RELAY CLOSES BUT NO TRANSFORMER HUM AND AMMETER DOES NOT
REGISTER
Check to be sure the power supply cord is securely connected to a live AC outlet. When three-prong
to two-prong adapters are used, they tend to work loose resulting in a poor connection. Check the AC line fuse
or circuit breaker and, if possible, measure the AC line voltage at the outlet to be sure AC power is present.
If necessary, connect a functioning charger, utility light or other electrical appliance to the outlet to verify the
presence of AC power.
IfAC power is present, disconnect the power supply cord from its outlet and the DC output connector
from the battery connector. By-pass the Electronic Timer Kit as described in Section 1, Part A, and with a
suitable continuity tester check the circuit across the power supply cord prongs. With the Electronic Timer
Kit bypassed, the CIRCUIT SHOULD BE COMPLETE. Ifthe circuit is complete, refer to the wiring diagram
and check the relay wiring and all connections. Ifthe circuit is not complete, check the wiring of the power
supply cord, transformer primary coil leads and the Electronic Timer Kit. If the charger is wired correctly,
individually check the continuity ofthe power supply cord, transformer primary coil and relay.
PARTC-RELAY CLOSES AND TRANSFORMER HUMS BUT AMMETER DOES NOT REGIS-
TER
If the relay closes and the transformer hums, the charger AC circuit and Electronic Timer Kit are
functioning properly. Ifthe ammeter does not register, a fault in the charger DC circuit exists and a continuity
check must be performed. Disconnect the power supply cord from its outlet and the DC output connector from
the battery connector, and check the charger fuse. If a fuse link is blown, refer to Section 2 - "Charger Fuse
Blows" for further tests. Ifthe fuse checks good, use a low voltage continuity tester to perform the following
tests:
1. Connect the tester leads to the charger DC output connector and note the reading. Reverse the tester
leads and check the output connector again. The circuit should be complete in only one direction. Ifthe circuit
does not conduct in either direction and the fuse is good, individually check the continuity of the DC output
cord, ammeter, diodes and all connections. If the circuit conducts in both directions, a "short" exists in the
charger DC circuit. First check the DC output cord for a "short" between the two wires. It is more likely that
one or both diodes have "shorted." Refer to Section 2 - "Charger Fuse Blows" for continuity test of diodes.
MANUAL 92351-002
JUNE 1991
• 2. Ifthe charger DC circuittest is good, a check ofthe capacitor is necessary. Disconnect the power supply
cord from its outlet and the DC output connector from the battery connector. Then disconnect
both transfomter coil leads from the capacitor terminals. Use care when disconnecting the capacitor
leads so the wires do not break. Using an ohmmeter, set the scale to R X 10K ohms and test the capacitor as
follows:
DANGER
mGH VOLTAGE: With the charger operating, the charger capacitor voltage is
approximately 650 volts AC. Use extreme caution when working near the capacitor terminals
GOOD CAPACITOR-When the ohmmeter leads are connected to the capacitor terminals, the meter needle
jumps to mid-scale and rapidly moves to high resistance.
OPEN CAPACITOR- When the ohmmeter leads are connected to the capacitor terminals, the meter needle
does not move and stays at high resistance. A bulge in the top of the capacitor may be visible if the capacitor
has failed "Open."
SHORTED CAPACITOR - When the ohmmeter leads are connected to the capacitor terminals, the
meter needle jumps immediately to zero ohms and remains there.Ifthe capacitor is open or shorted, it
must be replaced.
CAUTION
Use only a 6 Mfd, 660 volt AC rated capacitor for replacement (Part No. 02390S).
The use of a different value capacitor may result in improper charging, capacitor
failure, transformer burnout and/or battery damage.
3. If the charger DC circuit and capacitor check good, a test ofthe transformer is necessary. Refer to
Section 7 - "Transformer Short or Burnout" or test procedures.
PART D - ELECTRONIC TIMER KIT REPLACEMENT
The Electronic Timer Kit should always be replaced as a complete assembly. The tools required
are: a Phillips head screwdriver, 3/S" and 11/32 " wrenches, and pliers. No soldering is required. To replace
the kit, follow the step-by-step procedures listed below.
1. Disconnect the charger power supply cord from its outlet and the DC output connector from the
battery connector and remove the charger cover.
2. Disconnect the green, black and red wires ofthe Electronic Timer Kit. Then remove the black and
white leads of the power supply cord and both primary transformer coil leads from the Electronic Timer
Kit terminal tabs. The Kit can be removed by removing the three mounting screws on the charger front
panel. Save all hardware for reassembly.
3. Install the replacement Electronic Timer Kit by reversing the disassembly procedures
described in Step 2. When reconnecting the wires to the Electronic Timer Kit terminal tabs, support the
terminal board to prevent damage to the electronic circuit board. Connect either transformer primary lead
to terminal #2 and the remaining primary I lead to terminal #3.
MANUAL 92357'()()2
JUNE 1997
Connect the black lead of the power supply cord to terminal # 1 on the Electronic Timer Kit
and the white lead ofthe power supply cord to terminal #2.
Connect the red wire of the Electronic Timer Kit along with the white lead of the DC cord to
the Heat Sink Assembly. Connect the black wire of the Electronic Timer Kit along with the black lead of
the DC cord to the ammeter post. Do not allow the ammeter post to turn when tightening the nut. Recon-
nect the green wire of the Electronic Timer Kit along with the transformer secondary lead to the diode
lead terminal.
CAUTION
Be sure all connections are clean and tight. Also check to be sure all wires
and terminals are positioned so they do not short together or to the charger case.
4. Replace the charger cover and check the Electronic Timer Kit for proper operation as follows:
A. With the DC output connector disconnected from the battery connector, insert the power
supply cord into an outlet. The relay on the Electronic Timer Kit should not close. A DC
voltmeter connected across the DC output connector should indicate zero volts.
B. Disconnect the power supply cord from its outlet and connect the DC output connector to the
battery connector. The relay on the Electronic Timer Kit should close with an audible "click"
after a two to five second delay.
C. If the Electronic Timer Kit does not operate as (a) and (b) above, refer to the wiring diagram
and check to be sure the charger is wired correctly. If the Electronic Timer Kit operates
properly, the charger is ready for use. Always monitor the first charge cycle to verify that
the charger is turning off properly.
DANGER
Lead acid batteries generate highly explosive hydrogen gas especially

during the charging cycle. To AVOID the possibility of an explosion,
charge batteries ONLY in a well VENTILATED AREA. Keep fire, sparks
and burning material away from the charging area. Do Not smoke near a
battery, and always shield the eyes when working near a battery.
SECTION 2 - CHARGER FUSE BLOWS
The charger fuse assembly consists of a dual element fuse link under a transparent cover mounted
on the charger front panel. Each fuse element is electrically connected in series with a rectifier diode to
.provide protection for the transformer in the event of a diode failure. Visually inspect and electrically
test the fuse to determine ifone or both fuse links are blown and refer to Part A or Part B for test procedures.
LOCATE AND CORRECT CAUSE OF TROUBLE BEFORE REPLACING BLOWN FUSE. DO
NOT attempt to repair the fuse link as inadequate protection will result.
MANUAL 92357-002
JUNE 1997
• PART A - SINGLE FUSE LINK BLOWS
This condition is normally caused by a short circuit failure of one diode. The fuse link will blow
when the charger DC output connector is connected to the battery connector, regardless of whether the
power supply cord is connected to an outlet. To check the diodes, disconnect the power supply cord from
its outlet and the DC output connector from the battery connector, and then disconnect one transformer
secondary coil lead from the diode terminal. Using a low voltage continuity tester, connect one tester lead
to the diode mounting plate and the other tester lead to a diode terminal.
Note the reading and then reverse the tester leads and check each diode again. Ifa diode conducts
current in both directions, it is "shorted" and the complete Heat Sink Assembly with Diodes (Part No.
09653S) must be replaced.
On rare occasions a single fuse link may melt due to excessive heat. This can be caused by a loose
internal fuse connection. Check all three fuse connections inside the charger to be sure they are clean and
tight. The proper torque on the fuse connector nuts is 20 Inch-Pounds (23 Cm-Kg).
PART B - BOTH FUSE LINKS BLOW
This is normally caused by a reverse polarity connection between the charger DC output
connector and the battery connector. Check the battery pack and battery connector to be sure they are
wired in the correct polarity. If possible, check the voltage and polarity at the battery connector with a
DC voltmeter. Also, check the charger DC output connector for the correct polarity. The white wire
should be connected to the positive (+) contact, and the black wire to the negative (-) contact. Ifa reverse
polarity connection is made between the charger and batteries, both fuse links will blow, regardless of
whether the power supply cord is connected to an outlet.
Another cause for both fuse links blowing is the short circuit failure of both diodes. Although this is rare,
it may occur as the result of a lightning strike at the charging location. Excessive heat due to a loose
connection may also cause both fuse links to melt. Refer to Part A - "Single Fuse Link Blows" for
troubleshooting procedures.
MANUAL 92357-002
JUNE 1997
SECTION 3 - AMMETER READS 30 AMPS FOR MORE THAN 30 MINUTES
This high output condition is caused by misuse, connecting the charger to an incorrect battery
•
system which is lower than 24 volts. A common error is to install one or more ofthe 6 volt batteries in
a 24 volt battery pack reverse polarity. Using a suitable DC voltmeter, test to be sure all batteries in a
battery pack are correctly wired and also test the battery pack voltage at the charging connector. After
charging for 30 minutes at this excessive rate, the measured on charge voltage should rise to 22 to 26 volts
DC for a 24 volt system. Voltage measurements, while charging, lower than this indicate an incorrect
or failed battery pack that must be corrected before using the charger.
CAUTION
DO NOT connect the charger to battery packs which are not 24 volt
systems. This misuse will cause overheating and transformer burnout
will result.
SECTION 4 - CHARGER OUTPUT IS LOW
The most probable cause of low output is a single fuse link blowing as the result of a short circuit
failure of one diode. Refer to Section 2 - "Charger Fuse Blows" for troubleshooting procedures. On rare
occasions a short circuit failure of the transformer coils may cause the output to be low. Refer to section
7 - "Transformer Short or Burn Out" for test procedures.
CAUTION
Do not use the charger if the output is low. Batteries will not reach
full charge, thereby increasing the possibility of a harmful deep
discharge during their next use.
SECTION 5 - CHARGER TURN OFF MALFUNCTIONS
The Electronic Timer Kit turns the charger off as well as on. Proper charge time is determined by
many factors, but the main elements are: (I) battery size, (2) depth of battery discharge and (3) finish
charge rate. Large severely discharged batteries require more time to reach full charge than do smaller
lightly discharged batteries.
The charge rate, as indicated by current flow in amperes on the panel meter, is controlled by the
batteries' rising voltage during charge. The higher the on charge voltage will rise, the lower the finish
charge will be before the Electronic Timer terminates charging.
The following timer malfunctions are occasionally due to factors other than the charger's
performance. To help isolate the problem, it is often necessary to use the charger on a different set of
batteries and the original set of batteries on another charger.
MANUAL 92357-002
JUNE 1997
• PART A - CHARGER TURNS OFF TOO SOON
Check to be sure the power supply cord is securely connected to a live outlet. If the power supply
outlet is live, proceed with the next step.
To detennine if the charger did shut off too soon, disconnect and reconnect the charger DC output
connector. This will restart the charger. Observe charger output on the ammeter.
1. The ammeter needle jumps smartly to between 20 and 25 amps and then tapers below 14 amps
within 15 minutes. This indicates that the batteries were truly charged. The apparent short charging time
is in response to the batteries' ability to accept charge and the electronic timer is perfonning properly.
2. The ammeter needle jumps smartly to between 20 and 25 amps, but does not taper below 14 amps
within 15 minutes. If the batteries have been properly maintained and charged regularly, this generally
indicates that the batteries were not fully charged. If possible, use a hydrometer to check the specific
gravity of several battery cells. If the specific gravity readings are more than 30 points (.030) lower than
nonnal full charge readings, the electronic timer has malfunctioned and the complete Electronic Timer
Kit must be replaced. Refer to Section 1, Part D - "Electronic Timer Kit Replacement" for correct
procedures.
If the batteries have not been used or charged regularly, they may be sulfated and will not produce
their full capacity. Repeated cycles (at least 5) ofa light discharge followed by a full charge will generally
result in the recovery of most of the battery's capacity. Do not interpret this reduced battery capacity as
being caused by the charger turning offtoo soon. The charger is working properly if, after several charge
cycles, the battery capacity increases to near nonnal. Sulfation occurs most often when the batteries have
been stored without weekly charging. New batteries may also be sulfated due to extended shipment or
storage time prior to sale.
As batteries age, individual cells may weaken, causing a reduction in battery capacity. This
condition nonnally results in a finish charge higher than 10 Amps and less time is required to fully charge
the batteries. Do not interput this shorter charging time and reduced battery capacity as being caused by
the charger turning offtoo soon. The battery is aging naturally and the charger is working properly. When
the batteries will no longer perfonn as required, they should be replaced.
PART B - CHARGER DOES NOT TURN OFF
New batteries with all good cells should rise to at least 2.5 volts per cell. This will allow the finish
charge rate to taper below 8 amperes. As batteries age, individual cells may weaken and these cells may
not reach 2.5 volts. This will result in finish charge rates greater than 8 amperes, and less time will be
required for the batteries to reach full charge. At a finish charge rate of 8 amperes or less the charge time
should not exceed 18 hours. At a finish charge rate greater than 8 amperes the charge time should not
exceed 14 hours.
Ifthe charger remains on longer than the specified maximum time, check to see ifthe charger turns
on immediately when the DC output cord is connected without the nonnal two to five second delay. If
the charger turns on instantly without the two to five second delay the Electronic Timer Kit has probably
failed. This type of malfunction generally results in the charger not turning off and the complete
Electronic Timer Kit must be replaced. Refer to Section 1, Part D - "Electronic Timer Kit Replaceme~t"
for correct procedures.
MANUAL 92357-002
JUNE 1997
Ifthe charger remains on longer than the maximum time specified and the two to five second delay
is present, verify thatthe green wire from the Electronic Timer Kit and the secondary transformer coil lead
are securely connected to the diode lead as shown. The charger will NOT tum offifthe green wire is loose
or disconnected. If the green wire is securely connected, the Electronic Timer has malfunctioned and the
•
complete Electronic Timer Kit must be replaced.
If a precision digital type DC voltmeter is available, a test to verify that the Electronic Timer has
malfunctioned can be made. Connect the charger to the batteries and allow to charge normally. Afterthe
charge rate has tapered to its lowest point, measure the battery terminal voltage using a DC voltmeter
capable of reading in increments of .00 1 volts. Continue charging and check the battery voltage reading
every hour. Ifthe battery voltage increases less than .012 volts, or ifthe battery voltage decreases between
successive hourly readings, the charger should turn off. If the charger does not tum off, the Electronic
Timer has malfunctioned and the complete Electronic Timer Kit must be replaced.
PART C - CHARGER RUNS TOO LONG BUT DOES TURN OFF
In the event ofAC power interruption when the charger is on, the charger will automatically restart
when AC power is restored. This power outage can make the apparent charge time seem longer than the
actual charge time. To check for AC power interruptions, plug an electric clock into the same outlet to
which the AC cord is connected. Charge normally and note any time difference between the test clock
time and the actual time.
SECTION 6 - AC LINE FUSE OR CIRCUIT BREAKER BLOWS
Ifthis occurs when the charger power supply cord is connected to an outlet, without the DC output
connector connected to the battery connector, the charger power supply cord may be shorted. Disconnect
the power supply cord from its outlet and the DC output connector from the battery connector, then check
to be sure the Electronic Timer Kit is NOT bypassed. With a suitable continuity tester, check the circuit
across the power supply cord prongs as shown. THE CIRCUIT SHOULD NOT BE COMPLETE. Ifthe
circuit is complete, check the relay contacts to be sure they are open and have not welded closed. If the
relay contacts are open, the power supply cord is shorted and must be replaced. Ifthe power supply checks
good, the transformer coils may be shorted. Refer to Section 7 - "Transformer Short or Burnout" for test
procedures.
SECTION 7 - TRANSFORMER SHORT OR BURNOUT
Failure of the transformer can be the result of natural aging, premature shorting of adjacent coil
turns or overheating damage. The most common cause oftransformer overheating and premature burnout
is the result of misuse, connecting the charger to a battery system of lower voltage than specified on the
charger (See Section 3). Darkening of all the transformer secondary coil windings is an indication of
possible overheating damage. A low or complete lack of output would be observed on the ammeter,
however, the transformer may hum or the AC line fuse or circuit breaker may blow when the charger is
turned on. To test the transformer, disconnect the power supply cored from its outlet and the DC output
connector from the battery connector. Then disconnect the transformer secondary coil leads # 1 and #4
from the diode terminals and disconnect the transformer capacitor coil leads from the capacitorterminals.
Use care when disconnecting the capacitor lead so the wires do not break.
MANUAL 92357-002
JUNE 1997
DANGER
mGH VOLTAGE: With the charger operating, the charger capacitor voltage is
approximately 650 volts AC. Use extreme caution when working near the capacitor
terminals.
In order to apply AC power directly to the transformer primary coil, the Electronic Timer Kit must
be bypassed. Refer to Section I, Part A for by-pass procedures. With the Electronic Timer Kit bypassed
take caution in connecting the power supply cord to an outlet. Ifthe AC line fuse or circuit breaker blows,
the transformer is shorted internally and must be replaced. If this does not occur, check the transformer
secondary and capacitor coil voltages as shown in Figure 6, using a suitable AC voltmeter. Ifthe measured
voltages are substantially lower than those shown, the transformer is shorted internally and must be
replaced.
If the transformer secondary coil voltage and capacitor coil voltage check good, disconnect the
power supply cord from its outlet. Check the capacitor to be sure its rating is 6 Mfd. 660 volts AC, and
then carefully reconnect the capacitor coil leads to the capacitor terminals. Then, take caution when
reconnecting the power supply cord to an outlet and measure the transformer secondary voltage again.
The correct voltage reading is shown in Figure 7. Ifthe transformer secondary voltage reading is the same
as measured with the capacitor disconnected, from Figure 6, the capacitor may be open, the capacitor coil
may be open or the capacitor coil terminals may not be making proper electrical contact. Refer to Section
I, Part C, Item 2 for capacitor test procedures. Ifthe voltage readings are correct, both the transformer
and capacitor are good, refer to Section 1, Part C, Item 1 for further tests ofthe DC circuit.
If it should become necessary to replace a terminal on one of the transformer leads, the new
terminal must be crimped AND soldered. NOTE: Some transformer leads may be aluminum wire and
a solder must be used on these wires that is intended for use on aluminum, such as Alcoa #807 solder with
Alcoa #69 flux. If these materials are not available locally, contact the Lester factory.
MANUAL 92357-002
JUNE 1997
APPENDIX A
BOLT TORQUE CHART

BASIC STRESS TENSILE STRENGTH (T) MIN
MAJOR AREA PROOF LOAD (P) SAE GRADE 5 SAE GRADE 8
NOMINAL DlA ~.IN SAEGRAJ E(1957)
TIlREADS INCH GRADES GRADES CLAMP ASSEMBLY TORQUE CLAMP ASSEMBLYTOROUE
T P T P LOAD R=.200DRY -. 150 LUB LOAD R~.200DRY =.I50LUB
LBS. LBS.
4-4U .1120 .00604 I20KSl 8SKSl ISOKSl I20KSI 380 8LB-1N 6LB-1N S40 12LB-1N 9LB·1N
....... G .1120 .00661 120KSI 8SKSI 150KSI 120KSI 420 9LB-1N 7LB-1N 600 13LB-1N 10LB-1N
b-J1. .1380 .00909 120KSI 8SKSI ISOKSI 120KSI 580 16LB-1N 12LB·1N 820 23LB·1N I7LB·1N
b-4U .1380 .01015 120KSI 8SKSI ISOKSI 120KSl 640 18LB-1N 13LB·1N 920 2SLB·1N 19LB-1N
8-32 .1640 .01400 120KSI 8SKSI IS0KSI 120KSI 900 3OLB·1N 22LB-1N 1260 41LB·1N 31LB-1N
G-.)O .1640 .01474 I20KSI 8SKSI 1SOKSI 120KSl 940 31LB-1N 23LB·1N 1320 43LB-1N 32LB-1N
IU-1.4 .1900 .01750 120KSI aSKSI I50KSI 120KSI 1120 43LB-1N 32LB·1N 1580 6OLB·1N 4SLB-1N
IU-J1. .1900 .0200 120KSI 8SKSI I50KSI 120KSI 1285 49LB·1N 36LB-1N 1800 68LB·1N SILB-IN
114-1.U .2500 .03180 120KSI 8SKSI I50KSI 120KSI 2020 SLB·FT 7SLB-1N 2860 12LB-FT 9LB-FT
114-1.1S .2500 .03640 120KSI 8SKSI IsOKSI 120KSI 2320 IOLB-FT 86LB-1N 3280 14LB-FT 10LB·FT
'lib-lIS .3125 .05240 120KSI 8SKSI 150KSI 120KSI 3340 17LB-FT 13LB-FT 4720 2SLB-FT 18LB·FT
'1Jb-1.4 .3125 .05800 120KSI 85KSI I50KSI 120KSI 3700 19LB-FT 14LB-FT 5220 2sLB-FT lOLB·FT
JIIHb .3750 .07750 120KSI 8SKSI ISOKSI 120KSI 4940 lOLB-FT 23LB-FT 7000 45LB-FT 35LB-FT
3/11-1.4 .3750 .08780 I20KSI 8SKSI 150KSI 120KSI 5600 3sLB-FT 2SLB-FT 7900 sOLB-FT 35LB-FT
1111-14 .4375 .10630 120KSI 85KSI 150KSI 120KSI 6800 SOLB-FT 3sLB-FT 9550 7OLB-FT 55LB-FT
7Il6-20 ,4375 .11670 120KSI 8sKSI 150KSI I20KSI 7550 SSLB-FT 4OLB-FT 10700 80LB-FT 6OLB-FT
ll2,"!3 .5000 .14190 12OKS1 8SKSI I50KSI 120KSI 9OSO 75LB-FT SSLB-FT 12750 1I0LB-FT 8OLB-FT
112-20 .5000 .15990 120KSI 8SKSI 150KSI 120KSI 10700 9OLB-FT 6SLB-FT 14400 120LB-FT 9OLB-FT
9116-12 .5625 .18200 I20KSI 85KSI ISOKSI 120KSI 11600 1I0LB-FT 8OLB-FT 16400 ISOLB-FT 1I0LB-FT
911b-18 .5625 .20300 120KSI 8sKSI IsOKSI 120KSI 12950 120LB-FT 9OLB-FT 18250 17OLB-FT 130LB-FT
;)/IS-U .6250 .22600 120KSI 85KSI Is0KSI 120KSI 14400 150LB-FT \I0LB-FT 20350 22OLB-FT 17OLB-FT
:5/8-18 .6250 .25600 120KSI asKSI IsOKSI 120KSI 16950 180LB-FT \30LB-FT 23000 240LB-FT I80LB-FT
3/4-lU .7500 .33400 120KSI 8sKSI 1SOKSI 120KSI 21300 260LB-FT 2OOLB-FT 30100 38OLB-FT 28OLB-FT
3f4-1b .1500 .37300 120KSI 8SKSI 150KSI 120KSI 23800 300LB-FT 22OLB-FT 33600 420LB-FT 32OLB-FT
7/8-9 .8750 .46200 120KSI 8SKSI Is0KSI 120KSI 29500 S20LB-FT 39OLB-FT 41600 600LB-FT 460LB-FT
7/8-14 .8150 .S0900 120KSI 8SKSI 150KSI 120KSI 32400 S70LB-FT 43OLB-FT 45800 66OLB-FT 500LB-FT
-IS 1.000 .60600 120KSI 85KSI 150KSI 120KSI 38600 77OLB-FT 5SOLB-FT S4500 9OOLB-FT 68OLB-FT
1-12 1.000 .66300 120KSI 85KSI 150KSI 120KSI 42300 850LB-FT 630LB-FT 59700 lOOOLB-FT 74OLB-FT
1118-7 1.1250 .16300 IOSKSI 14KSI 150KSI 120KSI 42300 8OOLB-FT 600LB-FT 68100 128OLB-FT 960LB-FT
1 1I1S-11. 1.1250 .85600 10sKSI 14KSI 150KSI 120KSI 47500 880LB-FT 66OLB-FT 77000 144OLB-FT 1080LB-FT
11/4-7 1.2500 .96900 10SKSI 74KSI I50KSI 120KSI 53800 112OLB-FT 840LB-FT 87200 1820LB-FT 1360LB-FT
11/4-12 1.2500 1.0730 10SKSI 74KSI 150KSI 120KSI 59600 1248LB-FT 920LB-FT 96600 2000LB-FT OOLB-FT
1 3/1S-() 1.3750 1.1550 105KSI 74KSI lSOKSI 120KSI 64100 1468LB-FT llooLB-FT 104000 23SOLB-FT 80LB-FT
13/8-12 1.3750 1.3150 IOSKSI 74KSI ISOKSI 120KSI 13000 1680LB-FT 1260LB-FT 118400 2720LB-FT 2040LB-FT
1 IIJ.-() 1.5000 1.4050 IOSKSI 74KSI I50KSI 120KSI 78000 194OLB-FT 146OLB-FT 126500 316OLB-FT 2360LB-FT
1112-12 1.5000 1.5800 105KSI 74KSI 150KSI I20KSI 87700 22OOLB-FT I64OLB-FT 142200 3S6OLB-FT 2660LB-FT
NOTES:
1. THIS CHART SHOWS RECOMMENDED BOLT TORQUES.
2. TORQUE = R X D X T
R = .150 FOR LUB CONDITIONS
R = .200 FOR DRY CONDITIONS
TO ASSURE CONSISTENCY IN TORQUE, LUBRICATE FASTENERS WITH ENGINE OIL
(MAY BE USED OIL)
D = NOMINAL DIAMETER IN INCHES
T = DESIRED CLAMP LOAD IN POUNDS = 75% PROOFLOAD X STRESS AREA
MANUAL 92357-002
JUNE 1997
APPENDIX B
TIME CONDOR Coproration
BOLT TORQUE CHART
FOR METRIC HEX HEAD CAP SCREWS
- RECOMMENDED ASSEMBLY TORQUES IN FOOT-POUNDS

(*VALUES IN LB-IN, OTHERS ARE LB-FT.)
-THE TORQUE VALUES FOR EACH DIAMETER ARE ACCEPTABLE

FOR ANY THREAD PITCH IN THAT DIAMETER.
PROPERTY CLASS 8.8 PROPERTY CLASS 9.8 PROPERTY CLASS 10.9 PROPERTY CLASS 12.9
DIAMETER DRY LUBRICATED DRY LUBRICATED DRY LUBRICATED DRY LUBRICATED
tHREADS tHREADS tHREADS tHREADS tHREADS tHREADS lHREADS tHREADS
M4 27.5* 17* 30* 18* 38.5* 24* 53* 32.5*
M5 56.5* 33.5* 61* 37* 78* 47* 107* 65*
M6 95* 57.5* 103* 61* 132* 79* 180* 109*
M8 19 12 21 13 27 16 37 22
MIO 39 23 42 25 53 32 73 44
MI2 67 40 73 44 92 55 127 76
MI4 107 64 116 69 146 89 203 122
MI6 167 100 181 108 230 138 316 190
M20 325 195 352 211 449 269 617 370
M24 562 337 609 386 775 465 1066 640
M30 1117 670 1210 726 1540 924 2188 1271
MANUAL 92357-002
JUNE 1997
•
MANUAL 92357-002
JUNE 1997
ATTENTION
MANUAL OF RESPONSIBILITIES
for
Dealers, Owners, Users, Operators,
Lessors, Lessees and Brokers
of
ANSI/SIA A92.6-2006
Self-Propelled Elevating Work Platforms
WARNING
FAILURE TO COMPLY with your REQUIRED '
RESPONSmILITIES in the use and operation of the Aerial
Platform could result in DEATH OR SERIOUS INJURY.
IMPORTANT
You are required by ANSIISIA A92.6-2006 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 parts of
the Aerial Platfonn and are VITAL TO COMMUNICATE NECESSARY SAFETY
INFORMATION to users and operators. They MUST BE KEPT ON THE AERIAL PLATFORM
in the storage compartment.
The operation of any aerial platfonn is subject to certain HAZARDS that can be protected against
only by the exercise of INTELLIGENCE, CARE, AND COMMON SENSE. It is essential to
have COMPETENT, CAREFUL PERSONNEL, TRAINED in the INTENDED USE, SAFE
OPERATION, MAINTENANCE AND SERVICE ofthis type of equipment.
The USER and OPERATOR MUST MAKE DECISIONS )llalnt1enal.llcle, use and operation
of the Aerial Platfonn with due SAFETY OF THE
OPERATOR AND OTHER
COMPLY with your REQUIRED and operation of the Aerial
Platfonn could result in DEATH OR
Refer to the manufacturer's n",>r.,,",nn aerial

platfonn and
The Self-Propelled
Manual incorporates "p",,,nn
Definitions
Responsibilities of Dealers Page 2
Responsibilities of Owners Page 4
Responsibilities of Users Page 6
Responsibilities Page 10
Section 9 Page 13
Section 10 Page 13
Section 11 Page 13
Figure 1 Page 14
Single copy list price $4.95
Published by
Scaffold Industry Association, Inc.
Post Office Box 20574
Phoenix, AZ 85036-0574
Telephone: (602) 257-1144 / Fax: (602) 257-1166
e-mail: sia@scaffold.org / 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
RESPONSIBILITIES MANUAL Reprint from ANSI/SIA A92.6 2006
13. DEFINITIONS I Insulated platform. A platform designed and tested to meet the
specific electrical insulation ratings consistent with the
manufacturer's identification plate.
Aerial platform. A mobile device that has an adjustable position
platform, supported from ground level by a structure. Interlock. A control or mechanism that, under specified
Anchorage(s). A secure point of attachment to be used with conditions, automatically allows or prevents the operation of
personal fall protection equipment (PFPE). another control or mechanism.
Authorized personnel (authorized person). Personnel Lessee. A person(s) or entity to whom an aerial platform is
approved or assigned to perform a specific type of duty or duties provided by lease, rental, loan, or other arrangement. A lessee
at a specific location or locations at a work site. may also be a dealer, owner, user or operator.
Base. The relevant contact points of the aerial platform that form Lessor. A person(s) or entity who leases, rents, loans, or
the stability fulcrum (e.g. wheels, casters, outriggers, stabilizers). otherwise provides an aerial platform to another party for the
Broker. An independent business entity or person that arranges a beneficial use of that party (the user). A lessor may also be a
lease or transfer of ownership of an aerial platform, but does not dealer, owner, lessee, user, or operator.
own the aerial platform. If the entity or person is an employee of Maintenance. The act of upkeep such as inspection, lubrication,
the buyer, seller, lessor or lessee of the aerial platform, he shall adjustment and scheduled partes)
not be considered a broker.
Chassis. The integral part of the aerial platform that provides A document containing the
mobility and support for the elevating assembly. 3) and the requirements mandated in this
Configuration. All positions in which an aerial nht-fnll't'nd the following entities: Dealers (Section 5); Owners
part thereof can be placed within its intended operating 6); Users (Section 7); (Section 8); Lessors
Critical component(s). Load supporting elements which (Section ll).
or stabilize the platform or aerial platform. makes, builds, or
Dealer. A person or entity
distributor and who !o;"'l.''''lC:l.U aximUlm platform height or the
platforms.
Delivery. Transfer of care, custody of the aerial
platform from one person or entity to another person or entity. To make a change(s) to an aerial
Directional controls. Controls that initiate functions that affects the operation, stability, safety factors, rated
movement of the platform or the aerial platform. or safety of the aerial platform in any way.
Ductile materials. Materials having a mlllll1I\un Most adverse stability condition(s). The permitted
10% in 2 inches (50.8mm). configuration of the aerial platform most likely to cause
Elevating assembly. The instability while maintaining stability. Factors to be considered
platform relative to the aerial shall include:
Familiarization. Providing the control (I) With zero load to maximum test load.
functions and safety devices for aerial platform(s) to a (2) Up to arid including maximum platform height.
qualified person or operator who controls the movement of the (3) All positions and configurations of the platform(s).
aerial platform(s) being delivered. (4) All wheel and axle positions.
Guardrail system. A vertical barrier primarily intended to (5) Forward and backward configurations of the elevating
protect against personnel falling to lower levels. assembly:
Hazardous location. Any location that contains, or has the (6) All other moveable features which affect the stability of the
potential to contain, an explosive or flammable atmosphere as aerial platform.
defined in ANSIINFPA 505 - 1996, Powered Industrial Trucks. Multiple ratiog(s), multiple rated loads. Two or more different
Instability. A condition of an aerial platform in which the sum rated work loads based on alternative configurations of the aerial
of the moments that tend to overturn the unit exceeds the sum of platform.
the moments tending to resist overturning. Operation. Performance of functions of an aerial platform
within the scope of its specifications and in accordance with the
manufacturer's instructions, the user's work rules, and applicable
governmental regulations.
1
RESPONsmILITIES MANUAL Reprint from ANSIISIA A92.6 2006
Operator. A qualified person who controls the movement of an Stability/Stable. A condition of an aerial platform in which the
aerial platform. sum of the moments that tend to overturn the unit is less than or
Outriggers. Devices that increase the stability of the aerial equal to the sum of the moments tending to resist overturning.
platform and that are capable of lifting and leveling the aerial Stabilizers. Devices that increase the stability of the aerial
platform. platform but are not capable of lifting or leveling the aerial
Override. To take over aerial platform movement control platform.
functions at the upper control station by those at the lower control Training. Instruction to enable the trainee to become a qualified
station. person regarding the task to be performed, including knowledge
Owner. A person or entity who has possession of an aerial regarding potential hazards.
platform by virtue of proof of purchase. Unintended motion. Motion of the aerial platform or platform
Passive. Under specified conditions, automatically performed without activation of any control.
and not requiring any specific action to accomplish. Unrestricted rated workload. The maximum designed carrying
Platform. The portion of an aerial platform intended to be capacity of the aerial platform allowed by the manufacturer in all
occupied by personnel with their necessary tools and materials. operating configurations.
Platform height. The vertical distance measured from the floor User. A or entity who has care, control and custody of
of the platform to the surface upon which the machine is being the aerial This person or entity may also be the
supported. a dealer, owner, lessor, lessee, or
Powered functions. Those which control motion of the platform
or the aerial platform and are caused by eleCtfC)-IIleCinall
hydraulic or pneumatic forces. v1wmtacture:r's operating, maintenance, repair and parts
Qualified person. One who, by possession of a recognized A92.6 2006
certificate, or professional standing, or by
training, and experience, has aerial platform
ability to solve or resolve
work, or the project.
Rated horizontal force.
force at the top rail which can be
specified by the manufacturer.
Rated work load. The designed carrying capacity of the
platform as specified by the manufacturer.
Rebuild/recondition. The Basic principles. Sound principles of safety, training,
adjustment of an aerial inspection, maintenance, application, and operation consistent
replacement parts and with all data available regarding the parameters of intended use
beyond the scope of U"UHO."UUU~ and expected environment shall be applied in the training of
standard) in order to restore, to operators, in maintenance, application, safety provisions and
platform or component to manufactured operation of the aerial platform with due consideration of the
specifications. knowledge that the aerial platform will be carrying personnel.
Remanufacture. The modification of an aerial platform, either 5.2 Manuals.
by the original manufacturer or another qualified entity, so that 5.2.1 Machine manual(s). Dealers shall keep and maintain a
the aerial platform will comply with the ANSI Standard in effect copy(ies) of the :
on the date the modification is completed. (1 ) Operating manual
Repair. The act of restoring to good condition that which has (2) Maintenance manual
been broken, damaged or worn due to use, abuse or other (3) Parts manual
reasons. (4) Repair manual
Shall. The word "shall" is to be understood as being mandatory. The operating manual and maintenance manual shall be provided
Should. The word "should" indicates that the rule is a with each rental, lease or sale delivery and shall be stored in the
recommendation, the advisability of which depends on the facts weather resistant storage compartment on the aerial platform.
in each situation. Manual(s) are considered an integral part of the aerial platform
and are vital to communicate necessary safety information to
2
RESPONSIBILITIES MANUAL Reprint from ANSIISIA A92.6 2006
owners, users and operators. In addition, repair and parts (1) identify the weather resistant compartment (for manual
manuals should be provided with each sale delivery. storage).
5.2.2 Manual of Responsibilities. The current Manual of (2) confinn the manuals, as specified by the manufacturer, are on
Responsibilities for Dealers, Owners, Users, Operators, Lessors, the aerial platfonn.
Lessees, and Brokers of Self-Propelled Elevating Work Platfonns (3) review control functions
shall be provided and stored in the weather resistant storage (4) review safety devices specific to the model aerial platfonn
compartment. being delivered.
5.3 Pre-delivery preparation. Aerial platfonns shall be 5.9 Dealer as user. Whenever a dealer directs personnel to
inspected, serviced and adjusted to the manufacturer's operate an aerial platfonn (loading, unloading, inspecting, sales
requirements prior to each delivery by sale, lease or rental. demonstrations, or any fonn of use), the dealer shall assume the
5.4 Maintenance, inspection and repair. responsibilities of users as specified in Section 7 of this standard.
5.4.1 Maintenance. When a dealer accomplishes preventative All personnel authorized to operate the aerial platfonn shall have
maintenance on the aerial platfonn, it shall be in accordance with been:
the manufacturer's (remanufacturer's) recommendations, the (1 ) Trained.
environment, and severity of use. (2) Familiarized with the aerial platfonn to be operated.
5.4.2 Inspection. When the dealer accomplishes frequent and (3) of the responsibilities of operators as outlined in
annual inspections, they shall be accomplished in accordance Standard.
with the manufacturer's (remanufacturer's) manuals. owners and users. If a dealer is unable to
5.4.3 Repairs. Repairs accomplished to correct J.ua"LJ.UJ.l~" or user's question(s} relating to rated capacity,
and problems shall be in accordance with the J.u..J.J. ...,,,."l maintenance, repair, inspection, or operation of the
(remanufacturer's) manuals and instructions. platfonn, the dealer shall the proper infonnation
5.5 Maintenance safety precautions. if the manufacturer
repairs are started on an aerial infonnation to the
shall be taken as applicable:
(1) Power plant stopped rendered
inoperative;
(2) All controls in the "Off' years:
secured from inadvertent motion by brakes, blocks, or address of the purchaser of each aerial platfonn
means;
(3) Elevating assembly and platfonn lowered to Records of the predelivery preparation perfonned prior to
each delivery.
cribbing to prevent (3) Records of frequent and annual machine inspections
(4) Hydraulic oil pressure accomplished.
before loosening or rp.n1I"lV"111 (4) Records of repairs accomplished to correct malfunctions and
(2) Safety props or latches problems.
prescribed by the manufacturer. (5) Name of the person(s} trained.
5.6 Replacement parts. When parts or components are (6) Name of the person(s) providing the training.
replaced, they shall be identical or equivalent to original aerial (7) Date of training.
platfonn parts or components. (8) Name of person(s) receiving familiarization with the aerial
5.7 Training. The dealer shall offer appropriate training to platfonn upon each delivery unless this individual has been
facilitate owners, users, and operators to comply with provided with familiarization on the same model, or one
requirements set forth in this standard regarding the inspection, having characteristics consistent with the one being
maintenance, use, application, and operation of the aerial delivered, within the prior 90 days.
platfonn. (9) Name of person(s) providing familiarization with the aerial
5.8 Familiarization on delivery. Upon delivery by sale, platfonn upon each delivery.
lease, rental or any fonn of use, the dealer shall have the 5.11.2 Proof of training. The dealllr should provide trainees
responsibility with the person designated by the receiving entity who successfully complete training a means to evidence they are
for accepting the aerial platfonn to: trained. The dealer shall provide such proof if requested by the
3
trainee. The document evidencing training shall include the 16. RESPONSmILITIES OF OWNERS.
following information:
(1) Name of trainee
6.1 Basic principles. Sound principles of safety, training,
(2) Name of entity providing training or retraining.
inspection, maintenance, application, and operation consistent
(3) Name oftrainer(s).
with all data available regarding the parameters of intended use
(4) Clear identification that training covered Self-Propelled
and expected environment shall be applied in the performance of
Elevating Work Platforms.
the responsibilities of owners with due consideration of the
(5) Date of training.
knowledge that the aerial platform will be carrying personnel.
5.11.3 Record dissemination. Upon request, the dealer shall 6.2 Responsibilities upon purchase. Upon purchase of the
provide the following information: aerial platform, the buyer:
(1) Shall ensure the operating and maintenance manuals have
(1) To the owner of the aerial platform, a copy of frequent or
been received.
annual inspections performed. (2) Should acquire repair and parts manuals within sixty days
(2) To the owner of the aerial platform, a copy of repairs (60) of acquisition.
accomplished. (3) Shall within sixty days (60) of acquisition of the aerial
platform provide the manufacturer (remanufacturer), or its
(3) To a user, proof of training for an operator, including name existing) with the full name and address of the
of trainer and date of training. buyer the model and serial number of the aerial
(4) To a user, the name of the person(s) receiving familiarization
1'1"'UV'HHis used, ensure that frequent and
upon delivery of the aerial platform. are current.
5.12 Modifications. Modification, alteration or reIlnaIJlut~lCt\ familiar with and conform with the
of an aerial platform shall be made only with prior as set forth in the Manual of
Elevating Work
permission of the manufacturer. Should the
manufacturer no longer exist, a qualified
such modifications. All modltllcatl a copy(ies) of
manufacturer's requirements with each rental, lease,
(Responsibilities of maillutactur,ers they are properly stored in the
5.13 Manufacturer's that is a part of the aerial platform.
The dealer shall comply with safety COIISl(len:<1 an integral part of the aerial platform
from the manufacturer (remanufacturer). communicate necessary safety information to
5.14 Responsibilities upon sale. When the aerial users and operators, In addition, repair and parts
sold, the dealer: manuals should be provided with each sale delivery.
(1) Shall, upon delivery, ensure the 6.3.2 Manual of Responsibilities. The current Manual of
manuals are conveyed to the Responsibilities for Dealers, Owners, Users, Operators, Lessors,
(2) Shall, upon delivery, provide Lessees, and Brokers of Self-Propelled Elevating Work Platforms
Responsibilities for Dealers, shall be provided and stored in the weather resistant storage
Lessors, Lessees and Brokers compartment.
Work Platforms. 6.4 Maintenance, inspection and repair.
(3) Should, within 60 days of sale, provide repair and parts 6.4.1 Maintenance. The owner of an aerial platform shall
manuals. arrange that the maintenance specified in this standard is properly
(4) Shall, within 60 days of the sale, notify the manufacturer performed on a timely basis. The owner shall establish a
(remanufacturer) or its successor (if existing) of the sale, preventive maintenance program in accordance with the
providing the full name and address of the purchaser. manufacturer's (remanufacturer's) recommendations and taking
(5) Should, if the aerial platform is used, accomplish an annual into account the environment of the work place and severity of
machine inspection prior to delivery and provide a copy to use of the aerial platform.
the purchaser within 60 days of the sale. 6.4.2 Inspection. The owner shall arrange for frequent and
(6) Shall, upon delivery, familiarize the person designated by the annual inspections to be performed in accordance with the
receiving entity with the aerial platform being acquired. recommendations of the manufacturer (remanufacturer). All
malfunctions and problems identified in the inspection shall be
corrected before the aerial platform is returned to service.
4
6.4.3 Repairs. When the aerial platform is damaged or in need manufacturer (remanufacturer) for an annual inspection. The
of repair, all malfunctions and problems identified shall be owner shall not place the aerial platform into service until all
corrected before the aerial platform is returned to service. malfunctions and problems have been corrected.
6.5 Predelivery preparation. Aerial platforms shall be 6.8 Maintenance safety precautions. Before adjustments and
inspected, serviced, and adjusted in accordance with the repairs are started on an aerial platform, the following precautions
manufacturer's (remanufacturer's) requirements prior to each shall be taken as applicable:
delivery by sale, lease or rental. (1) Power plant stopped and starting means rendered
6.6 Frequent inspection. The owner of an aerial platform shall inoperative;
ensure that a frequent inspection is performed in accordance with (2) All controls in the "off position and all operating systems
the manufacture's (remanufacturer's) instructions, for the aerial secured from inadvertent motion by brakes, blocks, or other
platform: means;
(1) That was purchased used. This inspection shall be (3) Elevating assembly and platform lowered to the full down
accomplished unless it is determined that the frequent and position, if possible, or otherwise secured by blocking or
annual inspections are current; cribbing to prevent dropping;
(2) That has been in service for three (3) months or 150 hours, (4) oil pressure relieved from all hydraulic circuits
whichever comes first; or removing hydraulic components;
(3) That has been out of service for a period longer than three or latches installed where applicable as
months.
The inspection shall be made by a person qualified as a tnP('h!>",(' When parts or components are
on the specific type of aerial platform or one having shall be identical or equivalent to original aerial
design characteristics. The inspection shall be in accordance
shall train their
frequent inspection and shall of the
following:
(1 ) All functions and their 6.11 of this standard.
limits of motion;
(2) Lower controls including the Whenever an owner directs or
upper controls nnlOVf~e to operate an aerial platform (loading,
(3) All chain and cable mechanisms for adjustment and
damaged parts; responsibilities of the user as specified in Section 7 of this
(4)
(5) Lubrication of all (1) Trained.
element(s), hydraulic oil, (2) Familiarized with the aerial platform to be operated.
by the manufacturer; (3) Made aware of the responsibilities of operators as outlined in
(6) Visual inspection of structural and other critical Section 8 of this Standard.
components such as fasteners, pins, shafts and locking 6.11.2 Assistance to user. Upon request of the user, when an
devices; owner leases, rents or provides an aerial platform for any form of
(7) Placard, warnings and control markings; beneficial use, the owner at that time shall offer to do training or
(8) Additional items specified by the manufacturer. advise the user where training may reasonably be secured.
The owner shall not place the aerial platform into service until all 6.12 Familiarization upon delivery. Upon delivery for lease,
malfunctions and problems have been corrected. rental or any form of beneficial use, the owner shall have the
6.7 Annual inspection. The owner of an aerial platform shall responsibility with the person designated by the receiving entity
ensure that an annual inspection is performed on the aerial for accepting the aerial platform to:
platform no later than thirteen (13) months from the date of the (1) Identify the weather resistant compartment (for manual
prior annual inspection. The inspection shall be performed by a storage).
person(s) qualified as a mechanic on the specific make and model (2) Confirm that the manuals, as specified by the manufacturer,
of the aerial platform or one having similar design characteristics. are on the aerial platform.
The inspection shall be in accordance with items specified by the
5
(3) Review control functions with the operator or person(s) 6.15.3 Record dissemination. Upon request, an owner
designated by the user. accomplishing training and/or familiarization shall provide the
(4) Review safety devices specific to the model aerial platform following:
being delivered. (1) to a user, proof of training for an operator, including name of
6.13 Operation. When an owner operates an aerial platform, trainer and date of training;
the owner shall have the responsibilities of users as specified in (2) to a user, the name of the person(s) receiving familiarization
Section 7 of this standard and his operating personnel shall have upon delivery ofthe aerial platform.
responsibilities of operators as specified in Section 8 of this 6.16 Modifications. Modification, alteration or remanufacture
standard. of an aerial platform shall be made only with prior written
6.14 Assistance to users and operators. If an owner is unable permission of the manufacturer (remanufacturer). Should the
to answer a user's or operator's question(s) relating to rated manufacturer (remanufacturer) no longer exist, a qualified person
capacity, intended use, maintenance, repair, inspection, or may approve such modifications. All modifications shall meet
operation of the aerial platform, the owner shall obtain the proper the applicable manufacturer's requirements as specified in section
information from the dealer or manufacturer and provide that 4 (Responsibilities of manufacturers) of this Standard.
information to the user or operator. 6.17 Safety Bulletins. The owner shall
6.15 Record retention and dissemination. bulletins as received from the
6.15.1 Record retention. The owner shall date and retain the or the dealer
following records for at least 4 years: Upon sale of the aerial
(1) Name and address of the purchaser of each aerial
by serial number and date of delivery. upon delivery, ensure the operating and maintenance
(2) Written records of the frequent and annual inspections
repairs performed. The record shall current Manual of
found, corrective action Users, Lessors,
the person(s) np,'fnrTni"ncr' Elevating Work
(3)
platform. and parts manuals to the new owner.
the request of the new owner, offer to do training
the repairs. where training may reasonably be obtained.
(4) Pre-delivery preparation performed prior to each
(5) Name of the person(s) trained.
(6) Name ofperson(s) nrnvitiincr RESPONSIBILITIES OF USERS.
(7) Name of person(s)
on the same model, or one 7.1 Basic principles. The information in this standard must be
with the one being delivered, supplemented by good job management, safety control, and the
(8) Name ofperson(s) providing familiarization upon delivery. application of sound principles of safety, training, inspection,
6.15.2 Proof of training. Owners providing training should maintenance, application, and operation, consistent with all data
provide successful trainees a means to evidence their training and available regarding the parameters of intended use and expected
shall provide such proof if requested by the trainee. The environment. Since the user has direct control over the
document evidencing training shall include the following application and operation of aerial platforms, conformance with
information: good safety practices in this area is the responsibility of the user
(1) Name of trainee and the operating personnel, including the operator. Decisions on
(2) Name of entity providing training or retraining. the use and operation of the aerial platform must always be made
(3) Name oftrainer(s). with due consideration for the fact that the aerial platform will be
(4) Clear identification that training covered Self Propelled carrying personnel whose safety is dependent on those decisions.
Elevating Work Platforms. 7.2 Manuals.
(5) Date of training 7.2.1 Machine manuals. Users shall keep and maintain a
copy(ies) of the operating and maintenance manual(s) in the
6
weather resistant storage compartment provided by the (3) Elevating assembly and platform lowered to the full down
manufacturer. The manual(s) is considered an integral part of the position, if possible, or otherwise secured by blocking or
aerial platform and is vital to communicate necessary safety cribbing to prevent dropping;
information to users and operators. (4) Hydraulic oil pressure relieved from all hydraulic circuits
7.2.2 Manual of Responsibilities. The current Manual of before loosening or removing hydraulic components;
Responsibilities for Dealers, Owners, Users, Operators, Lessors, (5) Safety props or latches installed where applicable as
Lessees, and Brokers of Self-Propelled Elevating Work Platforms prescribed by the manufacturer (remanufacturer);
shall be provided and stored in the weather resistant storage (6) Precautions specified by the manufacturer (remanufacturer).
compartment. 7.4 Replacement parts. When parts or components are
7.3 Inspection and maintenance. Users shall inspect and replaced, they shall be identical or equivalent to original aerial
maintain the aerial platform as required to ensure proper platform parts or components.
operation. The frequency of inspection and maintenance shall be 7.5 Maintenance training. The user shall ensure only qualified
in accordance with the manufacturer's recommendations taking personnel inspect and maintain the aerial platform in accordance
into account the environment of the work place and the severity with the manufacturer's (remanufacturer's) recommendations and
of use of the aerial platform. Aerial platforms that are not in 7.4 of this standard.
proper operating condition shall be immediately removed from and retraining. Whenever a user directs
service until repaired. Repairs shall be made by a qualified individual to operate an aerial platform the user
person and the repairs shall be in conformance with the
manufacturer's recommendations. being assigned to operate the aerial platform.
7.3.1 Frequent inspection. Users of an aerial nl!,tTn1m with the aerial platform to be operated.
ensure that frequent inspections are conducted as as outlined in
Section 6.6 of this standard.
7.3.2 Annual inspection. observation and
ensure that annual
of the trainee's aerial platform
7.3.3 Prestart inspection.
beginning of each shift, the aerial shall be given a visua before use. The user shall permit only
inspection and functional test including but not limited to th personnel to operate an aerial platform. The user
following: ensure that before use the operator is familiar with the
(1) Operating and emergency controls. model of the aerial platform to be operated, and specifically:
(2) Safety devices. (1) knows where the weather resistant compartment for manual
(3) storage is located.
(4) Cables and wiring (2) knows the operating and maintenance manuals supplied by
(5) Loose or missing parts. the manufacturer (remanufacturer) are stored in the weather
(6) Tires and wheels. resistant compartment and is familiar with the operating and
(7) Placards, warnings, control markings, and operating safety manuals.
manual(s). (3) understands all control functions, placards and warnings.
(8) Outriggers, stabilizers, and other structures. (4) is aware of and understands all safety devices specific to the
(9) Guardrail system. model aerial platform being used.
(10) Items specified by the manufacturer. 7.8 Workplace inspection. Before the aerial platform is used
7.3.4 Maintenance safety precautions. Before adjustments and during use, the user shall check the area in which the aerial
and repairs are started on an aerial platform, the following platform is to be used for possible hazards such as, but not limited
precautions shall be taken as applicable: to:
(1) Powerplant stopped and starting means rendered inoperative; (1) Drop-offs or holes, including those concealed by water, ice,
(2) All controls in the "Off' position and all operating systems mud, etc.
secured from inadvertent motion by brakes, blocks, or other (2) Slope(s).
means; (3) Bumps and floor obstructions.
(4) Debris.
7
(5) Overhead obstructions and high voltage conductors. from overhead obstructions and energized electrical
(6) Hazardous locations and atmospheres (reference conductors and parts.
ANSIINFPA 505-1996). (7) Electrocution hazard. All applicable safety related work
(7) Inadequate surface and support to withstand all load forces practices intended to prevent electric shock covered by the
imposed by the aerial platform in all operating Code of Federal Regulations (CFR) 1910.333 shall be
configurations. defined and explained to the operator by a qualified person.
(8) Wind and weather conditions. In particular, such person shall direct the operator,
(7) Presence of unauthorized persons. commensurate with the operator's qualifications, to maintain
(8) Other possible unsafe conditions. the appropriate minimum approach distance (MAD) from
7.9 Determination of hazardous locations. It shall be the energized power lines and parts covered by CFR 1910.333
responsibility of the user to determine the hazard classification of (c).
the intended location of operation. Aerial platforms operated in (8) Personal protective equipment (PPE). The user shall
hazardous locations shall be approved in accordance with, and of direct the operator to ensure all personnel on the platform
the type required, by ANSIINFPA 505-1996. wear personal protective equipment (PPE) as required.
7.10 Operator warnings and instructions. The user shall (9)
direct personnel operating the aerial platform to be in compliance floor while working thereon. Climbing by
with the provisions set forth in section 8 of this standard. The midrail or toprail of the aerial platform is
user shall monitor their performance and supervise their work to of planks, ladders, or any other devices
ensure the use, application and operation of the aerial n1l1lttnrm for achieving additional height or reach is
in conformance with the provisions set forth in this
warn personnel of potential hazards, provide means to When other
against identified hazards, and explain the
of not following proper operating local ordinances or
guidelines regarding proper the workplace. Warnings
necessarily be limited to the roped off areas, flashing
(1) Fall protection. The guardrail be used as appropriate.
provides fall protection. If or malfunctions. The user shall direct
required to wear personal fall protection equipment (PFPE), to immediately report to a supervisor any
or malfunction(s) that become evident during
aerial platform manufacturer operation. The user shall ensure all problems and
anchorage( s). malfunctions are repaired prior to continued use.
(2) Slope and grade. The (12) Reporting potentially hazardous locations. The user shall
in any manner on grades, direct the operator to immediately report to a supervisor any
those for which the aerial potentially hazardous location(s) that become evident during
manufacturer (remanufacturer). operation.
(3) Deployment of stability enhancing means. Outriggers, (13) Hazardous location operation. Operation of aerial
stabilizers, extendible axles, oscillating axles or other platforms not approved and marked for operation in a
stability enhancing means shall be deployed and locked into hazardous location shall be prohibited.
place as required by the manufacturer (remanufacturer). (14) Entanglement. Care shall be taken to prevent rope,
(4) Guardrail system. Guardrails shall be installed and electric cords, and hoses, etc., from becoming entangled in
positioned, and access gates or openings shall be closed per the aerial platform.
the manufacturer's (remanufacturer's) instructions. (15) Capacity limitations. Rated capacities shall not be
(5) Distribution of load. The load and its distribution on the exceeded when loads are transferred to the platform at any
platform and any platform extension(s) shall be in height.
accordance with the manufacturer's (remanufacturer's) rated (16) Work area. The user shall direct the operator to ensure
capacity for that specific configuration. the area surrounding the aerial platform is clear of personnel
(6) Maintain overhead clearance. The operator shall be and equipment before lowering the platform.
instructed to ensure that adequate clearance is maintained
8
(17) Fueling. The engine (if applicable) shall be shut down personnel shall be removed from the platform/basket before
while fuel tanks are being filled. Fueling shall be done in a attempts are made to free the platform using lower controls.
well-ventilated area free of flame, sparks, or other hazards (28) Vacating (or entering) an elevated aerial platform. If
that may cause fire or explosion. permitted by the manufacturer, personnel shall only vacate
(18) Battery charging. Batteries shall only be charged in a or enter a raised aerial platform by following the guidelines
well-ventilated area free of flame, sparks, or other hazards and instructions provided by the manufacturer
that may cause fire or explosion. (remanufacturer).
(19) Improper platform stabilization. The aerial platform (29) Modifications. Modification or alteration of an aerial
shall not be positioned against another object to steady the platform or the fabrication and attaching of frameworks, or
platform or improve stability. the mounting of attachments for holding tools or materials
(20) Misuse as a crane. The aerial platform shall not be used onto the platform or the guardrail system shall only be
as a crane. accomplished with the prior written permission of the
(21) Unusual operating support conditions. The aerial manufacturer (remanufacturer). Should the manufacturer
platform shall not be operated from a position on trucks, (remanufacturer) no longer exist, a qualified person may
trailers, railway cars, floating vessels, scaffolds, or similar modifications. All modifications shall meet
equipment unless the application is approved in writing by manufacturer's requirements as specified in
the manufacturer (remanufacturer) or a qualified person. of manufacturers) of this
(22) Travel speeds. The user shall direct the operator to limit
travel speed according to conditions, including the l'.ntul,t,nn operator. If an operator encounters any
of the support surface, congestion, visibility, slope, malfunction of the aerial platform, or any hazard
of personnel, and other factors leading to hazards which
cause collision(s) or result
personnel. request further
(23) Driving requirements.
aerial platform, the user shall Any problem(s) or
(a) Maintain a clear view of
of travel. use of the aerial platform.
(b) Ensure personnel in the worksite area that (larger than the platform.) The user
affected are aware of the movement, cornmumc~ ensure that only tools and materials which are evenly
and maneuvering the aerial platform distributed and can be safely handled by a person(s) working
from the platform are transported.
(c) Maintain a safe distance (33) Rated horizontal force. The user shall direct the operator
offs, holes, depressions, not to exceed the manufacturer's (remanufacturer's) rated
ensure safe travel. horizontal force.
(d) Maintain a safe distance obstacles and (34) Bridge cranes. When an aerial platform is to operate within
energized electrical conductors. the area of travel of a bridge crane or similar equipment,
(24) Stunt driving. The user shall inform the operator that stunt steps shall be taken to prevent a collision with the aerial
driving and horseplay are prohibited. platform.
(25) Securing the aerial platform. The user shall direct the (35) Adequate support requirements. The user shall insure the
operator to implement means provided to protect against use support surface is adequate for the aerial platform and the
by an unauthorized person(s). load carried.
(26) Altering safety devices. Interlocks or other safety devices (36) Leveling the aerial platform. Outriggers and leveling
shall not be altered or disabled. devices supplied by the manufacturer (remanufacturer) shall
(27) Snagged platform. If the platform/basket or supporting be utilized to level the aerial platform when provided.
assembly becomes caught, snagged, or otherwise prevented (37) Protecting against unauthorized use. The user shall direct
from normal motion by adjacent structures or other obstacles the operator not to use, rent, lease, or provide the aerial
such that control reversal does not free the platform, all platform for any form of beneficial use unless so authorized.
9
RESPONSIBILITIES MANUAL Reprint from ANSI/SIA A92.6 2006
7.11 User as Operator. If a user is also the operator of an permission of the manufacturer (remanufacturer). Should the
aerial platform, the user shall have the responsibilities of manufacturer (remanufacturer) no longer exist, a qualified person
operators specified in Section 8 of this standard as well as may approve such modifications. All modifications shall meet
responsibilities of users as specified in Section 7 of this standard. the applicable manufacturer's requirements as specified in section
7.12 Shutdown of aerial platform. The user shall authorize 4 (Responsibilities of manufacturers) of this Standard.
and direct the operating personnel to cease operation of the aerial 7.15 Manufacturer's safety bulletins. The user shall comply
platform in case of any suspected malfunctions of the aerial with safety-related bulletins as received from the manufacturer
platform, or any hazard or potentially unsafe condition that may (remanufacturer), dealer or owner.
be encountered, and to request further information as to safe
operation from the owner, dealer, or manufacturer before further
operation of the aerial platform. 18. RESPONSIBILITIES OF OPERATORS.
7.13 Record retention and dissemination.
7.13.1 Record retention. The user shall retain the following
records for at least 4 years: 8.1 Basic principles. The information in this standard shall be
(1) Names of the operator(s) trained and retrained. SUIlplt:mtmtt:d by good judgment, safety control, and caution in
(2) Names of operator(s) provided familiarization. situation. Since the operator is in direct control of
(3) The owner (or the entity designated by the owner) is conformance with good safety practices in
responsible to ensure frequent and annual inspections are 1PP"lll)lUllllIY of the operator. The operator shall
conducted and written records are maintained. The on the use and operation of the aerial platform
shall include the date of the inspection, any consideration for the fact that his or her own safety as
found, the corrective action recommended and ,'u'"l1IU''' as the safety of platform is dependent
of the person(s) performing the inspection.
(4) When employees of the user
platform, the user shall
shall include the date 'l1(LUua,l<>are stored in the weather
accomplished, and ide:ntiticl the aerial platform. The
the repair. Insiide:red an integral part of the aerial platform and
7.13.2 Record dissemination communicate necessary safety information to the
(1 ) When the user directs personnel to accomplish The operator shall be familiar with the manuals and
annual inspections, not later than 60 reference them as required.
inspections. the appropriate 8.2.2 Manual of Responsibilities. The operator shall be
owner of the aerial nl<lttc\t'IT familiar with the requirements for operators as set forth in Section
(2) 8 of the Manual of Responsibilities for dealers, owners, users,
operators, lessors, lessees, and brokers of Self-Propelling
accomplished, the "nT'Tm,";"tp Elevating Work Platforms< The current Manual of
the owner. Responsibilities for Dealers, Owners, Users, Operators, Lessors,
7.13.3 Proof of training. Users providing training should Lessees, and Brokers of Self-Propelled Elevating Work Platforms
provide successful trainees a means to evidence their training and shall be provided and stored in the weather resistant storage
shall provide such proof if requested by the trainee. The compartment.
document evidencing training shall include the following 8.3 Prestart inspection. Before use each day or at the beginning
of each shift, the aerial platform shall be given a visual inspection
information: and functional test including but not limited to the following:
(1) Name of trainee. (1) Operating and emergency controls.
(2) Name of entity providing training or retraining. (2) Safety devices.
(3) Name oftrainer(s). (3) Personal protective devices.
(4) Clear identification that training covered Self Propelled (4) Air, hydraulic, and fuel systems leaks.
Elevating Work Platforms. (5) Cables and wiring harness.
(5) Date of training. (6) Loose or missing parts.
7.14 Modifications. Modification, alteration or remanufacture (7) Tires and wheels.
of an aerial platform shall be made only with prior written (8) Placards, warnings, control markings, and operating
manual(s).
10
(9) Outriggers, stabilizers and other structures. (1) Drop-offs or holes, including those concealed by water, ice,
(10) Guardrail system.
mud, etc.
(11)Items specified by the manufacturer (remanufacturer).
8.4 Problems or malfunctions. Any problems or malfunctions (2) Slope(s).
(3) Bumps and floor obstructions.
that affect the safety of operations shall be repaired prior to the
(4) Debris.
use of the aerial platform. (5) Overhead obstructions and electrical conductors.
8.5 Training, retraining, and familiarization. (6) Hazardous locations and atmospheres (reference
8.5.1 General training. Only personnel who have received ANSIINFPA 505-1995).
general instructions regarding the inspection, application and (7) Inadequate surface and support to withstand all load forces
operation of aerial platforms, including recognition and imposed by the aerial platform in all operating
avoidance of hazards associated with their operation, shall configurations.
operate an aerial platform. Such items covered shall include, but (8) Wind and weather conditions.
not necessarily be limited to, the following issues and (9) Presence of unauthorized persons.
requirements:
(10) Other possible unsafe conditions.
(1) The purpose and use of manuals.
(2) That operating manuals are an integral part of the aerial 8.8 Prior to each elevation. Before each elevation of the
platform and must be stored properly in the weather resistant platform, the operator shall ensure:
compartment when not in use.
extendible axles, or other stability
(3) A pre-start inspection.
(4) Responsibilities associated with problems or malfunctions are used as required by the manufacturer.
affecting the operation of the aerial platform. I-ll:>'Ci1U"U and access gates or openings are
(5) Factors affecting stability. i1Rl':hlrpr'" (remanufacturer' s) instructions.

(6) The purpose of placards and decals. its distribution on the platform and any
(7) Workplace inspection. extension(s) are in accordance with the
(8) Safety rules and regulations. ;,rh:1rPl"" rated capacity for that
(9) Authorization to operate. specific configuration.
(10) Operator warnings and instructions. All personnel on the
(11) Actual operation of the aerial platform.
gear for the work
of a qualified person, the
platform for a sufficient
proficiency in the actual to understand the hazard
8.5.2 Retraining. The op~~ratlor location of operation according to
directed by the user, based
evaluation of the operator. warnings and instructions. The operator shall
8.5.3 Familiarization. When an operator is directed to operation of the aerial platform is in compliance with
an aerial platform he/she is not familiar with, the
receive instructions regarding the following items: Fall protection. The guardrail system of the aerial platform
(1) The location of the weather resistant provides fall protection. If occupant(s) of the platform are
manual storage). required to wear personal fall protection equipment (PFPE),
(2) The purpose and function of occupants shall comply with instructions provided by the
aerial platform manufacturer (remanufacturer) regarding
(3) Safety devices and operating
anchorage( s).
aerial platform. (2) Slope and grade. The aerial platform shall not be operated
8.6 Before operation. Before in any manner on grades, side slopes or ramps exceeding
(1) Read and understand the ma:nufacnrrel"S (remanufacturer's) those for which the aerial platform is rated by the
operating instruction(s) and user's safety rules or have them manufacturer (remanufacturer).
explained. (3) Deployment of stability enhancing means. Outriggers,
(2) Understand all labels, warnings and instructions displayed on stabilizers, extendible axles, oscillating axles or other
the aerial platform or have them explained. stability enhancing means shall be deployed and locked into
(3) Ensure all occupants of the aerial platform wear appropriate place as required by the manufacturer (remanufacturer).
(4) Guardrail system. Guardrails shall be installed and
personal protection equipment (PPE) for the conditions,
positioned, and access gates or openings shall be closed per
including the environment in which the aerial platform will the manufacturer's (remanufacturer's) instructions.
be operated. (5) Distribution of load. The load and its distribution on the
platform and any platform extension(s) shall be in
8.7 Workplace inspection. Before the aerial platform is used
accordance with the manufacturer's rated capacity for that
and during use, the operator shall check the area in which the specific configuration,
aerial platform is to be used for possible hazards such as, but not (6) Maintaining overhead clearance. The operator shall
limited to: ensure that adequate clearance is maintained from overhead
obstructions and energized electrical conductors and parts.
11
(7) Electrocution hazard. The operator shall perfonn only that (21) Unusual operating support conditions. The aerial
platfonn shall not be operated from a position on trucks,
work for which he or she is qualified, in compliance with all trailers, railway cars, floating vessels, scaffolds, or similar
applicable safety related work practices intended to prevent equipment unless the application is approved in writing by
electric shock covered by the Code of Federal Regulations the manufacturer (remanufacturer) or a qualified person.
(22) Travel speeds. The operator shall limit travel speed
(CFR) 1910.333. The operator's level of competence shall according to conditions, including the condition of the
be established only by persons qualified to do so. Operators support surface, congestion, visibility, slope, location of
shall maintain the appropriate minimum approach distance personnel, and other factors leading to hazards which may
cause collision(s) or result in potential injury(ies) to
(MAD) from energized power lines and parts covered by personnel.
CFR 1910.333 (c). (23) Driving requirements. Before and during driving the aerial
(8) Personal protective equipment (PPE). The operator shall
ensure all occupants of the platfonn wear personal protective platfonn, the operator shall:
equipment as required. (a) Maintain a clear view of the support surface and route
(9) Personnel footing. Personnel shall maintain finn footing on of travel.
the platfonn floor while working thereon. Climbing by (b) Ensure personnel in the worksite area that may be
occupants on the midrail or toprail of the aerial platfonn is affected are aware of the movement, communicating
prohibited. The use of planks, ladders, or any other devices and maneuvering the aerial platfonn as required to
on the platfonn for achieving additional height or reach is against personal injury.
prohibited~ a safe distance from obstacles, debris, drop-
(10) Precaution for other moving equipment. When other depressions, ramps, and other hazards to
moving equipment and vehicles are present, special travel.
precautions shall be taken to comply with local ordinances a safe distance from overhead obstacles and
safety standards established for the workplace. mergl;led electrical conductors.
such as, but not limited to, flags, roped off areas, driving. Stunt driving and horseplay are prohibited.
lights, and barricades shall be used as appropriate. Securing the aerial The operator shall
(11) Reporting problems or malfunctions. The operator implement means against use by an
immediately report to a supervisor unauthorized
malfunction(s) that become (26) Altering or other safety devices
operator shall ensure shall not
affect the safety of (27) ISnal2geam platformibasket or supporting
use. snagged, or otherwise prevented
(12) Reporting potentially by adjacent structures or other obstacles
shall immediately report to supervisor control reversal does not free the platfonn, all
shall be removed from the platformibasket before
hazardous location(s) that become evident during UI.II'''I!''uu "tt,·...,."tQ are made to free the platfonn using lower controls.
(13) Hazardous location operation. Operation Vacating (or entering) an elevated aerial platform. If
marked for pennitted by the manufacturer, personnel shall only vacate
or enter a raised aerial platfonn by following the guidelines
hazardous location shall be and instructions provided by the manufacturer
(14) Entanglement. Care (remanufacturer).
cords, and hoses, etc., (29) Modifications. Modification or alteration of an aerial
platfonn. platfonn or the fabrication and attaching of frameworks, or
(15) Capacity limitations. the mounting of attachments for holding tools or materials
exceeded when loads are onto the platfonn or the guardrail system shall only be
height. accomplished with the prior written pennission of the
(16) Work area. The operator shall ensure the area surrounding manufacturer (remanufacturer). Should the manufacturer
the aerial platfonn is clear of personnel and equipment (remanufacturer) no longer exist, a qualified person may
before lowering the platfonn. approve such modifications. All modifications shall meet
(17) Fueling. The engine (if applicable) shall be shut down while the applicable manufacturer's requirements as specified in
fuel tanks are being filled. Fueling shall be done in a well- section 4 (Responsibilities of manufacturers) of this
ventilated area free of flame, sparks, or other hazards that Standard.
may cause fire or explosion.
(18) Battery charging. Batteries shall only be charged in a well- (30) Assistance to the operator. If an operator encounters any
ventilated area free of flame, sparks, or other hazards that suspected malfunction of the aerial platfonn, or any hazard
may cause fire or explosion. or potentially unsafe condition relating to capacity, intended
(19) Improper platform stabilization. The aerial platfonn shall use or safe operation of the aerial platfonn, the operator shall
not be positioned against another object to steady the cease operation of the aerial platfonn and request further
platfonn or improve stability. infonnation from the user.
(20) Misuse as a crane. The aerial platfonn shall not be used as
a crane.
12
RESPONsmILITIES MANUAL Reprint from ANSIISIA A92.6 2006
(31) Problem(s) or malfunction(s). Any problems or 9.4 Lessor as a user. When a lessor is the user of the aerial
malfunctions that affect the safety of operations shall be platform, the lessor shall have the responsibilities of users as
repaired prior to the use of the aerial platform. specified in Section 7 of this standard.
(32) Carrying materials (larger than the platform.) The 9.5 Lessor as an operator. When a lessor is the operator of the
operator shall ensure only tools and materials which are aerial platform, the lessor shall have the responsibilities of
evenly distributed and can be safely handled by a person(s) operators as specified in Section 8 of this standard.
working from the platform, shall be transported.
(33) Rated horizontal force. The operator shall not permit
personnel on the platform to exceed the manufacturer's 110. RESPONSIBILITIES OF LESSEES.
(remanufacturer's) rated horizontal force.
(34) Bridge cranes. When an aerial platform is to operate within
the area of travel of a bridge crane or similar equipment, 10.1 Basic principles. Sound principles of safety, training,
steps shall be taken to prevent a collision with the aerial
platform. inspection, maintenance, application, and operation consistent
(35) Adequate support requirements. The operator shall ensure with all data available regarding the parameters of intended use
the support surface is adequate for the aerial platform and the and expected environment shall be applied in the performance of
load carried.
(36) Leveling the aerial platform. Outriggers and leveling of lessees with due consideration of the
devices supplied by the manufacturer shall be utilized to the aerial platform will be carrying personnel.
level the aerial platform when provided. a Dealer. When a lessee is also the dealer for the
(37) Protecting against unauthorized use. The operator shall of the aerial platform, the lessee
Jll"lUllllU<;:' of dealers as specified in Section 5
not use, rent, lease, or provide the aerial platform
form of beneficial use to another entity as an Owner. When a lessee is the owner of the
authorization of the user. platform, the lessee shall the responsibilities of
8.11 Record of training. When provided or when obtained as specified in
the operator's request, proof of training 10.4 Lessee as a
entity should be retained by the platform, the lessee JU"'VU,,,,,,,, of users as
the following information: specified in
10.5 Lessee a lessee is the operator of the
(1) Name of trainee. have the responsibilities of
(2) Name of entity providing 8 of this standard.
(3) Name oftrainer(s).
(4) Clear identification that
Elevating Work Platforms.
(5) Date of training. OF BROKERS.
9. RESPONSIBILITIES OF 11.1 Responsibilities upon sale. The broker shall:

(1) Upon delivery, ensure the operating and maintenance
manuals are provided to the new owner.
(2) Upon delivery, provide a copy of the current Manual of
9.1 Basic principles. Responsibilities for Dealers, Operators, Users, Lessors,
inspection, maintenance, operation consistent Lessees, and Brokers of Self-Propelled Elevating Work
Platforms to the new owner.
with all data available regarding the parameters of intended use
(3) Maintain records of the sale for a minimum of four (4) years.
and expected environment shall be applied in the performance of 11.2 Responsibilities with re-rents, leases, or any other form
responsibilities of lessors with due consideration of the of beneficial use. When compensation is received as a result of a
knowledge that the aerial platform will be carrying personnel. re-rent, lease or any form of beneficial use of an aerial platform,
the broker shall:
9.2 Lessor as a dealer. When a lessor is a dealer for the (1) Upon delivery, ensure the operating and maintenance
manufacturer of the aerial platform being leased, the lessor shall manuals are provided to the user.
have the responsibilities of dealers as specified in Section 5 of (2) Upon delivery, provide a copy of the current Manual of
Responsibilities for Dealers, Operators, Users, Lessors,
this standard. Lessees, and Brokers of Self-Propelled Elevating Work
9.3 Lessor as an owner. When a lessor is the owner of the aerial Platforms.
platform being leased, the lessor shall have the responsibilities of (3) Ensure operating personnel are familiarized with the aerial
platform prior to use.
owners as specified in Section 6 of this standard.
(4) Retain records of the transaction for a minimum of four (4)
years.
13
Figure 1 - Typical Examples of Equipment Covered
SELF-PROPELLED


ILLUSTRATED PARTS MANUAL
CONDOR® CONDOR®
VVAco,TEXAs76712 VVACO, TEXAS 76702-1447
(254) 420-5200 (254) 420-5200
MANUAL 92357-003
JUNE 1997
i
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®.
THEOPERATOR'SMANUALMUSTBERETAINEDONTHECONDOR®ATALLT1MES.
Do not attempt to operate or service the CONDOR® until you have read and
understood all information provided in this manual. Familiarize yourself with
the functions and operations of the upper and lower controls. A good
understanding of the controls, their limitations, and their capabilities will
maximize operating efficiency. The various decals attached to this CONDOR®
also contain vital operational instructions. Read the decals before operating
this CONDOR®.
It is YOUR RESPONSIBILITY to follow procedures while operating the CONDOR®.

The manufacturer of this CONDOR® cannot control the wide range of applications that may be used
in carrying out a variety of jobs. Therefore, it is THE USER'S RESPONSIBILITY to consider all
personnel when making decisions regarding the CONDOR®'s intended use.
regarding the operation and use of aerial work platforms. A copy of the ANSIISIA 92.6-1990 Manual
of Responsibilities is attached for your use.
TIME CONDOR Corporation reserves the right to modify, improve, add, andlor 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 WRITTEN APPROVAL

FROM THE MANAGEMENT OF T1ME CONDOR CORPORATION
Many of the parts used in the manufacture of the CONDOR® have specific properties, and the
manufacturer recommends that replacement parts be purchased through TIME CONDOR Corporation
in order to ensure the original integrity of the product. Repairs and adjustments should only be made
by trained and qualified personnel. Please refer to the maintenance and parts sections of the 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, Mainte-
nance, & Parts Manual for information pertaining to your machine.
MANUAL 92357-003
JUNE 1997
ii
A div. of TIME Manufacturing Company
1. If you need assistance or have any service or maintenance questions, TIME CONDOR Cor-
poration service and parts personnel are always available by phone or fax. The telephone
numbers are:
(254) 420-5200 Telephone

(254) 420-5298 Voice Mail
(800) 443-5803 FAX
These procedures are available through the TIME CONDOR Corporation Service Department
to anyone who requests them.
3. Service and maintenance are not a substitute fortrained, qualified service technicians.
TIME CONDOR Corporation conducts service schools on a continuing basis. Call any of
our service or sales persons for a schedule. Remember, training of mechanics is the responsi
bility oftheir employer, but TIME CONDOR Corporation Service Schools help you provide
this training.
4. TIME CONDOR CorporationService School Training Manuals are available for purchase
through the parts department. The part numbers for these manuals are: #92333 for self- pro-
pelledmodels and #92334 fortruck-mounted models.
CONDOR DIVISION
8300IMPERIALDRlVE,P.O.Box21447, WACO, TEXAS 76702-1447 254-420-52005,254-443-5803 FAX

0
CONDOR® MODEL V2648/S3 & V2648/S3XL
ILLUSTRATEDPARTS~UAL
TABLE OF CONTENTS
•
INTRODUCTION ............................................................................................................. i
SERVICE INFORMATION ............................................................................................ ii
SERIAL NUMBER TO MODEL DESIGNATION •••••••.••.•••.•••••••••••••••••.••••••.•.••.••.••••••• iii
TABLE OF CONTENTS ................................................................................................. 1
FIGURE DESCRIPTION PAGE
A ............................................... Serial Number Location ............................................... 2

B ............................................... Recommended Spare Parts List ................................... 3
C ............................................... How to Order Parts .................................................. 4,5
1 ............................................... Final Installation ........................................................... 6

2 ...................................... ~ ........ Deca1Installation ......................................................... 8
3 ............................................... Chassis Assembly ..................... ........ ....... ........ ..... ..... 10
4 ............................................... -Hose Kit .................................................................. 14
5 ............................................... -Steer Cylinder .......................................................... 16
6 ............................................... -Brake Cylinder ......................................................... 17
7 ............................................... -Hub Motor Assembly................ ..... ...... ...... ........ ...... 18
8 ............................................... - Rear Hub Assembly ................................................ 19
9 ............................................... Belly Pan Assembly ................................................... 20
10 ............................................... Motor & Pump Assembly .......................................... 22
II ............................................... Pump Assembly ......................................................... 23
12 ........................................·....... Motor24VDCAssembly ..........................................·24
13 ............................................... Valve Installation ....................................................... 26
14 ............................................... ChargerI15V/60Hz-25A124VDC ............................ 30
15 ............................................... WrringInstallation ...................................................... 34
16 ............................................... Lower Control Box Assembly .................................... 36
17 ............................................... AnnstackAssembly ................................................... 44
18 ............................................... PlatformInstallation ................................................... 50
19 ............................................... Upper Control Box Assembly .................................... 52
20 ............................................... 110VoitExtensionToPIatform ................................. 56
21 ............................................... TraveIAlarm(Option) ............................................... 57
22 ............................................... MotionAlarm(Option) .............................................. 58
23 ............................................... StrobeLight(Option) ................................................ 59
24 ............................................... Descend Alarm (Option) ................................ ;........... 60
25 ............................................... SlopeAlarm(Option) ................................................ 61
26 ............................................... Hour Meter (XL-Option) ........................................... 62
27 ............................................... Battery Condition Indicator (XL-Option) ................... 63
28 ............................................... Low-Voltage Warning Interrupt (XL-Option) ............. 64
29 ............................................... Larger Batteries IPOS (XL-Option) ........................... 65
MANUAL 92351-003
JUNE 1991
• FIGURE A-Serial Number Location
TheCONDOR® Model V2648/53 & V2648/53XL Serial Number is stamped in two locations on the machine.
1. The first place to find the serial number is on the data plate affixed to the
chassis, at the rear between fork lift pockets.
2. The second place to find the serial number is at the front steering knuckle kingpin.
MANUAL 92357-003
JUNE 1997
FIGURE B-Recommended Spare Parts List •
CONDOR®MODEL V2648/53 & V2648/53 XL (I UNIT-I YEAR OPERATION)
V2648/53 V2648/53XL
PARTNUMBER DESCRIPTION QTY QTY
91029 .................................. NutLug 1/2" ••••••••••••••••••••••••••••••••••••••••••••••••••••••• 5 ......................... 5

55363-001 ........................... Stud Wheel 112"-20 xl 3/4" ............................. 5 ......................... 5
~ 54783-002 ........................... Cable Assembly, Emergency Lowering ............ 1 ......................... 1
54798 .................................. Coupling Nut, 10-32 UNF ................................. 1 ......................... 1
54048 .................................. Latch Door ........................................................ 1 ......................... 1
67408 .................................. Element, Hydraulic Filter PIN 33430 ................ 5 ......................... 5
36085 .................................. Fitting, Swivel 90° Elbow 6-6 ........................... 2 ......................... 2
51036 .................................. Switch Limit Body Only ................................... 1 ......................... 1
51037 .................................. Offset Head Limit Switch ................................. 1 ......................... 1
51039-002 ........................... Limit Switch, Arm Short ................................... 1 ......................... 1
67939-015 ........................... Fuse, 15 Amp .................................................... 1 ......................... 1
67940 .................................. Fuse Holder ....................................................... 5 ......................... 5
52138 .................................. Solenoid 24V ..................................................... 1 ......................... 1
206-00001-00 ...................... Diode ................................................................. 9 ......................... 9
54438 .................................. Relay, 24V SPDT Bosch ................................... 1 ......................... 1
34542 .................................. Jumper ............................................................... 4 ......................... 4
55999-005 ........................... Decal Installation, V2648 .................................. 1 .......................... .
55999-105 ........................... Decals, V2648 Essentials .................................. 1 .......................... .
55999-007 ........................... Decal Installation, V2653 ............................................................... 1
55999-107 ........................... Decals, V2653 Essentials ............................................................... I
55884 .................................. Hose Kit ............................................................ 1 ......................... 1
67758 .................................. Toggle Switch ............................................... :... 1 .......................... .
50075 .................................. Switch ............................................................... 2 ......................... 2
51913 .................................. Operator,RedP-Pull ......................................... 1 ......................... 1
51914 .................................. Base, 1 NC Contact ........................................... 1 ......................... 1
52671 .................................. Operator, 3 Pos Key .......................................... 1 .......................... .
52029 .................................. Base, 2 NO Contacts ......................................... 1 ..................... .... 1
55333 .................................. Charger .............................................................. 1 ......................... 1
55471 .................................. Plunger, Hand Retract Spring ........................................................ 3
55241 .................................. Spring Loaded Pull-Up Latch ........................................................ 3
54589 .................................. Controller, Drive/Steer ................................................................... 1
55999-006 ........................... Decal Installation, V2648XL ........................................................ , 1
55999-106 ........................... Decals, V2648XL Essentials .......................................................... 1
55999-008 ........................... Decal Installation, V2653XL ......................................................... 1
55999-108 ........................... Decals, V2653XL Essentials .......................................................... 1
55243 .................................. Spring-Deck Latch ......................................................................... 1
54910-102 ........................... Receptacle .................................................................. ........... ...... ... 1
54910-104 ........................... MountingBase ............................................................................... 1
52670 .................................. Operator, 3 Pos. Rot....................................................................... 1
34464 .................................. Base, NOINC Contacts ................................................................... 1
52669 .................................. Operator, Black P-Button .............................................•................. 1
52672 .................................. Base, 1 NO Contact ..................... ................. .............................. .... 1
69146 .................................. Operator, Green P-Button .............................................................. 1
54913 .................................. Operator, BlackIBlack Db. P-Button .............................................. 1
MANUAL 92357-003
JUNE 1997
• FIGURE C-How to Order Parts
1. When ordering parts for your CONDOR®, ensure that you are able to give the model and serial
numbers of all units for which parts are needed. The serial number(s) will assist the TIME
CONDOR Corporation Parts Department in providing the correct parts for your machine(s).
Please refer to FIGURE A for Serial Number Location on this model.
2. Ifknown, please specify the TIME CONDOR Corporation part number(s) for the part(s) you
require, and always provide a complete description of all parts.
3. Fax orders are preferable, though parts may also be ordered by mail and telephone. A sample
parts order (with fax number) follows this page.
4. Parts needed for a warranty repair must be purchased through the TIME CONDOR Corporation
Parts Department. Credit will be authorized through the Service Department after a Warranty
Claim has been submitted to TIME CONDOR Corporation A Warranty Claim is to be filed for
any part received as "defective". See Maintenance Manual for Warranty Procedures.
5. TIME CONDOR Corporation will ship parts as per our customers' request at the time of the
order-i.e., UPS, Federal Express, or preferred truck line. When shipping Federal Express, your
customer account must be given at the time of the order.
6. TIME CONDOR Corporation classifies its orders in the following ways:
Emergency (unit out of service) - Top priority. Shipping deadline for emergency
orders to ship same day is 2.00 p.m. Central Standard Time. Any
emergency order received after 2.00 p.m. will be shipped the
following day.
Order to be shipped within 1 week.
7. Condor Div. has a $25.00 Net Minimum Billing charge per order.
8. All price quotations will be valid for 90 days.
9. Parts shown as shipped on the TIME CONDOR Corporation packing list and subsequent invoice
but not received by the dealer/customer MUST be reported within 10 days after the date of
shipment. If the parts are still required, a NEW parts order must be submitted. Shortages and
discrepancies will be reviewed on an individual basis by the Parts staff and adjustments will be
made accordingly.
10. Invoice discrepancies regarding incorrect prices or discounts should be reported immediately to
the Parts Department. Report the Sales Order number, Purchase Order number, and Invoice
number. Your request will be reviewed and adjustments will be made accordingly.
MANUAL 92357-003
JUNE 1997
~COUNT#
TIME CONDOR CORPORATION PARTS DEPARTMENT
FAX ORDER FORM FAX NO. 800-443-5803
I PURCHASER SALES ORDER #

•
I ~AME
N NAME
C
U F
S 0 ADDRESS S ~DRESS
T R H T
0 M I 0
M A CITY STATE ZIP P ~ITY STATE ZIP
E T
R I
PHONE FAX HONE FAX
0
N ( ) ( ) ( ) ( )
CUST. PURCHASE ORDER NO. I ORDERDATE I RE QUEST DATE SPECIAL MARKS & NUMBERS
SHIPPING INSTRUCTIONS
J I
PART NUMBER QTY. DESCRIPTION NOTES
-'
FOR ORDER STATUS PLEASE CHECK

APPROPRIATE BOX BELOW
EMERGENCY
STOCK
MANUAL 92357.003
JUNE 1997
• FIGURE 1: Final Installation
MANUAL 92357-003
JUNE 1997
FIGURE 1: Final InStallation.
ITEM PART NUMBER DESCRIPTION QTY
Ref. 55865 ........................... Final Installation V26481XL ............................................................. Ref.

Ref. 55917 ........................... Final Installation V26531XL ............................................................ Ref.
1 55623 ........................... Chassis Assembly V26481XL ................................................................ 1
55834 ........................... Chassis Assembly V26531XL ............................................................... 1
2 55673 ........................... Bellypan Assembly ................................................................................ 1
3 55744 ........................... ArmstackInstallation ............................................................................. 1
4 55663 ........................... Platform Assembly ................................................................................ 1
5 55869-004 .................... Lower Box Assembly ............................................................................ 1
-6 55870 ........................... Wiring Installation ................................................................................. 1
7 55851 ........................... Upper Electrical Box Assembly ............................................................ 1
-8 55884 ........................... Hose Kit ................................................................................................. 1
-9 67837-007 .................... Tie, Black Nylon .................................................................................. 10
-10 54783-002 .................... Emergency Lowering Cable Assembly ................................................. 1
-11 ..................................... Hydraulilc Oil Tellus T32 ............................................................... 8GL
-12 55807 ........................... Cover Weldment LH Side ..................................................................... 1
-13 55768 ........................... Cover Weldment RH Side .................................................................... 1
14 54048 ........................... Latch Door ............................................................................................. 2
15 34354 ........................... Holder, Safety Manual- Blk Caps ......................................................... 1
-16 67793 ........................... Clamp Cable .......................................................................................... 2
-17 BOW31401 .................. Washer, Flat .25 ID x .63 00 ............................................................... 2
-18 BOW36780 .................. Nut, Hex Lock .25-20UNC ................................................................... 2
-19 92357-001 .................... Operator's Manual ................................................................................... .
-20 A630-V2648-1 ............. Manual M-2648\53-0 1 OIMIP ................................................................ .
-21 ..................................... Nameplate, Scissor Identification .......................................................... 1
-22 55999-006 ........ ~ ........... Decal Installation V2648 ....................................................................... 1
55999-008 .................... Decal Installation V2653 ....................................................................... 1
-23 55883 ........................... 110V Extension to Platform .................................................................. 1
-24 55844 ........................... Schematic, Electrical ............................................................................. 1
-25 55309 ........................... Schematic, Hydraulic ............................................................................. 1
-26 54701 ........................... Block, ArmstackNylatron ..................................................................... 2
-27 55279 ........................... Block, HOPE Slide ................................................................................ 2
-28 54616-014 .................... Shaft, Arm Pivot 28.38" LG ................................................................. 1
-29 54616-015 .................... Shaft, Arm Pivot 40.62" LG ................................................................. 2
-30 BOW30037 .................. Bolt, Hex .31-18UNC x 3.00 ................................................................ 4
-31 BOW31432 .................. Washer,Flat .31IDx.680D .............................................................. .4
-32 BOW36273 .................. Nut, Hex Lock 5/J6"-18UNC .................................................................. 4
MANUAL 9nS7-OO3
JUNE 1997
• FIGURE 2: Decal Installation
o I:
!II
ill
PA.RTlAL SECTION A
APPLIES TO All MODELS
MANUAL 92357-003
JUNE 1997
FIGURE 2: Decal Installation.
ITEM PARTNUMBER DESCRIPTION QTY
Ref 55999-005 ..................... Decal Installation V2648 .... ~ ............................................................ Ref.

55999-006 ..................... Decal Installation V2648XL ........................................................... Ref.
55999-007 ..................... Decal Installation V2653 ................................................................. Ref.
55999-008 ..................... Decal Installation V2653XL ........................................................... Ref.
*1 55890 ............................ Decal, V Upper Operator's Instructions (V2648/53) ................ :........... 1
155889 ............................ Decal, V XL Upper Operator's Instructions (V2648/53XL) ............... 1
*2 55894 ............................ Decal, V General Caution ..................................................................... 1
*3 54652-003 ..................... Decal, GuardraiVChain Caution ............................................................ 1
~
55944-1000 ................... Decal, 1000 Rated Work Load (V2648/53XL) .................................... 2
55480-001 ..................... Decal, Lower Controls .......................................................................... 1
*6 55480-002 ..................... Decal, Lower Operator Instructions ...................................................... I
*7 54652-002 ..................... Decal, Ann Stand Caution ..................................................................... 1
*8 ~ 54984-005 ..................... Decal, Rear Bumper .............................................................................. 1
*9 66973 ............................ Decal, Electrocution Hazard .................................................................. 2
*10 if 55871-001 ..................... Decal, V XL Upper Electrical Box Top .. , ............................................. 1
55856-001 ..................... Decal, V Upper Electrical ~ox Top ...................................................... 1

*11 55871-002 ..................... Decal, V Upper Electrical Box Front .................................................... I
55856-002 ..................... Decal, V XL Upper Electrical Box Front .............................................. 1
Sy~-tJO,*12 5~8j4 997 ..................... Decal, Hydraulic Fluid .......................................................................... 1 •
13 55940-023 ..................... Decal, CONDOR 3.45 X 23 .................................................................. 2
14 56004-006 ..................... Decal, V2648 ......................................................................................... 2
56004-008 ..................... Decal, V26531XL .................................................................................. 2
15 55941-017 ..................... Decal, Condor "Bird" ............................................................................ 2
16 53259 ..........................•. Tape, Non-Skid Jet Black ......................................................•..... 1.50LF
17 66921 ............................ Coating, Non-Skid Jet Black ........................................................ .25GL
18 55999 ............................ Dwg., Decal Installation ...........~ ............................................................ 1
19 54984-006 ..................... Decal, 110 Volt Ext. To Platfonn (V2648/53XL) ................................ 1
31 ...................................... Nameplate Scissors Indentification .................................................. Ref.


*Indicates Included In Essential Decals
. . . . . . . . 111 .. D ..
.. 0 0 0 .. 111 . . . . . .
.. .. .. .. .. .. .. 0
tI
.. .. . . . . .. .
.... D ..........
..
..
. . . . .. . . ..
•
..
..
•
III
I)
.... "
..........
....
............ CI ..
....
co
.. .. . .. . . .. .
....
(10 ..........
D ..........
.. 2 1/4 MARGIN
NO NON-SUP
COATING
PLANVIEW OF
MODELS V20/264B/53 PARTIAL REAR VIEW Of
MODELS V20/2648/S3
MANUAL 92357-003
JUNE 1997
• FIGURE 3: Chassis Assembly - V26481XL
10 PL 27
TOP VIEW OF STEERING COMPONENTS
SEE NOTE 3
2 PL
TOP VIEW OF REAR AXLE

SEE NOTE 1
2 2 PL
2 PL
NOTES:
1. BRAKE RELEASE HANDLES MUST SWING

FREEL Y. DO NOT TIGHTEN BOLTS AND NUTS
ANY MORE THAN SNUG FIT (2 PL).
2. LOCTITE BDLTS INTO STEER KNUCKLES.
TOP VIEW OF RIGHT FRONT CORNER
3. ITEM 38, SPINDLE ASSY, INCLUDES SPINDLE, OF CHASSIS WELDMENT
WASHER, CASTLE NUT, AND COTTER PIN.
SPINDLE ASSY IS PART OF CHASSIS WLDMNT.
4. EST WT = 1248.D6 LB
MANUAL 92357-003
JUNE 1997
FIGURE3: Chassis Assembly -V26481XL.

Ref. 55623 ............................ Chassis Assembly - V26481XL ........................................................ Ref.
1 55712 ............................ Chassis Weldment V26481XL .............................................................. 1
2 34145 ............................ Bushing - (R#81368)'............................................................................. 2
3 81368-40-40 ................. Bearing, 2.50 ID x 3.00 OD x 2.50 LG ................................................. 2
4 55831-001 ..................... Knuckle Weldment LH Steer V26481XL ............................................ 1
5 55831-002 ..................... Knuckle Weldment RH Steer V26481XL ............................................ 1
6 54776 ............................ Thrust Washer - Kingpin ....................................................................... 2
7 55402 ............................ Retainer - Kingpin ................................................................................. 2
8 BOW30106 ................... Bolt, Hex .50-13UNC x 1.5 GRS ........................................................ 2
9 55621 ............................ Link - Steering ....................................................................................... I
~ l!.10 81368-03-08 ................. Gar-Max 1.00 x 1.25 x .50L ................................................................. 4
11 BOW3870S ................... Washer, Flat .75 ................................................................................... 6
12 BOW38231 ................... Pin, Cotter .12 x 1.50 L ........................................................................ 4
13 65057 ............................ Pin, Steer Cylinder 1" Dia.................................................................... 2
14 55534 ............................ Steer Cylinder Assembly ....................................................................... 1
15 54644 ............................ Motor, Hydraulic Wheel 14.9 V20481XL ........................................... 2
16 BOW30 109 ................... Bolt, Hex .50-13UNC x 2.25 ................................................................ 8
17 BOW36~95 .jt.B.\.......... Nut - 1/ 2"-13 ...........: ............................................................................... 8
18 5):31)2 ....~U.~.. ~.\.. ......... Hub Assembly - Dnve w/Studs ............................................................. 2
19 02236 ............................ Elbow 900 MJ08 FO 10 1.00LG ........................................................... 6
20 BOW38232 ................... Pin, Cotter .12 x 1.75L ......................................................................... 2
21 54885-001 ..................... Adapter - MOR08 FORI0 1.00LG ........................................................ 1
22 54885-002 ..................... Adapter - MOR08 FROIO 1.812LG ..................................................... 1
23 54885-003 ..................... Adapter - MOR 08 FORIO 2.625LG ..................................................... 1
24 54885-004 ..................... Adapter - MOR08 FORI0 3 .438LG ...................................................... 1
25 36085 ............................ Fitting -900 Elbow 8-8 Swivel ............................................................... 4
26 54929 ............................ Tire & Wheel Assembly ........................................................................ 4
27 91029 ............................ Nut, Wheel .50-20UNF (R#30288) ................................................... 10
28 54714 ............................ Cylinder, Brake ..................................................................................... 2
29 54796 ............................ Pin - Brake ............................................................................................. 2
30 54795 ............................ Handle (Weldment), Brake Release ...................................................... 2
31 54779 ............................ Rear Wheel Hub Assembly ................................................................... 2
32 54779-DWG ................. DWG - Rear Hub Installation ................................................................ 1
33 BOW36058 ................... Bolt, Hex .38-16UNC x 2.00 GR8 ...................................................... 2
34 BOW36062 ................... Bolt, Hex .38-16UNC x3.00 GR8 ....................................................... 2
35 BOW36703 ................... Washer, Flat .37 ID .81 OD GR8 SAE ............................................... .4
36 BOW34274 ................... Nut, Hex Lock 3/s"-16UNC .................................................................. 4
MANUAL 92357-003
JUNE 1997
G FIGURE3: Chassis Assembly- V26531XL
2 PL
TOP VIEW OF STEERING COMPONENTS
SEE NOTE 3
4 PL 26 PL
2 PL
TOP VIEW OF REAR AXLE

SEE NOTE 1
2 PL
NOTES:
1. BRAKE RELEASE HANDLES MUST SWING

FREELY. DO NOT TIGHTEN BOLTS AND NUTS
ANY MORE THAN SNUG FIT (2 PL).
2. LOCTITE BOLTS INTO STEER KNUCKLES.
3. ITEM 38, SPINDLE ASSY, INCLUDES SPINDLE,
WASHER, CASTLE NUT, AND COTTER PIN.
SPINDLE ASSY IS PART OF CHASSIS WLDMNT. TOP VIEW OF RIGHT FRONT CORNER
OF CHASSIS WELPMENT
4. EST WT = 1427.28 LB
MANUAL 92357-003
JUNE 1997
.......
.. CALAVAR SERVICE
PART NUWBER DESCRIPTION
54644 100 SEAL KIT FOR WHEEL II!OTOR

54644-101 HOLSING. BEARING
54844-102 SHAFT & BEARING KIT (I 1/4 IN TAPERED
54644-103 KEY FOR TAPERED SHAFT
54644 104 NUT. HEX FOR TAPERED SHAFT)
54644-105 PLATE. WEAR
54644 108 DRIVE. VALVE
54644 109
54644-110 . PLATE. VALVE
VALVE
54644-111 BALANCE RING
54644-112 PIN
54644-113 SPRING
54644-115 HOUSING. VALVE 7 8-14 STAGGERED PORTS
54644-116 PLUG ASSEMBLY ·W6-20UNF
54644-114 5,4644 117 54644-120 54644-123 14384 008 14384-010 14384 007 14384-012 BOLT
54644-106 54644-118 54644-121 54644 124 21371 005 21371 006 21371 004 21371-007 DRIVE
54644-107 54644 119 54644-122 54644-125 21625-005 21625-006 21625-003 21625-007 GEROLER
~d ~rlt0"'i/~
.!~
tof..:::,
rid Id
/~
~c1
~.:::.
'''I,~!/;
~ ~
I~ ,;~
It;"::::
~vf .pqf ~II/ ~II{
CALAVAR # CHAR-LYNN CIPR REF USED ON

I
. 54644-001
54644-002
105-1005
105-1006
11.9
14.9
V2033
VXX48
I
54644-003 105-1003 8.0 V14/18

54644-004 105-1007 18.7 VXX53
-- - -,._.
0
C
10216
9921 10/15jS6 RAK
UNL£'S!j 01WEltM$t NOTED:
"'-"'-"
~:~(111
_ _FINISI1
SlJltFACE 1~
" .... @c::J
..
.,.XX""'""",
$:.03
.liO: II: .010 nTU:
~
DlVISIOH OF T1ME WF'G.
8300 IWPEfUAL DRIVE
w.wo. lEICAS 11712
co.
B 9759
A 8322 RAK "' .......... MOTOR CHART, HYD WHEEL
"PO. ......
8/2/95 _~1NCII!S
L11l o.t.IiI.NO. .• DAtt

4885 7/13/VO RAK
"""""
A.HITTLE 'talK
BI OR
.-,., 54644 IREVo
~-------
"'-~ OR-N. NO. _~!-!E: ___ ~ """'OO!D ___ RAI'~_7f13[94__ SCALE NON~ _ .. _ . iSHE!T _~_9f 1
FIGURE 3: Chassis Assembly - V26531XL •

Ref. 55834 ............................ Chassis Assembly - V26531XL ........................................................ Ref.
1 55802 ............................ Chassis Weldment V26531XL .............................................................. 1
2 34145 ............................ Bushing - (R#81368) ............................................................................. 2
3 81368-40-40 ................. Bearing, 2.50 ID x 3.00 OD x 2.50 LG ................................................. 2
4 55818-001 ..................... Knuckle Weldment LH Steer V26531XL ............................................ 1
5 55818-002 ..................... Knuckle Weldment RH Steer V26531XL ............................................ 1
6 54776 ............................ Thrust Washer- Kingpin ....................................................................... 2
7 55402 ............................ Retainer- Kingpin ................................................................................. 2
8 BOW30106 ................... Bolt, Hex .50-13UNC x 1.5 GRS ........................................................ 2
.9 55621 ............................ Link - Steering ....................................................................................... 1
10 81368-03-08 ................. Gar-Max 1.00 x 1.25 x .50L ................................................................. 4
Ii BOW3870S ................... Washer, Flat .75 ................................................................................... 6
12 BOW38231 ................... Pirl, Cotter .12 x 1.50 L ...................................................................... ~.4
13 65057 ............................ Pin, Steer Cylinder 1" Dia.................................................................... 2
14 55534 ............................ Steer Cylinder Assembly ....................................................................... 1
15 54644-004 ..................... Motor, Hydraulic Wheel 18.7 V26531XL ........................................... 2
16 BOW30117 ................... Bolt, Hex .50-13UNC x 4.500 .............................................................. 8
17 BOW36~5 ..511[ .. ·...... Nut - 1/2"-13 ...........: .......................................... ···········,······:1r················ 8
18 ~2 ..... j.c ............... Hub Assembly - Dnve w/Studs .........~L.~~.Q{ ................. 2
19 02236 ............................ Elbow 900 MJ08 FOI0 1.00LG .......................................................... :6
20 BOW38232 ................... Pin, Cotter .12 x 1.75L ......................................................................... 2
21 54885-001 ..................... Adapter- MOR08 FORIO 1.00LG ........................................................ 1
22 54885-002 ..................... Adapter - MOR08 FRO 10 1.812LG ..................................................... 1
23 54885-003 ..................... Adapter - MOR 08 FORI0 2.625LG ..................................................... 1
24 54885-004 ..................... Adapter _ MOR08 FORIO 3.438LG ...................................................... 1
25 36085 ............................ Fitting _90 0 Elbow 8-8 Swivel ............................................................... 4
26 65089 ............................ Tire & Wheel Assembly (Foam) .......................................................... 4
27 91029 ............................ Nut, Wheel .50-20UNF (R#30288) ................................................... 10
28 54714 ............................ Cylinder, Brake ..................................................................................... 2
29 54796 ............................ Pin - Brake ............................................................................................. 2
30 54795 ............................ Handle (Weldment), Brake Release ...................................................... 2
31 54779 ............................ Rear Wheel Hub Assembly ................................................................... 2
32 54779-DWG ................. DWG - Rear Hub Installation .................................................... ;........... 1
34 BOW36062 ................... Bolt, Hex .38-16UNC x 3.00 GR8 ....................................................... 2
35 BOW36703 ................... Washer, Flat .37 ID .81 OD GR8 SAE ............................................... .4
36 BOW34274 ................... Nut, Hex Lock 3/s"-16UNC .................................................................. 4
37 55834-I).WG ................. Dwg., Chassis Assembly ................................................................. Ref.
38 55924 ............................ Spindle Assembly, SA-1750 ........................................................... Ref.
MANUAL 92357-003
JUNE 1997
• FIGURE 4: Hose Kit
P2 Pl
HYDRAULIC TANK
ELECTRIC MOTOR
LIFT CYLINDER
TOP
BELLYPAN
BACK WALL
BOTTOM
RIGHT MOTOR LEFT MOTOR
STEER
MANUAL 92357-003
JUNE 1997
FIGURE 4: Hose Kit.
Ref. 55884 ............................ Hose Kit V2648/531XL .................................................................... Ref.
1 66698-031.00 ................ Hose Assembly, #06 66645 137 ST-ST ................................................. 1
5 66698-120.00 ................ HoseAssembly, #06 66645 137 ST-ST ................................................. 1
6 66700-031.00 ................ Hose Assembly, #06 66645137 ST-STJ ............................................... 1
7 66700-032.00 ................ Hose Assembly, #06 66645 137 ST-STJ ............................................... 1
8 66043-014.00 ................ HoseAssembly, #0367684137 STJ-STJ ............................................. 1
9 66043-016.00 ................ Hose Assembly, #0367684137 STJ-STJ ............................................. 1
12 66696-006.00 ................ Hose Assembly, #0466646 137 ST-ST ................................................. 1
15 66696-020.00 ................ Hose Assembly, #04 66646 137 ST-ST ..............•.................................. 1
TOP
BELLYPAN
BACK WALL
o
BOTTOM
RIGHT
NOTES:
1. TAG EACH HOSE ASSEMBLY WITH PART NUMBER.
2. THE HOSE KIT IS 55884.
3. THE HOSE INST DWG IS 55884-DWG.
4. THE DWG IS NOT PART OF THE KIT.
MANUAL 92357"()()3
JUNE 1997
.FIGURE 5: Steer Cylinder
Ref. 55534 ............................ Steer Cylinder Assembly .................................................................. Ref.

55534-100 ..................... Seal Kit .................................................................................................. 1
1 55534-101 ..................... Locknut ................................................................................................. 1
2 55534-102 ..................... Glandnut ................................................................................................ 1
3 BOW32288 ................... Jam Nut, 3/4 "-16UNF ............................................................................ 1
MANUAL 92357-003
JUNE 1997
FIGURE 6: Cylinder, Brake.
/' I
0- @ @ I
Gj-
I
"-
I
I
I
0-
"-<
7 /16-20 a-RING
PORT TYP
If - . - - - - - - - - - - - - - - I
1---'-
10.18 EXTENDED - - - - - - - - - - - - - - - - - 1 -
3.06 -----1-1
9.31 RETRACTED
Ref. 54714 ............................ Cylinder, 1.75B x l.13R x .88 Stroke .............................................. Ref.
54714-100 ..................... Seal Kit .................................................................................................. 1
1 54714-101 ..................... 1acketAssembly .................................................................................... 1
2 54714-I02 ..................... Piston Rod ............................................................................................. 1
3 54714-103 ..................... Spring .................................................................................... :............... 1
4 ...................................... Teflon Backup (Included in Seal Kit 54714-100) ................................. 1
5 ...................................... Polypak (Included in Seal Kit 54714-100) ............................................ 1
6 54714-104 ..................... Piston (Alum) ........................................................................................ 1
7 ...................................... O'Ring (Included in Seal Kit 54714-100) .............................................. 1
8 ...................................... Polypak (Type 'B') (Included in Seal Kit 54714-100) ........................... 1
9 ...................................... O'Ring (Included in Seal Kit 54714-100) .............................................. 1
10 54714-105 ..................... Gland Nut .............................................................................................. 1
11 ...................................... Rod Wiper (Included in Seal Kit 54714-100) ....................................... 1
MANUAL 92357"()()3
JUNE 1997
• FIGURE 7: Hub Motor Assembly
10
9 . 1 1
6 1
1 1 1
10 11
ITEM PART NUMBER DESCRIPTION QlY

Ref. 54644-002 ..................... Motor, 14.9 Hydraulic Wheel- V2648 ............................................. Ref.
Ref. 54644-004 ..................... Motor, 18.7 Hydraulic Wheel- V2653 ............................................. Ref.
1 54644-100 ..................... Seal Kit For Wheel Motor ..................................................................... 1
2 54644-101 ..................... Housing, Bearing ................................................................................... 1
3 54644-102 ..................... Shaft & Bearing Kit (1 1/4 in Tapered) ................................................. .4
4 54644-103 ..................... Key (For Tapered Shaft) ....................................................................... 1
5 54644-104 ..................... Nut, Hex (For Tapered Shaft) .............................................................. 1
6 54644-105 ..................... Plate, Wear ............................................................................................ 1
7 54644-124 ..................... Drive ...................................................................................................... 1
54644-118 ..................... Drive ...................................................................................................... 1
8 54644-125 ..................... Geroler- V2648 ..................................................................................... 1
54644-119 ..................... Geroler - V2653 ..................................................................................... 1
9 54644-108 ..................... Drive, Valve ........................................................................................... 1
10 54644-109 ..................... Plate Drive ............................................................................................ 1
11 54644-110 ..................... Valve ..................................................................................................... 1
12 54644-111 ..................... Balance Ring ......................................................................................... 1
13 54644-112 ..................... Pin .......................................................................................................... 2
14 54644-113 .....................Spring ..................................................................................................... 2
15 54644-123 .........'............ Bolt ........................................................................................................ 4
54644-117 ..................... Bolt ........................................................................................................ 4
16 54644-115 ..................... Housing, Valve (1/8-14 Staggered Ports) .............................................. 1
17 54644-116 ..................... Plug Assembly 7/16-20UNF ................................................................... 1
MANUAL 92357..003
JUNE 1997
FIGURE 8: Hub Assembly, Rear •
Chassis Weldment
Ref.
9
/J
4
10
Ref. 54779 ............................ Hub Assembly .................................................................................. Ref.
1 54779-109 ..................... Hub ........................................................................................................ 1
2 54779-101 ..................... Inner Cup ............................................................................................... 1
3 54779-102 ..................... Inner Cone ............................................................................................. 1
4 54779-106 ..................... Seal ........................................................................................................ 1
5 54779-103 ..................... 0uterCup .............................................................................................. 1
6 54779-104 ..................... Outer Cone ............................................................................................ 1
7 BOW36718-HD ............ Washer ................................................................................................... 1
8 BOWI802 ..................... S1ottedNut,3/4"-16UNF ........................................................................ 1
9 BOW38233 ................... CotterPin, .125" x 2.00" ....................................................................... 1
10 54779-105 ..................... DustCap ................................................................................................ 1
11 54779-107 ..................... Stud ....................................................................................................... 5
12 54779-108 ..................... Stud Nut ................................................................................................ 5

MANUAL 92357"()()3
JUNE 1997
• FIGURE 9: Belley Pan Assembly
2 PL
4 PL
2 PL
o
."" '" "" .~ IIII

2 PL TO MANIFOLD 17 TANK
TROJAN (J:® TROJAN

~ ~ ~ 1 f E L L Y PAN FRONT WALL
125®B
pcs
~==~~~~~===-~-~-~ - -
1 2 PL
,---,,--j,-j
MANUAL 92357-003
JUNE 1997
FIGURE 9: Belly Pan ASSemblY.
Ref. 55673 ............................ Belly Pan Assembly ......................................................................... Ref.

I 55671 ............................ BellyPan Weldment .............................................................................. 1
2 54989 ............................ MotorlPumpAssembly .......................................................................... 1
3 55379 ............................ Valve Installation ................................................................................... 1
4 55297 ............................ Hydraulic Tank Assembly ..................................................................... 1
5 50316 ............................ BreatherFiller .................... :................................................................... 1
6 52049 ............................ Gauge - Fluid Level ............................................................................ '" 1
7 04699-08 ....................... Plug - Socket Hex .50 NPT ................................................................. 1
8 02806 ............................ Straight MJI0MP12 ............................................................................ 1
9 33430 ............................ Hydraulic Filter Assembly ..................................................................... 1
110-2 ............................. --FilterHead - Return Line ................................................................... 1
110-1 ............................. --Filter Element ...................................................................................... 1
10 00324 ............................ Elbow 90° MJ-08 MP12 ....................................................................... 1
11 02430 ............................ Straight MJ04 MB04 ............................................................................ 3
12 02431 ............................ Fitting - Straight MJ06 MB06 ............................................................... 2
13 02303 ............................ Elbow 90° MJ06 MB06 ........................................................................ 2
14 00354 ............................ Tee MJ06 MJ06 MB06 ........................................................................ 1
15 00334 ............................ Nut - Bulkhead 04 ................................................................................ 5
16 00336 ............................ Nut - Bulkhead 06 ................................................................................ 5
17 02662 ............................ Elbow 90° MJ06 M006 ........................................................................ 2
18 55703 ............................ Cable Kit ............................................................................................... 1
19 04674 ............................ Elbow 90° MJIO M008 ........................................................................ 1
20 02407 ............................ Tee MJ()4 MJ04 MP04 ........................................................................ 1
21 55693 ............................ Charger Mod............................................ ,............................................ 1
22 52138 ............................ Solenoid 24V ........................................................................................ I
23 55334 ............................ Jumper Assembly -12 LG Wire ......................................•..................... 1
24 54627 ............................ Washer, Arm Stand Retainer ................................................................ 4
25 55505 ............................ Battery Tie Down Angle 22" ................................................................. 2
26 55506 ............................ J-Bolt - Battery Hold Down .................................................................. 2
27 BOW30054 ................... Bolt, Hex .38-16UNC x 1.00 GRS ...................................................... 1
28 BOW30055 ................... Bolt, Hex .38-16UNC x 1.25 ................................................................ 2
29 BOW30057 ................... Bolt, Hex .38-16UNCx1.75 ................................................................ 2
30 BOW31433 ................... Washer, Flat .38x.810D GRSSAE ................................................. 5
31 BOW34274 ................... Nut,HexLock 3/s"-16UNC .................................................................. 5
32 BOW30037 ................... Bolt, Hex .31-18UNC x 3.00 ............................................................... 2
34 BOW31432 ................... Washer, Flat .31 ID x .68 OD ............................................................ 12
35 BOW34273 ................... Nut, Hex Lock 5116 -18UNC ............................................................... 4
36 BOW30003 ................... Bolt, Hex .25-20UNC x .875 LG ......................................................... 4
38 BOW36780 ................... Nut, Hex Lock Nylon .25-20UNC ....................................................... 6
39 55695 ............................ Tube Kit ................................................................................................. 1
40 04185 ............................ Fitting- Bulkhead Tee ........................................................................... 2
MANUAL 92357'()()3
JUNE 1997
• FIGURE 10: Motor & Pump Assembly
Ref. 54989 ............................ MotorlPump Assembly ..................................................................... Ref.

1 54761 ............................ Duplex Pump & Parts (See Page 23) .................................................. 1
54761-101 ..................... Seal Kit (Pump) ..................................................................................... 1
2 BOW30029 ................... Bolt,Hex.31"-18UNCx 1.00" .............................................................. 4
3 ...................................... Tag Nails ............................................................................................... .
4 BOW31444 ................... Washer, Flat 5/16" ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4
5 54759 ............................ 24 Volt Motor (See Page 25) ............................................................... 1
6 54989-100 ..................... Gasket .................................................................................................... 1
7 54760 ............................ Replacement Coupling ........................................................................... 1
8 [Not Used] .................................. :................................................................................................. 1
•
MANUAL 92357·003
JUNE 1997
~,
/
?J f 7
/
LEfT
SlOE OP2 6l BACK
oP1 SlOE
...,MJ ?
~l
f-o$1 ()1
' - f-oS2 111 1M2
-
II
II
019
j I ? II
II
1
1
1
1
II
II
'0
;V
, II
"
II
~
01
1
---®
It f yv )
- 'I
I
II lB 1
~
II
II TANt< II 1 11 55048 1.00 EA lUBE ASSY, 26JJ CYL \lENT TO T
I I - J-I
10 55697 1.00 EA lUBE ASSY, VXX48/5J MJ BlKHD
I~"~--J
0 9 55694 1.00 EA lUBE ASSY, VXX48/5J 1.11
BEU.Y PAN BACK WAIl. 8 55696 1.00 EA lUBE ASSY, VXX48/5J T TO FILlER
0
0 7 55051
6 55324
1.00
1.00
EA lUBE ASSY, 26J3 BRAKES TO T
EA lUBE ASSY, MDD26JJ B
5 55072 1.00 EA lUBE ASSY, 2633 1.12
4 55050 1.00 EA lUBE ASSY, 2633 MJ
J 5506J 1.00 EA lUBE ASSY, 2633 L
2 55064 1.00 EA lUBE ASSY, 2633 51
---
1 55076 1.00 EA lUBE ASsy, 26JJ S2
.t:I.OlE;.
1. TAG EACH TUBE ASSY WITH PART NUMBER
ITEM PART NUMBER
--
==-__
"':..:.-
=:-= ~(II
....
.......
_ oX
QTY
......
*.t
JIll • .m
1I1I.E
UM DESCRIPlION
~ ---
............ co.
-.co. 1IXM 71712
--
SHOWN IN THE BILL OF MATERIAL 0 c::J lUBE KIT, VXX48!53
-. 1-
L1II. o.e.H. NO.
loa
DAlE
RAI<
8EASON
""""'" B _NO. 55695
L1II. DJt.IL NO. """"'"
DAlE -. RAI< I1J/OJIW7 ......: 1:8 SHIET I OF I
1
-
-. - ~ 2 2PL
~ m
27/8
(2.875 REF) [V 3 2 PL
_t__________________________________________________________________________
.....
-
6 3/8
(6.375 REF)
5 1/2
(5.500 REF)
~------------------------------------------------- 36 3~6 ------------------------------------------------~~

(36.188 REF)
3
01209 2.00 EA TUBE SLEEVE-#04 (1319)
2.
01214 2.00 EA TUBE NUT-#04 (1318)
RUR00100
1 3.40 LF 18 HYD .250 00 .035W R04623
IlEU PART NUMBER QTY UM DESCRIPll0N
_"3:l~ ~
=-----.-=r _..
~~----~---+--~ ... - . .- ... ~
-=-~
WACO, TEXAS
I=~==~---------------------------;
. . "'1ru
TUBE ASSY, 2633 S1
t--I-----+----+---I - 011: 171 m -=--
\R£V.
1 OF 1
11
,
,
I'"
r
I
?r /
/
YJ
r
/
LEFT
SIDE
"-
OP2
'\ ""'"'0 S1
OL
T
OPl
BACK
SIDE
,...11.3
.... ?
r
-...$2 ()Ml ()M2
II G1C~
\I
II II
./ "-
10
I
I
C)
II
II
8
I'"
• II
II
II
"'"
01
1
- I ..I
D
II II
II TANK \I 11 55048 1.00 EA TUBE ASSY. 2633 CYL VENT TO T
10 55697 1.00 EA TUBE ASSY. VXX48/53 M3 BLKHD
o 9 55694 1.00 EA TUBE ASSY, VXX48/53 Ml
BELL Y PAN BACK WALL BELL Y PAN FRONT WAll 8 55696 1.00 EA TUBE ASSY, VXX48/53 T TO FILTER
o
7 55051 1.00 EA TUBE ASSY. 2633 BRAKES TO T
6 55324 1.00 EA TUBE ASSY, MDD2633 B
5 55072 1.00 EA TUBE ASSY, 2633 M2
4 55050 1.00 EA TUBE ASSY. 2633 M3
.3 55063 1.00 EA TUBE ASSY, 2633 L
2 55064 1.00 EA TUBE ASSY, 2633 Sl';c / "~
1 55076 1.00 EA TUBE ASSY. 2633 S2
ITEM PART NUMBER QTY UM DESCRIPTION
•
UNLESS OTHERWISE 'iOlEO:
DIVISION OF TIME MFG. CO.
NOTE: 1---+----1-----+---1 TOlERANCES: 8300 IMPERIAL DRIVE
:.•.....
1-_-1-_ _-1-_ _--\_--1 ~~~~~S; ~(16 WACO. TEXAS 76712
1. TAG EACH TUBE ASSY WITH PART NUMBER SURF ACE FINISH 12V
SHOWN IN THE BILL OF MATERIAl. 1----+--_-1-_ _--\_--1 PROJECTION OF VIEWS' @ c:::J TUBE KIT, VXX48/53
ALL OIMENSIONS ARE IN INCHES
LTR. D.C.N. NO. DATE APPR. DRAWN BEASON 02/28/97 SIZE DRAWING NO.
~---+~~~4---~~~--~B
- 105:5'1 t..lz~jcI7 CHECKED AI, 55695
LTR. OcR.N. NO. DATE APPR. APPROVE0h1'& SCALE 1: 8 ISHEET 1 OF 1
FIGURE 11: Pump ASSembly.
SECTION A-A
A 14
15
©
© 12
A
HYDRAULIC SCHEMATIC
B 24 23 4 11
OUTLET PORTS
9/16-18 SAE 20
Ref. 54761 ....... u Duplex Pump & Parts .......................................... :............................ Ref.
•••••••••••••••••••
54761-100 ..................... Seal Kit .................................................................................................. 1

1 54761-103 ..................... Gear Housing ......................................................................................... 1
2
3
4 54761-108 ..................... DrivePin ............................................................................................... 1
5 ........ .....................................................................................................................................................
"
6 ...................................... Oil Seal (in seal kit) ............................................................................... 1

7 54761-112 ..................... Drive Shaft ............................................................................................ 1
8 ...................................... Lee Plug ................................................................................................ 1
9 54761-107 ..................... 375 Gear Face ....................................................................................... 1
10 ...................................... Gasket (in seal kit) ................................................................................. 1
11 54761-102 ..................... Needle Bearing ...................................................................................... 1
12 54761-101 ..................... Idler Shaft .............................................................................................. 1
13 54761-105 ..................... Stator ..................................................................................................... 1
14 54761-106 ..................... Screw ..................................................................................................... 8
15 54761-109 ..................... Shear Pin ............................................................................................... 1
16 ...................................... Plastic Plug ............................................................................................ 1
17 ...................................... Gasket (in seal kit) ....... ~ ......................................................................... 1
18 54761-111 ..................... Woodruff Key ....................................................................................... 1
19
20 ...................................... Plastic Plug ............................................................................................ 1
21 ....................................................................................................................................................... .
22 ........................................................................................................................................................
23 54761-110 ..................... CreascentRing ...................................................................................... 1
24 54761-104 ..................... Gear Housing ......................................................................................... 1
MANUAL 92357-003
JUNE 1997
• FIGURE 12: Motor 24VDC Assembly
-l----l-
NAMEPLATE
21
15
MANUAL 92357-003
JUNE 1997
FIGURE 12: Motor 24VDC ASSembly.
Ref. 54759 ............................ Motor, 24VDC Assembly ................................................................. Ref.

1 ...................................... Complete Stator Assembly .................................................................... 1
2 NSS ............................... CompleteTerminaIAssembly ............................................................... 2
3 ...................................... Screw Hex fill Cap 3/8"-16 ................................................................... 2
4 ...................................... JamNut, Hex 1/s"-16 ............................................................................. 2
5 ...................................... JamNut, Hex l /s"-16 ............................................................................. 2
6 ...................................... Insulator ................................................................................................. 4
7 ...................................... Insulator ................................................................................................. 2
8 ...................................... LockWasher,Split 3/ s" .......................................................................... 2
9 ...................................... LockWasher,Ext. TffI3/S" .................................................................. 4
10 ...................................... Field Coil Assembly .............................................................................. 1
II ...................................... Field Pole .............................................................................................. 4
12 ...................................... Screw, BTIN fill Socket, 3/8 "-16 x S/s" ................................................. 8
13 ...................................... Field Coil Terminal ............................................................................... 1
14 ...................................... Loctite,222 ............................................................................................. .
15 ...................................... Pulley Cover .......................................................................................... 1
16 ...................................... Screw, Socketfill#10-32xl.00" ......................................................... 4
17 54759-117 ..................... Complete Armature Assembly .............................................................. 1
18 54759-118 ..................... Fan ......................................................................................................... 1
19 54759-119 ..................... Bearing, Pulley ...................................................................................... 1
20 54759-120 ..................... Bearing,Comm ..................................................................................... 1
21 ...................................... Complete Comm Cover Assembly ........................................................ 1
22 54759-122 ..................... Complete Brush Ring Assembly ........................................................... 1
23 54759-123 ..................... Brush Spring ........................................................................................... 8
24 54759-124 ..................... BrushAssembly .................................................................................... 2
25 ...................................... Screw, RH Slotted #10-32 x 3/4" ............................................................ 4
26 ...................................... Nut, Hex #10-32 .................................................................................... 4
27 ...................................... Washer Bearing Spring ......................................................................... 1
28 ...................................... Screw, Hex fill #10-32 x 2.00" ............................................................. 4
29 54759-129 ..................... Brush Inspection Cover ......................................................................... 1
30 ...................................... Screw, PH fill #10-32 x 1-3/ 4" .............................................................. 1
31 ...................................... Nut, Square #10-32 ............................................................................... 1
32 ...................................... Insulator ................................................................................................. 1
33 ...................................... Screw, RH Slotted 1/4"-20 x 3/s" ............................................................. 2
34 ...................................... Lock Washer, Ext. TffI 1/4" .................................................................. 2
35 54760 ............................ CouplingAssembly ........................................................................... Ref
NSS - Not Sold Separately

MANUAL 92357-003
JUNE 1997
• FIGURE 13: Valve Installation
3
P2 L P1
~~ ~
~
M2
REAR VIEW
LEFT END VIEW

MANUAL 92357-003
JUNE 1997
FIGURE 13: Valve Insta1lation •
CREEP
o
.0
RIGHT END VIEW
Ref. 55379 ............................ Valve Installation ............................................................................. Ref.

1 55296 ............................ Valve Assembly .................................................................................... 1
2 54892 ............................ Valve, Load Control .............................................................................. 2
3 02525 ............................ Straight, MJ04 M004 ............................................................................ 3
4 02448 '" ......................... Straight, MJ06 M006 ............................................................................ 5
5 00458 ............................ Straight, MJ08 M008 ............................................................................ 1
6 04579 ............................ Elbow, 900 MJ06 M006 LL ................................................................. 1
7 04682 ............................ Tee, MJ04 M004 MJ04 ........................................................................ 1
8 04003 ............................ Nut, Cap #04 ......................................................................................... 2
MANUAL 92357-003
JUNE 1997
• FIGURE 13: Valve Assembly
A B
I 9
~
§]
A
FRONT VIEW
12
0
RIGHT END VIEW

J
B
=
= =
=
BACK VIEW B-B LEFT END VIEW A-A
MANUAL 92357-003
JUNE 1997
FIGURE 13: Valve Assembly •
ITEM PART NUMBER DESCRIPTION QIY
Ref. 55296 ............................ Valve Assembly ............................................................................... Ref.

1 55337-001 ..................... Manifold, Valve ..................................................................................... 1
2 54646-004 ..................... Valve, Drive .......................................................................................... 1
3 54646-001 ..................... Valve, Steer ........................................................................................... 1
4 54646-005 ..................... Valve, Select ................................................. ,....................................... 1
5 54639 ............................ Cartridge,2WayNOSpooIValve ......................................................... 2
6
7
54852-052 ..................... Orfice,0.052 Dia.lIF 1 °. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54641 ............................ Cartridge,4WayNOSpooIValve ......................................................... 2
1
8 54634 ............................ Cartridge, Flow Divider Valve ............................................................... 1

9 54890 ............................ Cartridge, Dir. Act. Relief Valve .......................................................... 1
10 54640 ............................ Cartridge, Check Valve ......................................................................... 1
11 54889 ............................ Cartridge, Flow Control Valve ............................................................... 1
12 54622 ............................ Cartridge, Needle .................................................................................. 1
13 54638 ............................ Cartridge, Sequence Valve .................................................................... 1
MANUAL 92357-003
JUNE 1997
.FIGURE 14: Charger 115V/60HZ-25A124VDC
( D
.,"·OLTS tERTZ MODEL DCYOlTS U." PAT.NO.:I.H4....

Dill [![] 1178701 [E] U.IR.PAT.NO.1.414.151
fA.PAT.NO.t ..oa,1"
PMAI£ SERtALNO. KAMPa
'-CAlI'"
CD m [KJ
W.CIR,PAT.NQ."U1.n1
JAPANPAT.NO.S31331117'
TERMINAL, 3/8 RING

I
2 PLCS.\
10
I
Blp..~
I
I
I DC CORD: #12 AWt;,
I R[D~ 2 PL
60 ± 1-----1
~o
III
2 PLCS.
.281 X .625 SLOT

I
MOUNTING HOLES
4 PLCS.
(IN BASE LEG)
AMMETER, 0-30 AMP
r I
r.1®
III .::::::=::::::: .::::::=::::::: .::::::=::::::: ~
I
II
.::::::=::::::: .::::::=::::::: .::::::=:::::::
.::::::=::::::: .::::::=::::::: .::::::=:::::::
~
I
I
.::::::=:::::::
.::::::=:::::::
.::::::=:::::::
.::::::=:::::::
.::::::=:::::::
.::::::=:::::::
.::::::=:::::::
.::::::=:::::::
.::::::=:::::::
.::::::=:::::::
.::::::=:::::::
.::::::=:::::::
\~
I
VENTILATION LOUVERS
ON BACK SIDE
I .::::::=::::::: .::::::=::::::: .::::::=::::::: I
.::::::=::::::: .::::::=::::::: .::::::=:::::::
I
I
.::::::=:::::::
.::::::=:::::::
.::::::=:::::::
.::::::=:::::::
.::::::=:::::::
.::::::=:::::::
.::::::=:::::::
.::::::=:::::::
.::::::=:::::::
\ps
® ®
MANUAL 92357.003
JUNE 1997
FIGURE 14: Charger 115V/60HZ-25N24VDC.
ELECTRIC TIMER
BLACK
RED
GREEN
TRANSFORMER FAN
RED or WHITE
+
TO SA TTERIES
BLACK
2
BLACK
WHITE
120 VOG
INPUT
-GREEN WIRE NOT USED
ON SOME MODELS.
Ref. 54908 ............................ Charger, 115V/60HZ-25N24VDC .................................................. Ref.

54908-101 ..................... Transformer Assembly ........................................................................... .
54908-102 ..................... Heatsink Assembly, with Diodes ........................................................... .
54098-103 ..................... Ammeter ................................................................................................. .
54908-104 ..................... Electronic Timer Assembly .................................................................... .
54908-105 ..................... Capacitor, 6.0 MFD,660VAC ................................................................ .
54908-106 ..................... Fuse Assembly ....................................................................................... .
MANUAL 92357-003
JUNE 1997
•
This Page Intentionally Left Blank
MANUAL 92357-003
JUNE 1997
FIGURE 14: Charger 115V/25AMOd. •
1 1 - - - - - - 23
BLK
BATTERY
CHARGER
REO
Ir----____ 36
Ref. 55693 ............................ Charger, 115V/25A Mod .......................................................... Ref.

I 54908 ............................ Charger, 115V/60HZ-25A124VDC ............................................... 1
2 BOW23065 ................... Ring Terminal, 12Ga. 3/8 Stud ..................................................... 2
MANUAL 92357-003
JUNE 1997
PROP DRIVE CABLE/HARNESS STANDARD
,'Tj
~-
OPTION IS INCLUDED IN LOWER BOX WlRINC CONNEcnON IN LOWER BOX
19120)2 PL CIRCUIT
>-<
10
,- COLOR
'GRN U:- NO OPTiONS
BLu
DRIVE VALVE
.Btl!.
BLU!BlK
STEER VAL\/[
REO/BLK BATTERY CONDITION INDICATOR OPTION
DRN STEER lEn
SELECT VALVE
10AI BlK
'1=8LK
ORN/BU< STEER RIGHT Vl
80 I WHT/BLK WHT RAISE PLATFORM
~
1111. REO WHT/BU( LOWER PJ...A Tf'ORM
12 GRN/SLK 10 BlK FAST DRIVE SPEED
laC=WHT MOTION
OPTION
OPTION
,aO .. WHT
TRAVEL
.f9.W~H DESCEND
11
12
BLK/WHT
GRN/BlK
CREEP DRIVE SPEED
POSITRACTION
BELOW ARE LISTED CONDUCTORS IN CABLE
5:
OPTIONAL
16GA/2C ALARM
THAT IS PART Of" CERTAIN OPTIONS.
(REF OPTIONAL 16GA/1SC 67295-003) cffl
[
67295-035 OPTIONS Ll PROPORTIONAL DRIVE OPTION
14 SLOPE ALARM OPTION
15 BlU T INDICATE LOW VOLT OPTION
....a-
} ,1-tlLK • ~ ) STROBE LICHT OPTION
16 BLK/RE'D OVERRIDE LOW VOLT OPTiON
\ CONNECTOR & CABLE
OPTIONAL 1SGA/2C IF295-0:l5 SU8-ASSY IS INCLUDED
IN ARM INST.
S ... ORN
(t~:,!KT 4---J VAL V( ON Crt
S .. WHT
2-SlU
0
III §
@J
12=GRN/BlK
~
~
00
Vi
w
~
~I
rg~
'86 .. WI-I1 SIGNAl
REF
WELD STUD
23) REF
'l=CRN :ROVND
-J~ 8D=WHT/BLK
".ORN CROUND
11.)=RED fOR PROPORTIONAL DRIVE OPTION

__ eLK PO'
'SB=BlU POWER
14=RED/BLK FOR STANDARD WIRING OPTIONAL 16GA/eC 67295-024 CABLE

14-SLU/8LK FOR PROPORTIONAL DRIVE OPTION FROM LOWER CONTROL BOX. REFER
TO STANDARD CABU: SHOWN BELOW REF
I1DA=BLK WELD STUD
7 .. 0RN/BLK
'ea .. WHT ~GN
l1A .. RED FOR STANDARD WIRING
I11A"SLK/WHT FOR PROPORTIONAL DRIVE OPTION I-eRN GROUND "
"B-alK POWER
RED/BLK-SPARE WITH PROPORTIONAL DRIIJE OPTION
l .. GRN SIGNAL HORN OPTiON
STANDARD CABLE fROM
LOWER CONTROL BOX
!!2ruiL
t. SEE 54918-0WG FOR 110',1 EXT
2. THIS OWG IS SIIolILAR TO 55647.
FIGURE 15: Wiring Installation - V2648/53XLG
Ref. 55870 ............................ Wiring Installation ............................................................................ Ref.

1 55331 ............................ Jumper, 3 Lg Wire ................................................................................. 6
2 55330-001 ..................... Jumper,21 1/2" LgWire ......................................................................... 1
3 55829 ............................ Harness, Lift Cylinder Valve ................................................................. 1
4 55330-003 ..................... Jumper, 14 1/ / ' Lg. Wire ........................................................................ 1
5 55878 ............................ Switch Assembly, V Chassis Limit ....................................................... 1
6 55868 ............................ Spacer, .5 OD x #10 ID x.5 L Nylon ................................................... 2
7 BOW31148 ................... Screw, Slotted Rnd. Head 10-32 x 2.00 ............................................... 2
8 BOW31233 ................... Nut, Hex Keps #10-32 .......................................................................... 2
9 67837-006 ..................... Tie, Nylon-6" Black .............................................................................. 1
10 55222 ............................ Cover, Chassis Electrical Terminal ....................................................... 1
11 34552-008 ..................... Terminal Strip ...................................... ,................................................ 1
12 BOW31130 ................... Screw, Slotted Rnd. Head #8-32 x .50 ........................... :..................... 2
13 BOW31232 ................... Nut, Hex Keps #8-32UNC ................................................................... 2
14 54952 ............................ Support (Weldment), Cable ................................................................... 1
15 BOW34980 ....................Pin,Roll .125 x 1.250 ........................................................................... 1
16 54926 ............................ Tray, Extension Cable ........................................................................... 1
17 BOW34575 ................... Bolt, Carriage .25-20UNC x .75" ......................................................... 2
18 BOW30002 ................... Bolt, Hex .25-20UNC x .75 .................................................................. 2
19 BOW31444 ................... Washer, Flat .251D x .63 OD ................................................................ 6
20 BOW34272 ................... Nut, Nylon Lock .25-20UNC ............................................................. 11
21 67281-005 ..................... Wrapping, Spiral- 3/4" Black ..........................................................66LF
22 65099-12 ....................... Clamp,Loop .75 Dia............................................................................ 2
23 55872-001 ..................... Jumper Assembly - 14 "L Ground Wire ................................................. 1
58274 ............................ --Wire - 12Ga. Green Bulk .......................................................... 1.12LF
BOW23 062 ................... --Terminal Ring #67960 12-10 .25 Stud ............................................... 1
BOW23068 ................... --Termina18 Stud 16/14Ga. Spade ........................................................ 1
24 55330-002 ..................... Jumper Assembly - 24 "L Wire .............................................................. 1
55298 ............................ --Wire, 16Ga. Green .................................................................... 1.93LF
BOW23 024 ................... --Terminal Ring #67960 16114Ga..25 Stud .......................................... 1
BOW23087 ................... --Coupler - R#67963 16114 Female ....................................................... 1
MANUAL 92357-003
JUNE 1997
.FIGURE 16: Box Assembly - Lower Control
OPERATING
o INSTRUCTIONS
fOOPERA'lEI'ROI.IIGROUND.
l'I.IRNSlilTCHTOi.0WER"f"OSI1ION.
.IJtAAlEIKllGEfrC.... PUSHlilroauTTON.
TO CIP£lI:iIo.lE. tuT'fCft IoIUST BE PUU.EI> OUT.
-PuSH 'ItlGQ.£ SWITCH 10 UO'o£ PLA1FOfIW.
TUaN S.lCH Tn "uPPER" POSItION.
TC OP£RAtE FRCt.I PLATFOItt/I.
NOTES:
1. DECALS. ON OUTSIDE OF BOX. ARE SHOWN FOR REF ONLY.
2. THIS ASSY IS SIMILAR TO 55853.
3. FEATURES SHOWN ".**" ARE TO BE PROTO TYPED.
PART NUMBER DESCRIPTION

55869-001 BOX ASSY. V2033 LOWER ELEC
55869-002 BOX ASSY. V2033XL LOWER EL
55869-003 BOX ASSY. VXX48/53 LOWER
EST. WT. = 15 LBS 55869-004 BOX ASSY. VXX4S/53XL LWR
WITH ALL OPTIONS
MANUAL 92357-003
JUNE 1997
FIGURE 16: Box Assembly - Lower Control.
Ref. 55869-004 ..................... Box Assembly - Lower Control ....................................................... Ref.

1 55488 ............................ Box, Mach. Lower Control ................................................................... 1
2 55893 ............................ Decal, Lower Control Box Electrical Tags ........................................... 1
3 51913 ............................ Operator, Red P-Pull ............................................................................. 1
4 51914 ............................ Base + 1 NC Contact ............................................................................ 1
5 52671 ............................ Operator, 3 Pos. Rot .............................................................................. 1
Akk02016 ...................... -Key ..................................................................................................... 1
6 52029 ............................ Base + 2 NO Contacts .......................................................................... 1
7 50075 ............................ Switch, (Ref PIN 67760) ....................................................................... 1
8 54438 ............................ Relay, 24V SPDT Bosch ...................................................................... 1
9 206-00001-00 ................ Diode ..................................................................................................... 8
10 67114-013 ..................... Strain Relief 1 NPT .62/.75 ................................................................... 1
11 67114-008 ..................... Connector, Strain Relief ........................................................................ 1
12 67114-009 ..................... Strain Relief, 3/4" NPT .62/.75 ............................................................... 2
13 67124-003 ..................... Locknut, 1" NPT .................................................................................... 1
14 67124-002 ..................... Locknut, 3/4NPT Conduit ...................................................................... 3
15 67123-003 ..................... Seal, Connector Elect 1" ........................................................................ 1
16 67123-002 ..................... Seal, Connector Elect. 3/4 " ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 3
17 BOW23022 ................... RingTongue .......................................................................................... 3
18 67837-006 ..................... Tie, Nylon 6" Black ............................................................................... 8
19 BOW31430 ................... Washer, Flat #10 ID .............................................................................. 1
20 BOW31129 ................... Screw, Slot Round Hd 8-32UNC x .375 ............................................... 1
22 BOW31124 ................... Screw, Round Hd #6-32UNF x 1/2"Lg .................................................. 4
23 BOW31231 ................... Nut, Hex Keps #6-32 ............................................................................ 4
24 BOW31428 ................... Washer, Flat #6 ..................................................................................... 4
25 67295-024 ..................... Cable, 8 Condo 16AWG Type SO .............................................. 9.50LF.
26 67295-004 ..................... Cable, 12 Conductor 16Ga ............................................................... 5LF.
27 67295-022 ..................... Cable, 12 Gal3C ......................................................................... 6.50LF
28 34552-016 ..................... TerminaIStrip ........................................................................................ 2
29 67940 ............................ Holder, Fuse .......................................................................................... 1
30 67939-015 ..................... Fuse, 15Ga 1/4" x 1-1/4" .......................................................................... 1
31 58251 ............................ Wire, 12Ga. White ........................................................................... 4LF.
32 58292 ............................ Wire, 16Ga. White ........................................................................... lLF.
33 66720-001 ..................... Disconnect, STA-KON Female ............................................................ 6
34 BOW23087 ................... Terminal, Female Push-On .250W ........................................................ 3
35 67960-006 ..................... Terminal, Ring 10 16-14AWG ............................................................... 2
36 BOW23024 ................... Ring, Tongue 16-14 Ga 1/4 Stud ............................................................. 1
37 BOW23025 ................... Terminal, Ring Tongue 16-14Ga ........................................................... 1
38 BOW18578 ................... Terminal, Piggyback R 67963 ................................................................ 1
39 BOW23087-2 ................ Terminal, Female Push-On .250W ........................................................ 2
40 BOW23028 ................... Terminal, 8 Stud 12/10Ga. Spade .......................................................... 4
41 67961-006 ..................... Terminal, 8 Stud 121l0Ga. Spade ........................................................ 10
MANUAL 92357-003
JUNE 1997
- - - - - - - - - - - - - - - -
,-
'"rj
I, '$0
~V
41 3 PL
3 I
5 t C\ 0
~ ~6rd
'i@1~
rl 1.--'
12 GA
5
50
12 GA l @
~
.....
~
r-=T~~ 3 ttl
~~p
41 2 PL 0
'f== I ~
10 -
\'~? '== 9 "DOWN" -;-;=;:r:
~r-- ~ ~
~"
SPARE V-- ~ ----" CI.I
~
F== I-
'l===
~~ 8 "UP"
T ~ ~
-<
'
~
~?
88
v--; ~? V
~34PL I
I
17 3 PL
w
I
t'""
~
~I
V- l=f2 ~2
~
0
~ i===
8 r.,..
7 IT , Ff3p
F=f4
---- 3 UPPER 3L~~
PL
50
I-
~I
~
""I
~ bl~c:a~
~5D
1Z GA
~~ ,
F=f5 po SPARE Q
rl~9~
6 ,
,)
F=r6 ISOLATE
ij
il f
~
8A
80
'=
I~ T
+=,?
o!==
/"
I
I
LOWER 5G 'i@1
39
40 J PL
I
-
0
~ ~1l" 5
r==:= ~
12 GA
J
-",
:Btl ~
.~ ~
39
0
38
34
58 V
I
- - - t- - - -
T
r--.
~HYD ~
TO T8 ON
CHASSIS ~
TO ARMS/
PLATFORM ( V~MOTORCONTACTOR
NOTES:
-
1. THIS SHEET SHOWS "STANDARD" WIRING ONLY.
FOR A~Y _A"i~ ~~L OPTI0"iS,_~E_E _S~EET_!. _ _
D, AS MARKED.
BOTTOM
3. LOCATE ITEM 2, "EL TAGS", BETWEEN TERMINAL BOARDS.
COVER, SHOWN
FOLDED OPEN
~
ITEM PARTNUMBER DESCRIPTION QIY

4 51914 ............................ Base + 1 NC Contact ............................................................................ 1
5 52671 ............................ Operator, 3 Pos. Rot .............................................................................. 1
Akk02016 ...................... -Key ..................................................................................................... 1
6 52029 ............................ Base + 2 NO Contacts .......................................................................... 1
7 50075 ............................ Switch, (Ref PIN 67760) ....................................................................... 1
9 206-00001-00 ................ Diode ..................................................................................................... 8
. 10 67114-013 ..................... Strain Relief 1 NPT .62/.75 ................................................................... 1
12 67114-009 ..................... Strain Relief, 3/4" NPT .62/.75 ............................................................... 2
13 67124-003 ..................... Locknut, 1" NPT .................................................................................... 1
14 67124-002 ..................... Locknut, 3/4NPT Conduit ...................................................................... 3
15 67123-003 ..................... Seal, Connector Elect 1" ........................................................................ 1
17 BOW23022 ................... RingTongue .......................................................................................... 3
18 67837-006 ..................... Tie, Nylon 6" Black ............................................................................... 8
23 BOW31231 ................... Nut, Hex Keps #6-32 ............................................................................ 4
24 BOW31428 ................... Washer, Flat #6 ..................................................................................... 4
27 67295-022 ..................... Cable, 12 Ga/3C ......................................................................... 6.50LF
28 34552-016 ..................... TerminaIStrip ........................................................................................ 2
29 67940 ............................ Holder, Fuse .......................................................................................... 1
30 67939-015 ..................... Fuse, 15Ga 1/4" x 1-;1/4" .......................................................................... 1
31 58251 ............................ Wire, 12Ga. White ........................................................................... 4LF.
32 58292 ............................ Wire, 16Ga. White ........................................................................... lLF.
38 BOW18578 ................... Terminal, Piggyback R 67963 ................................................................ 1
39 BOW23 087-2 ................ Terminal, Female Push-On .250W ........................................................ 2
MANUAL 92357'()()3
JUNE 1997
TABLE 1
H COLOR FUNCTION
o
":rj
......
~-
1 BLU GROUND
,1 ORN STROBE LIGHT OPTION
1:-r
10
lOB
BLK
WHT
"FAST" TO LIMIT SWITCH
FROM LS TO INHIBIT FAST
o o
9 WHT BLK LOWER PLATFORM
11 GRN "CREEP" TO LIMn 5WITCH
- -
l1A RED
RED/BLK
FROM LS TO CREEP VALVE
SEE NOTE 2 ON SHEET 4
R"
," I
(REF) ttl
~
67964-002
INSIDE I S' SLOPE SENSOR/WHT
CABLE FOR "XL" MODELS IN'~IDE INSIDE (REF)
~
1
BjOX I BOX 67964-002
TO HYD VALVE ASSY BOX
5' SLOPE SENSOR/RED
SEE TABLE 2
~
~
(REF)
I I: 67964-002
o I I o S' SLOPE SENSOR/BlK
FI::::l,
I
F::::l, -<
S10 CABLE
(REF)
~
~
TO MOTOR
CONTACTOR (REF) GROUND
SIGNAL CONTACTOR
CONTACTOR
SEE
TABLE 3 (J
iii'"
-~
~I-'"
TO HYD
VALVE ASSY
SEE TABLE 2
:gtl SIGNAL
-.~
"XL" MODELS TABLE 2 STANDARD

= 1. LENGTHS, SHOWN AS ..... ,
ARE TO BE PROTOTYPEO.
# FUNCTION COLOR FUNCTION N
IDA FAST BLK FAST IDA
B UP WHT UP 8
13 PROP OR RED CREEP l1A
1 GROUND GRN SPARE
6 LEn ORN LEFT 6
2 FORWARD BLU FORWARD 2
BD DOWN WHT/BLK DOWN BO
SPARE RED/BlK REVERSE 4
12 POSITRAC GRN/BlK POSITRAC 12
7 RIGHT ORN/BlK RIGHT 7
4 REVERSE BLU/BlK
l1A CREEP BlK/WHT
ITEM PARTNUMBER DESCRIPTION QIY

4 51914 ............................ Base + 1 NC Contact ............................................................................ 1
5 52671 ............................ Operator, 3 Pos. Rot .............................................................................. 1
Akk02016 ...................... -Key ..................................................................................................... 1
6 52029 ............................ Base + 2 NO Contacts .......................................................................... 1
7' 50075 ............................ Switch, (Ref PIN 67760) ....................................................................... 1
9 206-00001-00 ................ Diode ..................................................................................................... 8
10 67114-013 ...................... StrainReliefl NPT .62/.75 ................................................................... 1
12 67114-009 ..................... Strain Relief, 3/4 " NPT .62/.75 ............................................................... 2
13 67124-003 ..................... Locknut, l"NPT .................................................................................... 1
14 67124-002 ..................... Locknut, 3/4 NPT Conduit ...................................................................... 3
15 67123-003 ..................... Seal, Connector Elect 1,. ........................................................................ 1
17 BOW23022 ................... RingTongue .......................................................................................... 3
18 67837-006 ..................... Tie,Nylon6" Black ............................................................................... 8
19 BOW31430 ................... Washer,Flat#10ID .............................................................................. 1
23 BOW31231 ................... Nut, Hex Keps #6-32 ............................................................................ 4
24 BOW31428 ................... Washer, Flat #6 ..................................................................................... 4
27 67295-022 ..................... Cable, 12 Gal3C ......................................................................... 6.50LF
28 34552-016 ..................... Terminal Strip ........................................................................................ 2
29 67940 ............................ Holder, Fuse .......................................................................................... 1
30 67939-015 ..................... Fuse, 15Ga 1/4" x 1-1/4" ......•••..............•.......•........•••.••••..•.•....•.•.............. 1
31 58251 ............................ Wire, 12Ga. White ........................................................................... 4LF.
32 58292 ............................ Wire, 16Ga. White ........................................................................... lLF.
38 BOWl 8578 ................... Terminal, Piggyback R 67963 ................................................................ 1
39 BOW23 087-2 ................ Terminal, Female Push-On .250W ........................................................ 2
41 67961-006 ..................... Terminal, 8 Stud 121l0Ga. Spade ........................................................ 10
MANUAL 92357-003
JUNE 1997
• FIGURE 16: Box Assembly - Lower Control
- - - -
~l
5
~(\J
12 GA
~i~~f'
50
!2:
:3 12 GA
12 GA
:m
~ =
10 ~ I "DOWN"
5G
1c5A
= ------ I
'-'=.)
= "up"
;!"
r-: ~
~ 12
r- =IT'
14 I
15 "UPPER"
~ 8A 16 I
w
=f= C\
JE~r~-+--r--+----~1 ,= :.J
l,: 1 ==::-.
"LOWER"
i7i
l-
I
"oc
lQi: (crn~
I
-~
12 GA
I
- I-
--... /-.....
o HYD ( . 0 ARMS/ TO ~TACTOR
ifALvES ~-=--r-ooM AND SLOPE SENSOJ
BOTTOM OF BOX I
80W230"\
fiI-fi1 ~ ~'
- - :l m
SLOPE ALARM OPTION
U
EJ EJ ' :<1 NOTE 4 I
15 c==-- fT/;
F====~;~1~~~p
1'----f---=!8,Af-0--h
;
3
ALARM
1
~//
©
I
§
B~j;O 4 INTERRUPT
16 ~ 0 5 RESET
1 ~ 6 GROUND
~~ ~ POWER _ _ COVER
NOTES:
1. THIS SHEET SHOWS ALL OPTIONS, SEE SHEET 2 FOR "STANDARD" WIRING.
2 ALL WIRING TO BE 16 GA, EXCEPT CIRCUITS 3,5 & 50, AS MARKED.
3 . • IF NO ALARM OPTION, OR IF DESCEND ALARM OPTION, THEN CONNECT "RED/BLK"

TO "BLANK" TERMINAL, AS SHOWN. IN THIS CASE THE RED/BLK CONDUCTOR
IN THE CABLE TO THE TERMINAL BOARD ON THE CHASSIS, IS A SPARE.
DESCEND ALARM IS CONNECTED TO CIRCUIT #9 ON THE TERMINAL BOARD
ON THE CHASSIS.
• FOR MOTION ALARM OPTION, MOVE "RED/BLK" TO TERMINAL 8C AND ADD
TWO DIODES TO TERMINAL 8C AS SHOWN.
• FOR TRAVEL ALARM OPTION, JUMPER "BLANK" TO 8D AND MOVE WHT /BLK
CONDUCTOR, IN CABLE TO HYD VALVES, FROM 8D TO "BLANK" TERMINAL.
4. IF LOW VOLT OPTION IS USED, THEN REMOVE JUMPER BETWEEN 8A AND 8B
AND ADD A JUMPER, 34542, AS SHOWN AT TERMINAL 3.
MANUAL 92357-003
JUNE 1997

2 55893 ............................ Decal, Lower Control Box Electrical Tags ........................................... I
4 51914 ............................ Base + 1 NC Contact ............................................................................ 1
5 52671 ............................ Operator, 3 Pos. Rot .............................................................................. 1
Akk02016 ...................... -Key ..................................................................................................... 1
6 52029 ............................ Base + 2 NO Contacts .......................................................................... 1
7 50075 ............................ Switch, (Ref PIN" 67760) ....................................................................... 1
9 206-00001-00 ................ Diode ..................................................................................................... 8
10 67114-013 ..................... Strain Relief 1 NPT .62/.75 ................................................................... 1
12 67114-009 ..................... Strain Relief, 3// NPT .62/.75 ............................................................... 2
13 67124-003 ..................... Locknut, 1" NPT .................................................................................... 1
14 67124-002 ..................... Locknut, 3/4 NPTConduit ...................................................................... 3
15 67123-003 ..................... Seal, Connector Elect 1" ............ ;........................................................... 1
16 67123-002 ..................... Seal, Connector Elect. 3/4" ••....•.•......•.......•.•••..•...••..•..•..............•.••.•..•..•. 3
17 BOW23022 ................... RingTongue .......................................................................................... 3
18 67837-006 ..................... Tie, Nylon 6" Black ............................................................................... 8
22 BOW31124 ................... Screw, Round Hd #6-32UNF x '/2"Lg .................................................. 4
23 BOW31231 ................... Nut, Hex Keps #6-32 ............................................................................ 4
24 BOW31428 ................... Washer, Flat #6 ..................................................................................... 4
27 67295-022 ..................... Cable, 12 Ga/3C ......................................................................... 6.50LF
28 34552-016 ..................... Terminal Strip ........................................................................................ 2
29 67940 ............................ Holder, Fuse .......................................................................................... 1
30 67939-015 ..................... Fuse, 15Ga 1/4" x 1-1/4" ......•.....••.••.••.••.•....•....•.•.••.•..•••.........•.........•......• 1
31 58251 ............................ Wire, 12Ga. White ........................................................................... 4LF.
32 58292 ............................ Wire, 16Ga. White ........................................................................... lLF.
38 BOW18578 ................... Terminal,PiggybackR67963 ................................................................ 1
39 BOW23087-2 ................ Terminal, Female Push-On .250W ........................................................ 2
41 67961-006 ..................... Terminal, 8 Stud 12/10Ga. Spade ........................................................ 10
MANUAL 92357-003
JUNE 1997
.FIGURE 17: AnnstackAssembly
~~------____________ SEE NOTE 1 ; 2 _------------------~

---- ---- ---- -- ---- ------ -- ---- - ----- -
---- ---- ----
---- -<::::
22 SEE NOTE - ~ >-____ _ b~-
- ---- ~..::----
------ -:..>- - ------ -
____ - - ---- -- ---- ______ ---- - - ---- - - ---- --
25 26 ---- - _ ____ ----- - - ---- - _____
- ---- ---- --
Q~--------::--..::-- SEE NOTE 1\3 ~>-<.~-
----- ---- -- ---- -- ---- -- ---- -- ---- --
25 26 - - ---- - - ---- _ ------ - - - --c::.: ----- -- _---- ------ --
------ ----..-----
_------->------~-o ----_--~
0 -,
~
2 SEE NOTE 1 ______ - ____ - - - - _____
_----- ------ ____ - - ------ L

25 -6 ------ __ "
q __ -<:-- ------ -7
L .::>-- __
~~-;-::::::=
~
~ 36 28 - ____
: "" , : ~ ~
2 PL
~--
22 SEE NOTE 1
------ - - ~-_-:::::--
39
)----=-----=----::-- ------
---- - _- - ____
---=:::: ----:::::-- ----
32 33 2 PL ~~_-_ Q
------- -
\\
*
\ -- - ---- -- ~--
2 PL
---
22 SEE NOTE 1
-
____ - -
____ -
----
- ----
----
\ " ------- - -------~------

~ --- ----=---~-
r.::-~-- -~~-=;->~-- ~-~--~--~--------~-:;:;
~_----------- 25 26 2 PL -------_~ __ ~
~
1. BOLT IS TO BE ON UPHill SIDE OF
ROUND TUBE. NUT AND WASHER ARE
TO BE ON DOWNHill SIDE OF ROUND
TUBE.
2. EST WT 1992 lB FOR 55744
EST WT 2002 LB FOR 557 44Xl
MANUAL 92357-003
JUNE 1997
FIGURE 17: Armstack ASSemblY.
~IT~E~M~~P~AR~T~N~U~M~B=E~R~~D~E~S~C~RI~P~T~I~O~N~ ______________________~QTY
Ref. 55744 ............................ ArmstackAssembly ......................................................................... Ref.
1 56135 ............................ Arm Weldment, Lower Outer ................................................................ 1
2 56106 ............................ Arm Weldment, Lower Inner ................................................................ 1
3 56159 ............................ Arm Weldment, Lower LH ................................................................... 1
4 56160 ............................ Arm Weldment, Lower RH ................................................................... 1
5 56168 ............................ Arm Weldment, Middle ........................................................................ 1
6 56157 ............................ Arm Weldment, UpperLH .................................................................... 1
7 56158 ............................ Arm Weldment, Upper RH .................................................................... 1
8 56089 ............................ Arm Weldment, Upper Cylinder ........................................................... 1
9 55748 ............................ Arm Weldment, Upper Outer ................................................................ 1
10 55749 ............................ Arm Weldment, Upper Inner ................................................................. 1
11 81368-007 ..................... Bearing, 1.50 ID x 2.50 OL x lIs" W .................................................. 18
12 81368-11-040 ............... Bearing, 2.0 ID x2.50 OL x lIs" W ...................................................... 2
13 54616-003 ..................... Pin, Arm Pivot 1.50 Dia 6.38LG .......................................................... 2
14 54616-016 ..................... Pin, Arm Pivot 1.50 Dia. 7.88LG ......................................................... 2
15 54616-012 ..................... Pin, Arm Pivot 1.50 Dia. 26.25LG ....................................................... 6
17 56073-012 ..................... Pin, Arm Pivot 1.50 Dia. 26.25LG 4140 ............................. ~ ............... 1
18 56090 ............................ Pin, Arm Pivot 2.00 Dia. 26.50LG 4140 ............................................. 1
19 55744-Weldment .......... Armstack Weldment- V2648/531XL .................................................... 1
20 167-00002-00 ............... Collar, 2" Shaft ...................................................................................... 2
21 66388-001 ..................... Collar, 1 1/ 2 " Shaft ................................................................................ 18
22 BOW30037 ................... Bolt, Hex .31-18UNC x 3.00 .............................................................. 11
23 BOW30039 ................... Bolt, Hex .31-18UNC x 3.50 ................................................................. 1
24 BOW30040 ................... Bolt, Hex .31-18UNC x 4.00 ................................................................ 2
25 BOW31432 ................... Washer, Flat .31 ID x .68 OD ............................................................. 13
26 BOW36273 ................... Nut, Lock Hex 5/16"-18UNC ............................................................. 10
27 02236 ............................ Elbow 90° MJ04 MOO4 ....................................................................... 1
28 02662 ............................ Elbow 90° MJ06 M006 ....................................................................... 1
29 81368-07-16 ................. Bearing, 1.5 ID x 1.0 L X I/s"W ............................................................. 4
30 BOW32606 ................... Clamp, Wire Loom I" ............................................................................ 9
31 BOW9977 ..................... O-Ring .375 x .500 OD ......................................................................... 1
32 BOW30002 ................... Bolt, Hex .25-20UNC x .75 .................................................................. 2
33 BOW31401 ................... Washer, Flat .25 ID x .68 OD ............................................................... 2
34 55848-026 ..................... "V" Main Cable Harness ....................................................................... 1
55849-026 ..................... "V" "XL" Main Cable Harness .............................................................. 1
35 BOW30035 ................... Bolt, Hex .31-18UNC x 2.50 ................................................................ 2
36 55083 ............................ Manifold Assembly - Lift Cylinder ....................................................... 1
37 55715 ............................ Bracket Weldment, Lower .................................................................... 1
38 54798 ............................ Coupling Nut, #10-32UNF .................................................................... 1
39 56007 ............................ Cylinder, Lift V2648/53 ........ ('1' .•............................•.•....•....•................. 1
55511 ............................ Cylinder, Lift V2648/53XL ..1.\~ ...\I.~.~... 5.5.~?:\ .......................... 1
40 67281-005 ..................... Wrapping, Spiral 3/4" ................................................................. .3.75LF
41 BOW34272 ................... Nut, Lock Hex 1/4"-20UNC ................................................................... 9
42 67295-017 ..................... Cable, 12Ga.l3C ............................................................................. 47LF
MANUAL 92357-003
JUNE 1997
.FIGURE 17: ArmstackAssembly
REF-BRG BLOCK IS IN PLTFRM ASSY

REF-PAD IS IN FINAL ASSY REF-PIN IS IN FINAL ASSY
E
- - - , 7 PL
i 42
10
RIGHT NEARSIDE
c
RIGHT NEARSIDE
40 4 PL
RIGHT SIDE VIEW
REF-PAD IS IN
4 PL
FINAL ASSY
2 PL
1. IF COLLARS HAVE MANUFACTURER

STAMPED ON ONE SIDE, PLACE
STAMPED SIDE TOWARD ARMSTACK,
2. USE ITEM 17 AT #8 TO #3/4 ARM JOINTS,
INSTALL ARMS #3 & #4 WITH BACKUP Scale= 1: 3
PLA TE AT JOINT WITH ARM #8. PL
MANUAL 92357-003
JUNE 1997
FIGURE 17: Armstack ASSembly.
~IT~E=M~~P~AR~T~N~UMB~==E~R~~D=E=S=C=RI=P~T=I=O=N~ ______________________~QTY
Ref. 55744 ............................ ArmstackAssembly ......................................................................... Ref.
1 56135 ............................ Arm Weldment, LowerOuter ................................................................ 1
2 56106 ............................ Arm Weldment, Lower Inner ................................................................ 1
3 56159 ............................ Arm Weldment, Lower LH ................................................................... 1
4 56160 ............................ Arm Weldment, Lower RH ................................................................... 1
5 56168 ............................ Arm Weldment, Middle ........................................................................ 1
6 56157 ............................ Arm Weldment, UpperLH .................................................................... 1
7 56158 ............................ Arm Weldment, Upper RH .................................................................... 1
8 56089 ............................ Arm Weldment, Upper Cylinder ........................................................... 1
9 55748 ............................ Arm Weldment, Upper Outer ................................................................ 1
10 55749 ............................ Arm Weldment, Upper Inner ................................................................. 1
12 81368-11-040 ............... Bearing, 2.0 ID x 2.50 OL x lIs" W ...................................................... 2
13 54616-003 ..................... Pin, Arm Pivot 1.50 Dia 6.38LG .......................................................... 2
14 54616-016 ..................... Pin, Arm Pivot 1.50 Dia. 7.88LG ......................................................... 2
17 56073-012 ..................... Pin, Arm Pivot 1.50 Dia. 26.25LG 4140 ............................................. 1
18 56090 ............................ Pin, Arm Pivot 2.00 Dia. 26.50LG 4140 ............................................. 1
19 55744-Weldment .......... Armstack Weldment- V2648/531XL .................................................... 1
20 167-00002-00 ............... Collar, 2" Shaft ...................................................................................... 2
21 66388-001 ..................... Collar, 1 1/ 2 " Shaft ................................................................................ 18
22 BOW30037 ................... Bolt, Hex .31-18UNC x 3.00 .............................................................. 11
23 BOW30039 ................... Bolt, Hex .31-18UNC x 3.50 ................................................................ 1
24 BOW30040 ................... Bolt, Hex .31-18UNC x 4.00 ................................................................ 2
25 BOW31432 ................... Washer, Flat .31 ID x .68 OD ..................,,, ........................................ 13
26 BOW36273 ................... Nut,LockHex 5/16"-18UNC ............................................................. 10
27 02236 ............................ Elbow 90° MJ04 M004 ....................................................................... 1
28 02662 ............................ Elbow 90° MJ06 M006 ....................................................................... 1
29 81368-07-16 ................. Bearing, 1.5 ID x 1.0 Lx I/s"W ............................................................. 4
30 BOW32606 ................... Clamp, Wire Loom 1" ........................................................................... 9
31 BOW9977 ..................... O-Ring .375 x .500 OD ......................................................................... 1
32 BOW30002 ................... Bolt, Hex .25-20UNC x .75 .................................................................. 2
33 BOW31401 ................... Washer, Flat .25IDx.680D ............................................................... 2
55849-026 ..................... "V" ·'XL" Main Cable Harness .............................................................. 1
35 BOW30035 ................... Bolt, Hex .31-18UNCx2.50 ................................................................ 2
36 55083 ............................ Manifold Assembly - Lift Cylinder ....................................................... 1
38 54798 ............................ CouplingNut, #10-32UNF .................................................................... 1
39 56007 ............................ Cylinder, Lift V2648/53 ........................................................................ 1
55511 ............................ Cylinder, Lift V2648/53XL .................................................................. 1
42 67295-017 ..................... Cable, 12Ga./3C ............................................................................. 47LF
MANUAL 92351-003
JUNE 1991
• FIGURE 17: Armstack Assembly
12 PL
6 PL
12 PL
SECTION E-E 6 PL
SEE NOTE 1
Scole= 1: 3
18
- --------------------------------------------------------------$------------------------------------------------------------ ----
2 PL 20
SECTION D-D
SEE NOTE 1
Scole= 1: 3
BACKUP
PLATE REF
SEE NOTE 2
- -----------------------------------------------------------+-----------------------------------------------------------
2 PL 21 SECTION C-C
SEE NOTE 1 Scole= 1: 3
SECTION 8-8
Scole= 1: 3
SEE NOTE 1
2 PL 14 I
2 PL 21 SECTION A-A
Scole= 1: 3
SEE NOTE 1
MANUAL 92357-003
JUNE 1997
FIGURE 17: AnnstackAssemblyG
~IT~E=M~~P~AR~T~N~U~MB~~E~R~~D~E=S~C~RI=P~T~I~O~N~ ______________________~QTY
Ref. 55744 ............................ AnnstackAssembly ......................................................................... Ref.
1 56135 ............................ Ann Weldment, Lower Outer ................................................................ 1
2 56106 ............................ Ann Weldment, Lower Inner ................................................................ 1
3 56159 ............................ Ann Weldment, Lower LH ................................................................... 1
4 56160 ............................ Ann Weldment, Lower RH ................................................................... 1
5 56168 ............................ Ann Weldment, Middle ........................................................................ 1
6 56157 ............................ Ann Weldment, UpperLH .................................................................... 1
7 56158 ............................ Ann Weldment, UpperRH .................................................................... 1
8 56089 ............................ Ann Weldment, Upper Cylinder ........................................................... 1
9 55748 ............................ Ann Weldment, Upper Outer ................................................................ 1
10 55749 ............................ Ann Weldment, Upper Inner ................................................................. 1
12 81368-11-040 ............... Bearing, 2.0 ID x 2.50 OL x I Is" W ...................................................... 2
13 54616-003 ..................... Pin, Ann Pivot 1.50 Dia 6.38LG .......................................................... 2
14 54616-016 ..................... Pin, Ann Pivot 1.50 Dia. 7.88LG ......................................................... 2
15 54616-012 ..................... Pin, Ann Pivot 1.50 Dia. 26.25LG ....................................................... 6
16 54616-013 ..................... Pin, Ann Pivot 1.50 Dia. 14.25LG ....................................................... 2
17 56073-012 ..................... Pin, Ann Pivot 1.50 Dia. 26.25LG 4140 ............................................. 1
18 56090 ............................ Pin, Ann Pivot 2.00 Dia. 26.50LG 4140 ............................................. 1
19 55744-Weldment .......... Annstack Weldment - V2648/531XL .................................................... 1
20 167-00002-00 ............... Collar, 2" Shaft ...................................................................................... 2
21 66388-001 ..................... Collar, 1 1/ 2" Shaft ................................................................................ 18
22 BOW30037 ................... Bolt,Hex .31-18UNCx3.00 .............................................................. 11
23 BOW30039 ................... Bolt, Hex .31-18UNC x 3.50 ................................................................ 1
24 BOW30040 ................... Bolt,Hex .31-18UNC x 4.00 ................................................................ 2
25 BOW31432 ................... Washer, Flat .31 ID x .68 OD ............................................................. 13
26 BOW36273 ................... Nut, Lock Hex 5/16"-18UNC ............................................................. 10
27 02236 ............................ Elbow 90° MJ04 MOO4 ....................................................................... 1
28 02662 ............................ Elbow 90° MJ06 M006 ....................................................................... 1
29 81368-07-16 ................. Bearing, 1.5 ID x 1.0 Lx I/s"W .............................. _.............................4
30 BOW32606 ................... Clamp, Wire Loom 1" ........................................................................... 9
31 BOW9977 ..................... O-Ring .375 x .500 OD ......................................................................... 1
32 BOW30002 ................... Bolt, Hex .25-20UNCx.75 .................................................................. 2
33 BOW31401 ................... Washer, Flat .25IDx.680D ............................................................... 2
55849-026 ..................... "V" "XL" Main Cable Harness .............................................................. 1
35 BOW30035 ................... Bolt, Hex .31-18UNC x 2.50 ................................................................ 2
36 55083 ............................ Manifold Assembly - Lift Cylinder .............................................. ~ ........ 1
38 54798 ............................ CouplingNut, #10-32UNF .................................................................... 1
39 56007 ............................ Cylinder, Lift V2648/53 ........................................................................ 1
55511 ............................ Cylinder, Lift V2648/53XL .................................................................. 1
42 67295-017 ..................... Cable, 12Ga./3C ............................................................................. 47LF
MANUAL 92357-003
JUNE 1997
• FIGURE 18: Platform Installation
17
ATTACH CHAIN
ON RIGHT SIDE
~
18 ' FAR SIDE
4 NEAR SIDE 2 PL
2 PL
----- ---- --- ~iF====~~~I=========I
14
MANUAL 92357-003
JUNE 1997
FIGURE 18: Platform InstallationG
Ref. 55663 ............................ Platform Installation V2648/53XL ................................................... Ref.

1 55572 ............................ Platform Weldment ............................................................................... 1
2 54582 ............................ Block, ArmIPlatform Bearing ................................................................ 2
3 55599-001 ..................... Toeboard WeldmentLH ........................................................................ 1
4 55599-002 ..................... Toeboard Weldment RH ....................................................................... 1
5 55607 ............................ Handrail Weldment ................................................................................ 2
6 55612 ............................ Gate Weldment, Lift-Up ........................................................................ 1
7 54685 ............................ Strap Weldment, Lift-Up Gate .............................................................. 2
8 164-00013-00 ................ Chain,2/0 ..................................................................................... 2.62LF
9 50286 ............................ Chain Snap ............................................................................................ 1
10 BOW2548 ..................... S-Hook .................................................................................................. 1
11 54682 ............................ Roller Weldment, Extension Deck Mount ............................................. 4
12 54689 ............................ Roller, Extension Deck .......................................................................... 4
13 BOW367U-HD ........... Washer, Flat 3/4 " SAE Thick ................................................................. 4
14 55600 ............................ Deck Weldment, Extension ................................................................... 1
15 55563 ............................ Bracket Weldment, Lock Mount ........................................................... 1
16 55241 ............................ Latch Assembly, Deck .62-11UNC Mount.. ........................................ l
55245 ............................ -Latch Body, Deck .62-11UNC Mnt. ................................................. 1
55243 ............................ -Spring, Deck Latch ............................................................................. 1
55242 ............................ -Plunger, Deck Lazwtch ...................................................................... 1
55031 ............................ -SlitRing,Zinc-Plated ........................................................................... 1
17 55567 ............................ Handrail Weldment, Extension .............................................................. 1
18 55670 ............................ Tube, Lift-Up Guide .............................................................................. 2
19 55681 ............................ Tube, Extension Deck Rear .................................................................. 2
20 55929 ............................ Dwg.-Extension Deck Foot ................................................................... 1
21 55207 ............................ Foot,HandraillEntryGate ...................................................................... 4
22 BOW30027 ................... Bolt, Hex .31-18UNC x .75 ................................................................ 16
23 BOW34602 ................... Bolt, Carr. .31-18UNC x 1.25 ............................................................ 16
24 BOW30036 ................... Bolt, Hex .31-18UNC x 2.75 ................................................................ 4
25 BOW30002 ................... Bolt, Hex .25-20UNC x .75 .................................................................. 6
26 BOW30008 ................... Bolt, Hex .25-20UNC x 2.00 .............................................................. 18
27 BOW34273 ................... Nut, Hex Lock .31-18UNC ................................................................ 36
28 BOW36780 ................... Nut, Hex Lock .25-20UNC ................................................................ 24
MANUAL 92357-003
JUNE 1997
• FIGURE 19: Upper Control Box Assembly
33 REF
17
:I!-<"O> ...,,, <Dr r REF 31

00"" oc ".c;
""C:~M
"''''
>I
-<I
;;1-<
0
;:2~::o;;O
-<-< ~~
Z<D :E
~~~~
OC
~~~~
I-< "'il
,.,0 Z".
'"2 ,.,'" 0
'"-<
<
5~~
"'-< 0 " ,
(.... 0 r
~'i' ~
~;"u ;CO
_lJ
'"C-< C'" ",-<
Z'"
~-I i: -<> £1-<
".".
>
"'-< ZI G>
'"
Vl !"'" 0'" m
4 3
37 REF
FORWARD
L@>
19
.P DRIVE SPEED
REVERSE
17
(------------------------------'1
D \j
POWER RAISE 10 11
20
I
I
I
I
I
I
I
I
LOWER I
I
I I' I I :
I I' I I r
l ___________________________ ll J_~ _____I
MANUAL 92357-003
JUNE 1997
FIGURE 19: Upper Control Box ASSembly.
Ref. 55317 ............................ Upper Control Box Assembly .......................................................... Ref.

1 54587 ............................ Box, Upper Control ............................................................................... 1
2 54589 ............................ Contr. BMS4RM9071 WIRG5 + Lever ................................................ 1
54589-100 ..................... -Boot ...................................................................................................... 1
3 51913 ............................ Operator-PushPull ................................................................................ 1
4 51914 ............................ Contact Block NC ................................................................................. 1
5 52670 ............................ Operator Selector .................................................................................. 1
6 34464 ............................ Contact·Block NO-NC .......................................................................... 1
7 [Not Used] .......................................................................................................... :.......................... .
8 [Not Used] ..................................................................................................................................... .
9 69146 ............................ Operator, Green Pushbutton .................................................................. 1
10 54913 ............................ Operator - BlackIBlack Dual Switch ..................................................... 1
11 52029 ............................ Block Contact 2 NO wlBase ................................................................ 1
12 54910-104 ..................... Mounting Base - AG Panel ................................................................... 1
13 54910-102 ..................... Recep. Screw Term. #1-16 ................................................................... 1
14 67837-006 ..................... Tie, Nylon 6.00" Black ...................................................................... :.... 5
15 BOW31125 ................... Screw, Slotted Pan #06-32UNF x .62" .................................................. 4
16 BOW31231 ................... Nut, Hex Keps #6-32 ............................................................................ 4
17 55012 ............................ Insert, Control Box Plastic ..................................................................... 2
18 58300 ............................ Wire, 16GaBIack ............................................................................ 8LF.
19 54976-001 ..................... Decal, Upper Control Box ..................................................................... 1
31 A620-2633 .................... BatleryConditionIndicator(Option) ................................................ Ref.

32
33 A353-2633 .................... Slope Alarm (Option) .................................................... :.................. Ref.
34
35 A626-2633 .................... LowVoltAlarmlInterrupt(Option) .................................................. Ref.
36
37 A304-2633 .................. :.SignaIHorn(Option) ......................................................................... Ref.
MANUAL 92357-003
JUNE 1997
,-----------------,
,
§-
"r:I
OPTIONAL
~
-
SLOPE
ALARM
...
SEE 13
15
8: \0
NOTE 1
~
r-- --.-.. -- _. L1.~ ~L1PPED ~~EN) -1- -- ~F! ~'~ - - - -
I
-1---- --- --- --- -1------1 ~

, n
o
~
OPTIONAL
SA TTERY
-
o
tc
~
INDICATOR
OPTIONAL
LOW VOLTAGE
:>
en
en
~I
OVERRIDE SWITCH
3A ~,
01
80"
~
q
:::: "'""o
i~
_'D
~Ij
~ ~Q~ I SEE 1 SEE ~ 16

~'NOTEI
OPTIONAL
SIGNAL HORN
SWITCH
.16 r----------I----~------- i;--~ ---I

(p1'b J
______ ~~
\lJ>
~:
jA _
L ______
VIEW OF INSIDE OF BOX
L _________________ .--J
_'M,"'''''_ I~
NOTES:
~'!:!~~nlLE WACO, TEXAS
1. CONNECT CIRCUIT 3 AS REQUIRED BY OPTIONS. ~~.~5 BOX ASSY, MDD2633
2. CIRCUITS 1, 5, 13, 14, 15. & 16 ARE FOR OPTIONS. ,au:-a:5"':':1Im~ UPPER CNTRL
APf'1iI. rDIWM 8_ SfFCIK I'/lOII5 C 55317 c
RN< 02/01 SC.tl£ 1:1.5 2 or 2
FIGURE 19: Upper Control Box ASSembly.
Ref. 55317 ............................ Upper Control Box Assembly .......................................................... Ref.

1 54587 ............................ Box, Upper Control ............................................................................... 1
2 54589 ............................ Contr. BMS4RM9071 WIRG5 + Lever ................................................ 1
54S89-100 ..................... -Boot ...................................................................................................... 1
3 51913 ............................ Operator-PushPull ................................................................................ 1
4 SI914 ............................ ContactBlockNC ................................................................................. 1
5 52670 ............................ Operator Selector ................................................................................... 1
6 34464 ............................ ContactBlockNO-NC .......................................................................... 1
7 52669 ............................ Operator Black Pushbutton ................................................................... 1
-s-=--52672 ............................ Contact Block 1 NO .............................................................................. 2
9 69146 ............................ Operator, Green Pushbutton .................................................................. 1
10 54913 ............................ Operator - BlackIBlack Dual Switch ..................................................... 1
11 52029 ............................ Block Contact 2 NO wlBase ................................................................. 1
12 54910-104 ..................... Mounting Base - AG Panel ................................................................... 1
13 54910-102 ..................... Recep. Screw Term. #1-16 .................................................................... 1
14 67837-006 ..................... Tie, Nylon 6.00" Black .......................................................................... 5
IS BOW31125 ................... Screw, Slotted Pan#06-32UNF x .62" .................................................. 4
16 BOW31231 ................... Nut, Hex Keps #6-32 ............................................................................. 4
17 5S0 12 ............................ Insert, Control Box Plastic .................................................................... 2
18 58300 ............................ Wire, 16Ga Black ............................................................................ 8LF.
31 A620-2633 .................... Battery Condition Indicator (Option) ............................................... Ref.

32
33 A353-2633 .................... Slope Alarm (Option) ....................................................................... Ref.
34
35 A626-2633 .................... Low Volt Alarm/Interrupt (Option) .................................................. Ref.
36
37 A304-2633 .................... Signal Hom (Option) ........................................................................ Ref.
MANUAL 92357-003
JUNE 1997
• FIGURE 20: 110 Volt Exte~ion To Platform
GREEN
WHITE
OF PLATFORM-NOT ILLUSTRATED
0
WHITE
'"g
«
lOH
0
BLACK
2
3 PL - LOCA TED
UNDER
PLATFORM
RE~ CABLE IS INCLUDED

IN ARMSTACK
AT CHASSIS
12
REF. LEFT
GOLD SCREW
FRONT OF CHASSIS
BLACK
GREEN SCREW
GREEN
WHITE
SILVER SCREW

Ref. 54918 ............................ 110 Volt Extension To Platform (Option) ........................................ Ref.
1
2 66357 ............................ Receptacle, Ground Fault ...................................................................... 1
3 55019 ............................ OutletBox, Platform ............................................................................. 1
4 66358 ............................ Cover, Weatherproof ............................................................................. 1
5 67114-003 ..................... StrainReliefI/2"NPT .37/.5 ................................................................... 1
6 67124-001 ..................... Locknut, 1f2''NPT Strain Relief.. ............................................................ 1
7 67123-001 ..................... Seal, Connector Elect. 1/2" ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1
8 BOW31105 ................... 10-32 x .75 Slotted Pan Head, Machine Screw ..................................... 2
9 BOW31233 .................... Nut, Hex Keps #10-32 ........................................................................... 2
10 BOW32603 ................... Clamp, Wire Loom .50 .......................................................................... 4
11 52710 ............................ Plug, 110 Volt ....................................................................................... 1
12 55036-001 ..................... Grommet, 1/2 " ID 114 x 13/ 16" Dia. Grv ................................................... 1
13 BOW34272 ................... Nut, Hex Lock .25"-20UNC .................................................................. 4
MANUAL 92357-003
JUNE 1997
BILL OF MATERIALS INQUIRY Date: 07/22/99
'.1 of Mat'l No: A317-V2033-1 Desc: V20/26 PROPORTIONAL DRIVE
, .I: ERCN 11009
"
08/26/1997 Last Activity: 07/20/99
----------------------------------------------------------J---------------------
Lne Part No. Description Req I U/M Qty Reqd Lower
----------------------------------------------------------T----------------Leve1
1 55852 BOX ASSY; V14/26 PROP DRV UPR W N EA 1.00 N
2 55851 BOX ASSY; V XL UPPER W N EA -1.00 N
3 55842-002 VALVE MOD, PROP DR HF V20/26 N EA 1.00 Y
4 55379 VALVE INST, V20/26 N EA -1.00 Y
5 55845 SCHEMATIC - V PROP DRIVE EL X N EA 1.00 N
6 55838 SCHEMATIC - V PROP DRIVE HYD X N EA 1.00 N
7 56003 INST DWG; PROPORTIONAL DRIVE X N EA 1.00 N
8 66043-031.00 HOSE ASSY #3 67684 J37 STJ-STJ 1 Y EA 1.00 N
9 55324 TUBE ASSY; MDD2633 B U Y EA -1.00 N
CTL III to Restart, CTL IV to END ... Line Number:

FIGURE 21: Travel Alann(Option) •
Ref. A301-2633 .................... Travel Alarm .................................................................................... Ref.

-1 80188-024 ..................... Wobbulator and Speaker ....................................................................... 1
-2 67295-035 ..................... Cable, 16Ga.l2 Conductor SJO ....................................................... 2LF
-3 BOW23027 ................... Terminal 6 Stud 16/14Ga. Spade ........................................................ .4
-4 55036-001 ..................... Grommet, !fz"ID 1/4" x 13/16"Dia. Grv .................................................... 1
MANUAL 92357-003
JUNE 1997
• FIGURE 22: Motion Alarm (Option)

Ref. AJ09-2633 .................... Motion Alarm ................................................................................... Ref.
-1 80188-024 ..................... Wobbulator and Speaker ....................................................................... 1
-2 67295-035 ..................... Cable, 16Ga'/2 Conductor SJO ....................................................... 2LF
-3 BOW23 027 ................... Terminal 6 Stud 16/14Ga. Spade ......................................................... 4
-4 55036-001 ..................... Grommet, 1/2"ID 1/4" x 13/1/Dia. Grv .................................................... 1
-5 206-00001-00 ............... Diode ..................................................................................................... 2
MANUAL 92357-003
JUNE 1997
FIGURE 23: Strobe Light (Option) •
REF. RIGHT SIDE VIEW

OF PLATFORM.
Ref. A310-2633 .................... Strobe Light ...................................................................................... Ref.

1 58395 ............................ Light Amber Strobe 12-72 VDC .......................................................... 1
2 BOW31400 ................... Washer, Flat #10 .................................................................................. 3
3 BOW31 144 ................... Screw, SlotRnd. #1O-32UNF x .50 ...................................................... 3
4 55400 ............................ Mount - Strobe Light 14" ..................................................................... 1
5 BOW3400 1 ................... Bolt, Hex .25-20UNC x 1.00 ................................................................ 2
6 BOW31432 ................... Washer, Flat .31 IDx.680D ............................................................... 2
7 BOW36780 ................... Nut, Hex .25-20UNC Nylon Lock ....................................................... 2
8 67295-035 ..................... Cable, 16Ga'/2 Conductor SJO .................................................... 50LF
9 52672 ............................ Base + 1 NO Contact ZB2BZ 101 ......................................................... 2
10 58259 ............................ Wire, 18Ga. Black-Bulk .................................................................. lLF
MANUAL 92357-003
JUNE 1997
• FIGURE 24: Descend Alarm (Option)
Ref. A312-2633 .................... DescendAlann ................................................................................. Ref.

-1 80188-024 ..................... Wobbulator and Speaker 24V ............................................................. 1
-2 67295-035 ..................... Cable, 16Ga'/2 Conductor SJO ...................................................... 2LF
-3 BOW23 027 ................... Terminal 6 Stud 16114Ga. Spade ........................................................ 4
-4 55036-001 ..................... Grommet, 1/2"ID 1/4" x 13/16"Dia ............................................................ 1
-5 34542 ............................ Jumper .................................................................................................. 1
MANUAL 92357-003
JUNE 1997
FIGURE 25: Slope Alarm (Option) •

Ref. A353-2633 .................... Slope Alarm ...................................................................................... Ref.
-1 32002 ............................ Slope Sensor 2-Axis ............................................................................. 1
-2 BOW30002 ................... Bolt, Hex .25-20UNC x .750 ................................................................ 2
-3 BOW31432 ................... Washer, Flat .31 ID x .68 OD ............................................................... 2
-4 67295-024 ..................... Cable, 8 Conductor 16AWG Type SO ........................................... 7LF
-5 BOW23003 ................... Terminal Ring #6796022-18 #10 Stud ................................................ 2
-6 34644 ............................ Alarm ..................................................................................................... 1
-7 58259 ............................ Wire, 18Ga. Black-Bulk .................................................................. 2LF
MANUAL 92357-003
JUNE 1997
• FIGURE 26: Hour Meter (XL-Option)
8 2 PL
8B=WHT
#1 =BLK
#1=BLK 8B=WHT
REFERENCE
MOTOR CONTACTOR
Ref. A619-2633 .................... HourMeter ....................................................................................... Ref.

-1 80027 ............................ Meter, Hour 4/40V DC ......................................................................... 1
-2 67840-001 ..................... Bracket, Gage Mounting ....................................................................... 1
-3 BOW30003 ................... Bolt, Hex .25-20UNC x .875 ................................................................ 2
-4 BOW31401 ................... Washer, Flat .25IDx.630D ............................................................... 4
-5 BOW36780 ................... Nut, Hex .25-20UNC Nylon Lock ....................................................... 2
-6 67295-035 ..................... Cable, 16Ga.l2 Conductor SJO ...................................................... 6LF
-7 BOW23087 ................... Coupler - R#67963 16-14 Female ......................................................... 2
-8 67960-006 ..................... Terminal Ring - 16-14 # 10 Stud ........................................................... 2
-9 67837-004 ..................... Tie, Nylon-4" Black .............................................................................. 4
MANUAL 92357-003
JUNE 1997
FIGURE 27: Battery Condition Indicator (XL-Option) •
Ref. A620-2633 .................... Battery Condition Indicator .............................................................. Ref.

-1 37716 ............................ Meter, 24V Battery .............................................................................. 1
-2 37993 ............................ Meter Guard .......................................................................................... 1
-3 58300 ............................ Wire, 16Ga.-Black ........................................................................... 2LF
-4 67963-00 1 ..................... Coupler - 22-18 Male ............................................................................ 2
MANUAL 92357-003
JUNE 1997
• FIGURE 28: Low-Voltage Warning Interrupt (XL-Option)

Ref. A626-2633 .................... Low-Voltage Warning Interrupt ....................................................... Ref.
-1 54169 ............................ Low Voltage Interrupt 24V .................................................................. 1
-2 54967-104 ..................... Operator, Blue IlIum Pushbutton ........................................................... 1
-3 55902 ............................ Base + NO/Ne Contact w/24V Bulb ..................................................... 1
-4 58259 ............................ Wire, 18Ga. Black-Bulk .................................................................. 6LF
-5 54935 ............................ Decal- Low Volt Warning/Override ..................................................... 1
-6 BOW31141 ................... Screw, Slotted Rnd. #10-24 x 2.00 ....................................................... 2
-7 BOW31288 ................... Nut, Hex #10-32 ................................................................................... 2
-8 BOW31430 ................... Washer, Flat #10ID ............................................................................. 4
MANUAL 92357-003
JUNE 1997
FIGURE 29: Larger Batteries IPOS (XL-OptiOn).
Ref. A629-2633 .................... Larger Batteries IPOS ..................................................................... Ref.

-1 50046 ............................ Battery - 6 Volt ...................................................................................... 4
-2 52627 ............................ Battery - 6V Trojan T125-WT ............................................................ -4
-3 54836 ............................ Angle - Option Battery Tie-Down ......................................................... 2
-4 55505 ............................ Angle, E2633 Battery Tie-Down 22" ................................................ -2
MANUAL 92357-003
JUNE 1997
SELF-PROPELLED

Serial Number XS15-9700 1
Serial Number XS35-97001
VENDOR SECTION
CONDOR® CONDOR®
(254) 420-5200 (254) 420-5200
MANUAL 92356-004
May 1997
CONDOR® MODEL V2648/53XL, V2648/53
VENDOR SECTION
TABLE OF CONTENTS
CONTROLLER .................................................................................................. OEM CONTROLS
CHARGER ................................................................................................ LESTER ELECTRICAL
OPEN CIRCUIT TRANSFORMER TEST ........................................................................................ .
2000 SERIES MOTOR ............................................................................................... CHAR-LYNN

V2648XL 92357

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V2648XL 92357

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TIME CONDOR Corporation

MODEL V2648XL, V2648

MODEL V2653XL, V2653

SHIPPING ADDRESS MAILING ADDRESS

MODEL V2648XL, V2648

MODEL V2653XL, V2653

SIDPPING ADDRESS MAILING ADDRESS

THIS MANUAL MUST BE RETAINED ON THE CONDOR® AT ALL TIMES.

It is YOUR RESPONSIBILITY to follow procedures while operating this CONDOR®. The

DO NOT ALTER OR MODIFY THIS CONDOR® WITHOUT PRIOR WRITTEN

SERVICE & MAINTENANCE

TIME CONDOR Corporation

(254) 420-5200 Telephone

8300 OOERIALDIuVE,P.O. Box21447, WACO, TEXAS 76702-1447- 254-420-5200, 254-443-5803 FAX

I. PREPARATION, INSPECTION, AND MAINTENANCE •••••••••••••••••••••••.••••••.••••••••••••••••••••••.••.••••• 1

A. Overall Machine Condition ....................................................................................................... 1

A. Rated Work Load ...................................................................................................................... 2

ill. MOVING FR.OM JOB--SITE TO JOB-SITE •••••••••.••••••••••••••••••••••••••.•.••••••.••••••..•..••••.•••.••..•••••.•.••••••• 5

A. Loading and Unloading ............................................................................................................. 5

APPENDIX: DECALS ILLUSTRATION ••••••••••••••••••••••••••••.•..••.••...•••.••••••••••••.•••••••..•••••.••••••••.•...••....••.•. 8

ANSI/SIA A92.6 -1990 MANUAL OF RESPONSmILITIES

I. PREPARATION. INSPECTION, AND

The condition of this CONDOR® is very

Some major areas to check daily are:

D Check cylinder mounting pins, pivot pins,

D Check for damaged or cracked welds

D Check for cracks, tears, cuts, or missing or

D Check that extension deck is locked in

D Check that drive control lever returns freely

The platform will support a combined weight equal

D Check for hydraulic leaks at all fittings B. LOWER CONTROLS

CAUTION 1. To engage arm stand, raise platform,

free water to bring the level to 1/2 " above

To steer left or right, squeeze lever switch on

G. 'REMOVABLE' UPPER CONTROL CAUTION

III.MOVING FROM JOB-SITE TO

This CONDOR® can be easily transported

Block all wheels to prevent forward and reverse

Tie down the CONDOR® with chains or cables,

Always tum the power off at the lower control

Never exceed 5 mph when moving the

When you get out ofthe platform, leave it all the

31 ...................................... Nameplate Scissors Indentification .................................................. Ref.

* 55999-101 ..................... Decal Kit, V2648 Essential .............................................................. Ref.

- Indicates Items Not Shown

OPERA TING INSTRUCTIONS

RA TED WORK LOAD

RA TED WORK LOAD

$ TO OPERATE, BUTTON MUST BE PULLED OUT.

8300 IMPERIAL DRIVE 0

8300 IMPERIAL DRIVE 0

8300 IMPERIAL DRIVE 0

IMANUFACTURED IN U.S.A. II SERIAL NO.

8300 IMPERIAL DRIVE 0

MODEL V2648XL, V2648

MODEL V2653XL, V2653

SHIPPING ADDRESS MAILING ADDRESS

THE OPERATOR'S MANUAL MUST BE RETAINED ON THE CONDOR® AT ALL TIMES.

DO NOT ALTER OR MODIFY THIS CONDOR® WITHOUT PRIOR WRITTEN APPROVAL

SERVICE & MAINTENANCE

TIME CONDOR Corporation

CONDOR® SERVICE INFORMATION

(254) 420-5200 Telephone