Condor A38 A42j 92379

OPERATOR'S, SERVICE AND
PARTS MANUAL
ARTICULATING
MODEL A38/42J
BOOM-SUPPORTED ELEVATING WORK PLATFORM
MANUAL92379-001
July 1998
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 UNIT AT ALL TIMES.
Do not attempt to operate the CONDOR® until you have read and
understood all information provided in this manual. Familiarize
yourself with the functions and operations of the upper and lower
controls. A good understanding of the controls, their limitations, and
their capabilities will maximize operating efficiency and safety. The
various decals attached to this machine contain vital information.
Read the decals before operating this machine.
It is YOUR RESPONSIBILITY to follow safe procedures while operating the CONDOR®. The
manufacturer of this unit cannot control the wide range of applications that may be used in carrying
out a variety of jobs. Therefore, IT IS THE USER'S RESPONSIBILITY to consider the safety of
all personnel when making decisions regarding the unit's intended use.
It is also YOUR RESPONSIBILITY to understand and obey all federal, state, and local regulations
regarding the safe operation and use of aerial work platforms. A copy of the ANSI/SIA A92.5-1992
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 UNIT WITHOUT PRIOR WRITTEN

APPROVAL FROM THE MANAGEMENT OF TIME CONDOR Corporation
SERVICE & MAINTENANCE
Many of the parts used in the manufacture of the CONDOR® have specific properties, and the
manufacturer recommends that replacement parts be purchased through 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's Operation, Parts & Maintenance Manual for information on
service and maintenance oftheCONDOR®.
MANUAL92379-002
May1998
Revised11198
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. Thetelephone
numbers are:
(254)420-5200 Telephone
(817)420-5298 Voice Mail
(800) 443-5803 FAX
2. TherearenumerouswrittenMaintenanceProceduresavailableforthismachine. Theseprocedures
are availab Ie through the TIME CONDOR Corporation ServiceDepartmentto anyone who
requests them.
3. Service and maintenance are not a substitute for trained, qualified service technicians . TIME
CONDOR Corporation conducts service schools ona continuing basis. Call any ofour service or
sales persons for a schedule. Remember, training ofmechanics is the responsibility of their
employer, butTlME CONDOR Corporation. Service Schools help you provide this training.
4. TII\1E CONDOR Corporation Service School TrainingManuals are availableforpurchasethrough

the parts department. Thepartnumbers for thes e manuals are: #92333 forself-propelled models;
and #92334 fortruck -mounted models.
TIME CONDOR Corporation
8300 IMPERIAL DRIVE, P.O. Box21447, WACD, TEXAS 76702-1447' 817-666-4545, 817-666-4544 FAX
Condor® Self-Propelled Booms and Scissors
WARRANTY
TIME CONDOR Corporation warrants to the purchaser that each new aerial work platform made by
TIME CONDOR 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 workplatformfrom TIME CONDOR's plant; and in the case of all otherparts, for a period of one (1) year
aftertheaerialworkplatformisplacedinseIViceortwo(~yearsaftertheoriginalshipmentoftheaerialworkplatform
from TIME CONDOR's plant, whichever comes first.
The obligation and liability under this Warranty is expressly limited to repairing or, at TIME CONDOR's
option, replacing free of charge at its factory in Waco, Texas or alan authorized repair facility designated by TIME
CONDOR, the defective part. In no event shall TIME CONDOR 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 of customers, loss of goodwill orwork stoppage, claims
by any party other than the purchaser, or any other similar damage or loss even if TIME CONDOR, 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 factory for inspection. This Warranty applies to replacement parts provided under the
terms of this Warranty only for the remainder of the Warranty period applicable to the original purchase.
Any operation of the equipment beyond rated capacity, improperuse or application of the equipment, substitution
upon it of parts not approved by TIME CONDOR or alteration or repair of the equipment by any person
notauthorizedbyTIMECONDORshall,atTIMECONDOR'soption,voidthisWarranty. TIME CONDOR shall
have no liability or responsibility for damages resulting from accident or the malfunction of equipment and
components not supplied by TIME CONDOR.
No agent, employee, distributor, dealer, or other representative of TIME CONDOR is authorized to modify
this Warranty in anyway. Accordingly, additional statements orpresentations by any such representative, whether
oral or written, do not constitute warranties by TIME CONDOR and should not berelied upon as limited warranties
of TIME CONDOR, and no attempt, effort, or promise to repair equipment by TIME CONDOR or any such
representative at anytime shall modify or extend this Warranty in any way. If the purchaser has used its own order
fonn, no additional or different warranty terms contained in the purchaser's form will behonoredby TIME CONDOR
This Warranty covers only new and unused aerial work platforms manufactured by TIME CONDOR. Products or
parts manufactured by others are covered only by such warranties as are extended to the purchaser by TIME
CONDOR's suppliers.
This Warranty is in lieu of all other warranties, expressed or implied, including but not limited to warranties
ofmerchantibilityandfitnessforaparticularpurpose. Any applicable implied warranty shallbe limited induration
to the warranty period.
8300 ImperialDrive, P.O. Box21447, Waco, Texas76702-1447'254-420-5200,254-666-4544FAX
FormNo.513-3M-392 Effective Date 9/1/90

Printed in U.S.A.
OPERATOR'S MANUAL
ARTICULATING
MODEL A38/42J
MANUAL92379-001
July1998
TABLE OF CONTENTS •
INTRODUCTION ..................................................................................................................... i
TABLE OF CONTENTS ........................................................................................................... 1
I. SAFETY ................................................................................................................................ 3
A Safety Symbols ........................................................................................................... 3

B. Safety Rules ............................................................................................................... 4
C. Safety Decals ....... .... ........ .................. ............................ .......... ...... ................ ........ .... 8
II. MACHINE OPERATION ................................................................................................ 12
A Primary Machine Components ............. .......................................... ...... .... ...... ...... ..... 13
B. Ground Controls ..... ........ ........ .................................. .......... ............ .... .............. ....... 14
C. Platform Controls ... .... ........ .................. .............. ...... ........ .......... ...... ........................ 16
D. StartUp Procedures ................................................................................................. 19
1. Shift Check ......... .......... .................. ...... .................. .... ................ ...... ............ ....... 19
2. Machine Start Up ................................................................................................. 19
3. Ground Operation and Checks ..................................... ................................ ........ 20
4. Platform Operation and Checks ..................................... .......... ...... .......... ............ 22
5. Cold Weather Operation ...................................................................................... 25
E. General Operation . ........ ........ ............ .... ................................ .......... ........ ............ .... 26
1. Drivers and Steering ............... .......... ........................... ....... ........ .......... ................ 26
2. Braking ................. ...... ........ .............. ............ ................ ...... .... ............................ 26
3. Booms, Turret and Platform ................................................................................. 27
F. ShutDown Procedures ............................................................................................. 28
III. MOVING FROM JOB SITE TO JOB SITE ..................................................................... 28
A Unloading ............. ...................... .................... .... ...... .... .... ........ ........ ........ ...... .... ..... 28
B. Loading ....... ........ .... ...... ........ ........ .... ...... ...... ...... ...... ...... .... ...... ........ ........ .... .......... 28
C. Tie Down ....... ...... ...... ...... .......... .... ........ .................... ...................... ............ ........ ... 28
D. TowingProcedure.................................................................................................... 30
IV. EMERGENCY PROCEDURES ....................................................................................... 31
V. MAINTENANCE ........................................................................................................... .
VI. MACHINE SPECIFICATIONS ................................................................................... 34
VII. MACHINEDIAGRAM ................................................................................................. 35
ANSIISIA 92.5-1992 MANUAL OF RESPONSIBILITIES
MANUAl92379-001
July 1998
SAFETY SYMBOLS
This manual contains imponant information on the safe use ofyour COND OR A Series. Your failure to read,
•
understand and follow all safety rules, warnings and instructions will unnecessarily expose you and others to
dangerous situations. For your safety and the safety of those around you, you must operate your aerial platform
as instructed in this manual.
You the operator, are the single most imp on ant factor for safety when usinganypieceof equipment. Learn to
operate your work platform in a safe manner.
To help you recognize imponant safety information, we have identified warnings and instructions that directly
impact on safety with following signals:
A DANGER
"DANGER" INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH,IF NOT
AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY. THIS SIGNAL WORD IS LIM-
ITED TO THE MOSTEXTREME SITUATIONS.
AWARNING
"WARNING" INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH,
IF NOT AVOIDED, COULD RESULT IN DEA TH OR SERIOUS INJURY.
A CAUTION
"CAUTION" INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH,
IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT IS ALSO
USED TO ALERT AGAINST UNSAFE PRACTICES, AND FOR PROPERTY-
DAMAGE-ONLYSITUATIONS.
One final note: The best method to protect yourself and others from injury or death is to use common
sense. If you are unsure of any operation, don't stan until you are satisfied that it is safe to proceed.
MANUAL92379-001
July 1998
.SAFETY RULES AND PRECAUTIONS
A DANGER
• ELECTROCUTION HAZARD!! THIS MACHINE IS NOT INSULATED!!
Maintain safe clearance from electrical lines and apparatus. You must allow for
machine sway (side to side movement) when elevated, and electrical line
movement. This machine does not provide protection from contact with or
proximity to an e1ectricallychargedconductor.
You must AVOID CONTACT between any pan of the machine, or its load, and
any electrical line or apparatus carrying up to 300 volts.
You must maintain CLEARANCE OF AT LEAST 10 FEET (3.05 M) between any

pan ofthe machine, or its load, and any electrical line or apparatus carrying over
300volts up to 50,000 volts. One foot (30.5 cm) additional clearance is required
for every additional 30,000 volts.
DEATH OR SERIOUS INJURY will result from contact with, or inadequate

clearance from, any e1ectricallychargedconductor.
• Read and understand all safety and control information found on the machine
and in this manual before operating the unit.
• Only trained, competent personnel should operate the aerial work platform.
• Be aware of all Government and Local rules which may apply to this machine
and its safe operation.
• Approved safety belts must be worn at all times when operating the unit from the
platform. In addition, approved headgear and other protective equipment must
be worn as required. (In the U.S.A., OSHA approved equipment is required. For
other countries, the appropriate equivalent government body should be consulted.)
• NEVER fasten safety belt to an adjacent structure while on the work platform.
• Make sure that entry gate to platform is secured before operating unit from the
platform.
• DO NOT block the foot switch or anyfunctioncontrolin the operating position.
• DO NOT exceed the platform capacity of the unit in any configuration. Review
the section titled "MACHINE SPECIFICATIONS", later in this manual,
regarding this model's capacities and dimensions.
MANUAL92379-001
July 1998
SAFETY RULES AND PRECAUTIONS (Continued)
•
A DANGER
• SECURE all tools and other loose items to prevent injury to persons working on
or below the work platform.
• DO NOT use scaffolding, ladders or similar items to extend your reach while on
the work platform.
• DO NOT attempt to climb down the boom assembly if the unit fails while the
operator's platform is raised or extended.
• Since the machine may be operated from the ground controls, precautions
should be taken to prevent unauthorized personnel from operating the work
platform with the ground controls while the platform is in use.
• The "UNPOWERED EMERGENCY MOVEMENT" procedure (described later

in this manual) requires releasing the brakes, which results in there being
no means to stop the unit's travel. TIME CONDOR recommends using this
procedure only in cases of emergency, and onlyfor a short distance. Be on
guard against unit runaway on sloping surfaces. Movement speed shall not
exceed 1M.P.H. (1.6K.P.H.).
• DO NOT attempt to open any hydraulicline orcomponent without first relieving

all system pressures and shutting off fluid flow from the tank.
• DONOTallowanyonetotamperwith,serviceoroperatethemachinefrom
the ground control station while personnel are on the platform, except in
an emergency.
• DO NOT alter, modify or disable any safety devices or interlocks.
• DO NOT use the aerial work platform outdoors in electrical storms or high wind
situations.
• DO NOT raise the aerial work platform unless the unit is on a firm, level surface.
MANUAL92379-001
July1998
• SAFETY RULES AND PRECAUTIONS (Continued)
A. DANGER
• Use caution to prevent ropes, cords, hoses, etc. from becoming entangled in the
unit's boom sections when being raised, lowered or repositioned.
• Ensure that the area surrounding the mo bile platform is clear of personnel and
equipment before: driving the unit; or raising, lowering or extendingthe boom; or
swinging the turret; or, rotating or tilting the platform.
• Maintain a safe distance from overhead and ground obstacles, debris, drop-off,
holes, depressions, electrical wires and other hazards to travel.
• Limit travel speed according to conditions of the ground surface, congestion,

slope, location of personnel or any other factors that could cause hazard of
collision or injury to personnel.
• DO NOT sit, stand or climb on platform rails.
• DO NOT operate this machine while under the influence of any drugs or alcohol.
• DO NOT operate this machine if you are bothered by heights, seizures, or dizzy
spells.
• DO NOT indulge in stunt driving or horseplay while operating this machine.
AWARNING
• Complete the "Operational Checklists" found in this manual (see Table of
Contents) at designated intervals.
• Ensure that the machine is in "CREEP" drive speed while unloading from a truck
onrailer.
• Always attach the unit to a winch when loading or unloading from a truck ortrailer.
TIME CONDOR does not recommend unassisted loading or unloading of any
aerial work platform.
• With the turret swung away from the stowed position, use caution when
selecting travel or steering direction. Travel and steer direction will be
opposite switch or lever movement. Refer to the large "FORWARD" arrows
on the chassis.
MANUAL92379-001
July 1998
SAFETY RULES AND PRECAUTIONS (Continued) •
AWARNING
• Actuation of the red "EMERGENCY STOP" button will apply brakes
immediately, causing unexp ected platform movement as the machine comes
to a sudden stop. Brace yourself.
• Whenever disengaging the brakes or before disconnecting from towing

vehicle, ensurethatthe unit cannot roll.
• Immediately report any erratic noises, vibrations or malfunctions of the unit to

supervisor. Machine must be removed from service until diagnosis and any
necessary repairs have been comp leted.
• Operating this equipment without all safety and control decals in place can be
hazardous.
A CAUTION
• Fortransportingthe machine, the platform must not be tied to the trailer bed.
• Be sure to turn all hydraulic valves back "ON" before starting the machine, or
extensive pump damage will occur.
• DONaT exceed the maximum platform horizontal pulloflOOlbs. (45.4 kg).
• DO NOT use the boom or platform as a crane to lift oversized or hanging loads.
• DO NOT raise, extend, retract, tilt, rotate, or lowerthe platform or booms into
stationary objects, as this will cause damage to mechanical and hydraulic
components.
• DO NOT use the platform or boom functions to push ortowthe unit or another
vehicle.
• Avoid sudden braking or steering, go slowly and leave more maneuvering room
during cold weather operation until the machine is warm.
MANUAL92379-001
July1998
• SAFETY RELATED DECALS
ELECTROCUTION HAZARD
KEEP CLEAR
DEATH OR SERIOUS INJURY CAN
RESULT FROM CONTACT WITH TIllS
EQUIPMENT OR VEHICLE IF IT SHOULD BE
ELECTRICALLY CHARGED
21882-001
21882-001 - Decal, Electrocution Danger
• DO NOT OPERATE THIS CONDOR ® UNTIL YOU HAVE BEEN

PROPERLY TRAINED AND HAVE COMPLETELY READ AND
UNDERSTOOD THE OPERATOR'S MANUAL LOCATED ON
THIS CONDOR, ®
• PRIOR TO EACH DAY'S USE, CHECK TO MAKE SURE ALL

FUNCTIONS ARE OPERATING PROPERLY PERFORM ALL
INSPECTIONS REQUIRED BY SECTIONS 6,5, 6.6 AND 7.3.3
OF THE ANSI 92.5 STANDARD.
• DO NOT USE THIS CONDOR® IF IT IS MALFUNCTIONING OR

DAMAGED IN ANY WAY, OR If THE WIND BLOWS OVER 25 MPH.
• RAISE PLATFORM ONLY WHEN CONDOR ® IS ON FIRM,

LEVEL GROUND.
• AL WA YS LOOK IN THE DIRECTION IN WHICH THE PLATFORM IS

MOVING, WATCH FOR AND AVOID OVERHEAD OBSTRUCTIONS
AND ANYTHING ELSE THAT MAY STRIKE PLATFORM,
PERSONNEL, CONTROLS OR CONDOR ®,
@
• THIS CONDOR ' IS NOT ELECTRICALL Y INSULATED.
SEE OPERATOR'S MANUAL FOR SAFE APPROACH DISTANCES
TO ENERGIZED POWER LINES,
• DO NOT MAKE ANY MODIFICATIONS TO THIS CONDOR@

WITHOUT WRITTEN APPROVAL FROM CONDOR'S MANAGEMENT.
• IN CASE OF EMERGENCY,
PUSH RED "EMERGENCY STOP" BUTTON,
:3853.}
38533 - Decal, Lower Boom Caution
MANL!AL92379-001
July 1998
•
SAFETY RELATED DECALS
Ii ·
ILh CAUr~ON I
BEFORE OPERATING CONDOR®, ALL PERSONS IN i~.
~~; PLA TFORM MUST HAVE APPROVED FALL :;.
} PROTECTION SYSTEMS ATTACHED..
"f
.~ • THIS CONDOR® IS NOT ELECTRICALLY INSULATED.
SEE OPERA TOR'S MANUAL FOR MINIMUM SAFE'
APPROACH DISTANCES TO ENERGIZED POWER
LINES.
RAISE PLATFORM ONLY WHEN CONDOR® IS ON

t •
Ii FIRM, LEVEL GROUND.
i • ALWAYS LOOK IN THE DIRECTION IN WHICH THE'

" PLATFORM IS MOVING. WATCH FOR, AND AVOID, f;
'; OVERHEAD OBSTRUCTIONS AND ANYTHING ELSE
THAT MAY STRIKE PLATFORM, PERSONNEL,
CONTROLS. OR CONDOR.®
, • NORMAL TRAVEL POSITION IS WITH BOOM

" POSITIONED OVER FIXED (REAR) AXLE.
DIRECTION OF TRAVEL AND STEERING REVERSES
IN RELATION TO CONTROL MOTION WHEN BOOM
IS OVER STEER (FRONT) AXLE.
DO NOT DRIVE ON A SLOPE UNLESS BOOM IS

FULLY RETRACTED AND LEVEL OR LOWER.
{ ~
M
~
• IF SLOPE ALARM SOUNDS, CONDOR@> lS OUT OF 1
x
i LEVEl. REVERSE DIRECTION OF TRAVEL AND'"
I REPOSITION CONDOR® ON FIRM, LEVEL GROUND. i.'
1• IN CASE OF EMERGENCY, PUSH RED t
"EMERGENCY STOP" BUTTON. 6957~
69573 - Decal, Upper Boom Caution
RATED WORK LOAD

500 LB 37958-500
37958-500 - Decal, Rated Work Load
MANUAL92379-OO1
Ju1y1998
8)
SAFETY AND CONTROL DECAL LOCATIONS
AWARNING
OPERATING THIS EQUIPMENT WITHOUT ALL SAFETY AND CONTROL
DECALS IN PLACE CAN BE HAZARDOUS.
If any of these items are damaged or missing, replace them immediately.

Decals are shown for standards machine. Optional equipment may change
the decal locations.
6
8
Rear
Front
20
Right Hand Side
Rear
Front
8
1----+1--1+- 21
Left Hand Side
MANUAL92379-001
July 1998
SAFETY AND CONTROL DECAL DESCRIPTIONS
CD
ITEM PART NUMBER DESCRIPTION QTY
Ref. 76412-A38/A42J ......... DecalInstallationM-A38-01M-A42J-Ol ................................. Ref.

-1 76412-DWG ............... Decal Installation Drawing .......................................................... 1
2 76105 .......................... Decal; Turret Control Box .......................................................... 1
3 21882-001 .................... Decal; ElectroocutionDanger ..................................................... 2
4 37958-500 .................... Decal-500 lb Rated Work Load .................................................. 1
5 38176 .......................... Decal-AuxHydraulic Valve Lowering .......................................... 3
6 38533 .......................... Decal-LowerCautionBoom ....................................................... 1
7 38550 .......................... Decal-PlatformFallArrest .......................................................... 2
8 52759 .......................... Decal-Stand Clear ....................................................................... 2
9 54182 .......................... Decal-BatteryChargerPlug ......................................................... 1
10 54652-005 .................... Decal, BatteryService Caution ..................................................... 2
11 55940-023 .................... Decal-3.50x23.33 Gray Condor ................................................ 2
12 54984-004 .................... Decal-Lift and Tie Down ........................................................... 4
13 54984-006 .................... Decal-ll0 Volt Ext To Platform ................................................ 1
14 54984-007 .................... Decal-HydraulicFluid ................................................................. 1
15 56024 .......................... Decal-Forward2.5x17Gray ....................................................... 2
16 56023 .......................... Decal-Arrow7x6.1 Gray .......................................................... 2
17 56033 .......................... Decal-Twin Stripe 3.5 Gray .............................................. 12.23LF
18 56034-500 ................... Decal; Rtd Work LD 3.5 x 13.7 Gray .......................................... 1
19 55941-017 .................... Decal-"Bird" 2.5 x 17 Gray ......................................................... 1
20 58399 .......................... Decal-Tire Replacement Solid ...................................................... 4
21 69573 .......................... Decal-Boom Upper Caution ...................................................... 1
22 71615 .......................... Decal;PanicStop ........................................................................ 1
23 76102 .......................... Decal;PlatfromControlBox ...................................................... 1
24 76407 .......................... Decal; A38 ................................................................................. 2
76408 .......................... Decal;A42J ................................................................................ 2
- Indicates Items Not Shown
MANUAL92379-001
July1998
G)
PRIMARY MACHINE COMPONENTS
PLATFORM ----~
,..-,11------ PLA TFORM CONTROLS
\'\¢&,¥---------- JIB BOOM

\ "'~------ JIB CYLINDER
UPPER BOOM
LIFT CYLINDER - - - - - - - - - - - - \ -
-1----------- MID-BOOM
LOWER BOOM --------------1
1------------- LIFT CYLINDER
GROUND CONTROLS , - - - - - TURRET
MANUAl92379-001
Ju1y1998
OPERATOR CONTROLS DESCRIPTION
(GROUND CONTROLS)
2
6
8
~
RIGHT
'-r-r---=-' 5
~ t BOOM
UP
~'----"'---'
7
L
"
)18
DOWN
BOOM
UP
+
PLATFORM LEVEL
4
9
LOWER OFF UPPER
CONTROL CONTROL
10
MANUAL92379-001
July 1998
(GROUND CONTROLS)
Item Control Location Description
1. Main Power Key On Ground Three position main power "ON/OFF" switch.
Switch Console Panel Straight up position is "OFF".
Turn key left (counterclockwise) one position to turn

power"ON" for ground control operation. Turn key
right (clockwise) one position to turn power "ON" for
platform control operation.
With key switch "OFF", the key may be removed to

prevent unauthorized operation.
2. Hour/VoltMeter On Ground Indicates that elapsed time that the unit has been oper-
Console Panel ated in hours and tenths. Also LED Lights indicate the
electrical system voltage.
3. EmergencyStop On Ground Used to stop all functions in an emergency. Push for

Button Console Panel emergency stop. Pull or rotate clockwise to reset,
depending on style used.
4. Lower Boom Lift On Ground Push switch up to raise Lower Boom. Pull switch down
Console Panel to lower Lower Boom. (Boom speed will be controlled
byProportional Control Knob.)
5. Upper Boom Lift On Ground Push switch up to raise Upper boom. Pull switch down
Console Panel to lower Upper boom. (Boom speed will be controlled
by Proportional Control Knob.)
6. Boom Extend! On Ground Switch Control the Boom/Retract Function. Push left to
Retract Console Panel Extend Boom. Push right to Retract Boom.
7. Jib Boom Switch On Ground Push switch up to raise Jib Boom. Pull switch down to
Console Panel lower Jib Boom.
8. Platform Rotate On Ground Push and hold switch to the left to rotate platform to
Toggle Console Panel the left (counterclockwise). Push and hold switch to the
right to rotate platformto the right (clockwise).
9. Platform Levelling On Ground Push and hold switch to the left to tilt the platform
Toggle Console Panel backwards. Push and hold switch to the right to tilt the
platform forwards.
10. Swing Switch On Ground Push switch to right to swing turret to right (counter-
Console Panel clockwise). Push switch to left to swing left (clockwise).
Turret can rotate 355° non-continuous. (Swing speed
will be proportional to Proportional Control Knob.)
MANUAL92379-001
July 1998
(PLATFORM CONTROLS)
1 6
13 5 10
4 11
8
BOOM
UP
+
DOWN
JIB
DOWN
BOOM'"
T
'---t------.J' UP
o
+
DRIVE
FORWARD
~ORIVE
T REVERSE
3
12 7 9
MANUAL 92379·001
July 1998
(PLATFORM CONTROLS)
Emergency Stop On Platform Used to stop all functions in an emergency. Push for
1. Button Console Panel emergency stop. Pull or rotate clockwise to reset,
depending onstyle used.
Circuit Breaker On Platform Pops out when the 48 Volt electrical circuit is
2. Console Panel overloaded. Push in to reset.
Lower Boom Lift OnPlatfrom Push switch up to raise Lower Boom. Pull switch down
3. Console Panel to lower LowerBoom. Boom speed will be controlled by
Proportional Control Knob.
Upper Boom Lift OnPlatfrom Push switch up to raise Upper boom. Pull switch down
4. Console Panel to lower Upper boom. Boom speed will be controlled
by ProportlOnal Control Knob.
Boom Extend/ OnPlatform Switch controls the Boom Extend/Retract function.

s. Retract Console Panel Push Left to Extend Boom. Push Right to Retract
Boom.
Jib Boom Switch On Platform Push switch up to raise Jib Boom. Pull switch down to
6. Console Panel lower Jib Boom. Boom speed will be controlled by
Proportional Control Knob.
7. Platform Leveling On Platform Push and hold switch to the left to tilt the Platform
Toggle Console Panel backwards. Push and hold switch to the right to tilt the
Platform forwards.
8. Platform Rotate On Platform Push and hold switch to the left to rotate Platform to
Toggle Console Panel the left (counterclockwise).Push andholdswitch to the
right to rotate Platfo rm to the right (clockwise).
9. Swing Switch On Platform Push switch to right to swing Turret to right (counter-
Console Panel clockwise). Push switch to left to swingleft (clockwise).
Turret can rotate 355 0 non-continuous. Swmg speed
will be proportional to Proportional Control Knob
Lever controls forward and reverse travel of machine

10. Drive Lever On Platform at aspeedproportional to handle movement.
Console Panel
A. WARNING I
WITH PLATFORM SWUNG OVER STEERING

WHEELS, USE CAUTION WHEN SELECTING
THE TRAVEL DIRECTION. TRAVEL
DIRECTION WILL BE OPPOSITE DRIVE
LEVER MOVEMENT.
MANUAL92379-001
July 1998
CD OPERATOR CONTROLS DESCRIPTION
(PLATFORM CONTROLS, CONTINUED)
11. Steer Switch On end of Drive Move switch left and hold to turn Steer Wheels to left,
Lever and right to turn Steer Wheels to right. Push and hold
in opposite direction to straighten Wheels.
~ WARNING
WITH PLATFORM SWUNG OVER THE STEER-
ING WHEELS, USE CAUTION WHEN SELECT-
ING THE STEERING DIRECTION. STEERING
DIRECTION WILL BE OPPOSITE STEER
SWITCH MOVEMENT.
12. Proportional On Platform The Proportional Control Knob controls the speed of
Control Knob Console Panel all hydraulicfunctions except steering (upper boom,
lower boom, jib, and swing). To increase the speed of a
h ydraulicfunction, rotate the Control Knob to the right
(counterclockwise). To decrease the speed of a boom
function, rotate the Control Knob to the left (clock-
wise).
13. Horn Button On Platform Press button to sound warning horn.

Console Panel
MANUAL 92379-001
July 1998
START-UP PROCEDURES
SHIff CHECKS
Before the CONDOR A-Series is put into use each shift, the following checks should
be completed to make sure that the machine is safe and in good condition.
Referto check lists at back of this manual for periodic maintenance requirements
and additional procedures for severe duty applications:
Visually inspect all machine components, i.e. missing parts, torn or loose hoses,
hydraulic fluid leaks, torn or disconnected wires, flat or damaged tires, etc. Both
compartment doors can be opened to inspect components inside.
Check volt meter on ground controls for battery condition and wire connections.
Check hydraulic fluid level with booms fully retracted end lowered.
Check wheellug nuts tightness. Check tire pressure (see Machine

Specifications).
Check hoses and cables for worn areas.
Check platform rails and safety gate latch for damage.
Check pivot pins for security.
Check that all warning and instructional labels are legible and secure.
MACHINE START-UP
.. DANGER
ALL OPERATORS MUST THOROUGHLY READ AND UNDERSTAND
THE "SAFETY RULES AND PRECAUTIONS" SECTION OF THIS
MANUAL PRIOR TO OPERATING THE MACHINE.
A COMPLETE VISUAL INSPECTION OF THE MACHINE MUST BE

PERFORMED PRIOR TO OPERATIONAL CHECKS.
• Ensure that "EMERGENCY STOP" buttons on ground control panel and platform control
console panel are disengaged. Pull out ortwist to reset, depending on style.
MANUAL92379-001
July1998
GROUND OPERATION AND CHECKS
A WARNING
BE SURE BOOM TRAVEL AREA IS CLEAR OF OBSTRUCTIONS.
DO NOT OPERATE THE MACHINE IF THE FOLLOWING CHECKS

REVEAL A DEFECT.
• Select "GROUND CONTROLS" with the " GROUND IPLA TFORM" key switch.
• Press and hold the upper "BOOM" toggle to the "UP" position to raise the upper boom
to the horizontal position or slightly above. Release the "BOOM" toggle.
• Press and hold the "JIB BOOM" toggle on the ground controls to the "UP" position to
raise the jib boom to the end of its travel. Release the "JIB BOOM" toggle.
Listen for any unusual noises.

Check foranyvibration while the boom travels up.
Check for uneven or jerky operation.
Check for hydraulic leaks.
Check pivot pin security. Make sure that all retaining bolts and rings are
in place on the pin locking point.
• Press and hold the "JIB BOOM" toggle on the ground controls to the "DOWN"
position to lower the jib boom to the end of its travel. Release the "JIB BOOM" toggle.
• Inspectthe boom sections visuallyfor any damage along their entire lengths.
• Push down on each of the three fastened corners of the tilt alarm located in the D rive
Axle. The alarm should sound as each corner is pressed beyond 5 degrees.
• Press and hold the upper "BOOM" toggle to the "UP" position. Raise the upper boom to
the end of its travel. Then, release the "BOOM" toggle.

Checkforanyvibration while the boom travels up.
Check pivot pin security. Make sure that all securing bolts are
in place on the pin locking point.
Visually confirm that the platform has remained level duringboomt ravel.
Report to supervisor and repair anyproblem.
MANUAL92379-001
July 1998
GROUND OPERATION AND CHECKS (Continued)
• Press and hold the "BOOM" toggle to lower the boom slightly.
• Press the "EMERGENCY STOP" button. All machine functions must stop. Then, check
to see if the auxiliary lowering valve on the upper lift cylinder works. After the valve on
the upper lift cylinder is closed, pull the "EMERGENCY STOP" button out to reset. Fully
lower the upper boom and repeat the procedure for the lower boom.
• Return the booms to their stowed positions byusing the appropriate toggles for "DOWN".

Checkforanyvibration while the booms lower.
Report to supervisor and repair any problem.
• Operate the "SWING" toggle in each direction.
Listen for anyunusual noises.

Check for anyvibration while the turret swings up.
• Release the "SWING" toggle.
• Press the "EMERGEN CY STOP" button. AIHunctions must stop immediately. Pull the
button out or twist to reset.
• Return the machine to the stowed position by pressing appropriate toggle switches
correspondingly.
MANUAL92379-001
July1998
PLATFORM OPERATION AND CHECKS
• Complete Ground Operation Checks before p erforming Platform Operation Checks.
• Select "PLATFORM CONTROLS" with the "GROUND/PLATFORM" Key switch.
• Entertheplatform. Close gate securely.
• Ensurethatthe "EMERGENCY STOP" button is released.
A WARNING
BE SURE BOOM TRAVEL AREA IS CLEAR OF OBSTRUCTIONS.
DO NOT OPERATE MACHINE IF THESE CHECKS REVEAL ANY

DEFECT OR ABNORMALITY.
• Depress the foot switch mounted on the floor of the platform. (Activate foot switch
to operate any of the machine functions.)
• Move the "JIB BOOM" switch up to the "JIB UP" position. The jib boom will start to rise.
Function speed is controlled by the proportional control knob. Raise the jib boom to the
fully raised position. Slowly return the leverto the center position.
• Move the "UPPER BOOM" switch up to the "UP" position. The upper boom will start to
rise. Function speed is controlled by the Proportional Control Knob.

Check for anyvibration while the upper boom travelsup.
Checkforunevenorjerkyoperation.
• Move the "LOWER BOOM" switch up to the "UP" position. The upper boom will start to
rise. Function speed is controlled by the Proportional Control Knob.

Checkfor anyvibration while the lower boom travels up.
Check for uneven or jerkyoperation.
Checkfor hydraulicleaks.
MANUAL92379-001
July 1998
PLATFORM OPERATION AND CHECKS (Continued)
• Return the booms to the travel position by operating the "LOWER BOOM" and
"UPPER BOOM" switches down to the "DOWN" position. Function speed is controlled
by the Proportional Control Knob.

Check for any vibration while the upper and lower booms are lowered.
• Move the "SWING" switch right to swing right (counterclockwise) and left to swing left
(clockwise). Swing speed is controlled by the Proportional ControlKnob.

Check for anyvibration while the unit rotates.
IMPORTANT: JIB BOOM SHOULD BE RAISED FOR SUFFICIENT

GROUND CLEARANCE.
A WARNING
WITH THE PLATFORM SWUNG OVER THE STEERING WHEELS, USE CAUTION
WHEN SELECTING THE TRAVEL DIRECTION. TRAVEL AND STEERING
DIRECTION WILL BE OPPOSITE CONTROL OPERATION.
• Slowly move the "D RNE" lever forward"The machine should smoothly accelerate in the
forward direction.

Check for anyvibration while the unit travels.
Checkfor hydraulicleaks.
MANUAL 92379-001
July1998
PLATFORM OPERATION AND CHECKS (Continued)
• Operate the "STEER" rocker switch and check for proper steering control. Note position
of the platform to the steering wheels.
• Return the wheels to the straight ahead position.
• Slowly move the"D RIVE" lever backward. The machine will smoothly accelerate in the
reverse direction.
• Press "EMERGENCY STOP" button. All functions must stop

immediately.
A. WARNING
BRACE YOURSELF FOR UNEXPECTED PLATFORM MOVEMENT BECAUSE
THE MACHINE COMES TO A SUDDEN STOP.
ACTUATION OF THE "EMERGENCY STOP" BUTTON WILL APPLY BRAKES

IMMEDIATELYl
• Reset "EMERGENCY STOP" button by turning or pulling.
• Raise the upper or lower boom to above horizontal, and repeat the drive tests. Machine
should travel a maximum ofO.s M.P.H (0.8 K.P.H.). This condition is referred to as "creep
speed", and is the maximum rate of travel with the upper or lower boom raised.
• Return the machine to the straight ahead position, with the upper and lower boom in the
stowed position. Position jib boom for adequate ground clearancefortravel.
• Move all switches back to their neutral positions. Release the foot switch.
NOTE: All machine motion should stop upon release of the foot switch.
MANUAL92379-001
July 1998
COLD WEATHER OPERATION
• In below zero weather, the hydraulic fluid should be allowed to warm before full
operation of the unit.
• Check for water contamination of the fluid.
• Check for and remove ice on the platform, swing gear teeth and steering
linkage(s) prior to operation.
• Check that all switches operate smoothly, and return freely to the neutral position.
A CAUTION
Avoid sudden braking or steering, go slow and leave more
maneuvering room during cold weather operation.
MANUAL92379-001
July 1998
DRIVING AND STEERING
it.. WARNING
ENSURE THAT THE ROUTE OF TRAVEL IS CLEAR OF PERSONNEL AND DE·
BRIS.
Depress the foot switch. Slowly push the "DRNE" lever forward to provide forward travel,
or pull the lever backward for reverse travel.
NOTE: The speed of the unit will be proportional to handle movement.
To steer, press "STEER" rocker switch on the end of the drive lever to the left or right as
required.
Although the unit can be driven with the platform positioned at either end of the unit, the
operator may find driving easier when the platform is overt he non-steering axle.
The stowed position can be identified by the large "FORWARD" arrows on the chassis.
When driving with the platform overthe opposite axle, rememberthat all directions given to
the steer and drive controls will be reversed.
When descending a ramp (incline), it is necessary to control the travel speed. To slowthe
unit, move the drive lever slowly towards the center "neutral" position.
BRAKING
For parking, the brakes are automatically applied when the drive lever is in the center
"neutral" position.
it.. WARNING
RELEASE OF THE DRIVE LEVER OR ACTUATION OF THE RED
"EMERGENCY STOP" WILL APPLY BRAKES IMMEDIATELY!
BRACE YOURSELF FOR UNEXPECTED PLATFORM MOVEMENT

AS THE MACHINE COMES TO A SUDDEN STOP.
MANUAl92379-001
July 1998
BOOMS, TURRET AND PLATFORM
Depress the foot switch, then select the required function. A vailablefunctions are:
• Lower boom UP or DOWN
• Upper boom UP or DOWN
• Jib boom UP or DOWN
• TurretswingLEFTorRIGHT
Each function can be selected by moving the appropriate lever or toggle in the
proper direction.
NOTE: Function speeds will be proportional to the position of the Proportional

Control Knob.
MANUAL92379-Q01
July 1998
SHUT -DOWN PROCEDURES
• When finished with the machine, placethe booms in the stowed position.
• Park the unit on a level surface.
• Turn "OFF" the "GROUND/PLATFORM" key switch. Remove key to prevent

unauthorized operation.
MOVING JOB SITE TO JOB SITE
• Inspectthe outside of the unit for damage (including the underside).

Inspect all hoses,and boom sections for chafing or road damage.
Confirm that all wheel lug nuts and swing bearing bolts are tight
(refer to specifications).
UNLOADING PROCEDURES
• Remove all machine tie downs. Remove wheel chocks, if used. Switch the
"GROUNDIPLATFORM" key switc h to "PLATFORM".
• Enterthe platform, and test all platform functions.
• Raise the boom and the jib so that the platform will clear any obstacles as the
machine is driven down the loading ramp.
• Carefully drive the unit off the truck ortrailer .
• Before placing the unit into service, all operators must read and understand
the contents ofthis Operator'sManual.
Upon initial unloading of the machine the "Prede1ivery InspectionReport"

must be completed and returned in order to activate the Time Condor
LimitedWarranty.
MANUAl92379-001
July 1998
Thispage intentionallyleft blank
MANUAL92379-001
July1998
TRUCK OR TRAILER TRANSPORT
UNASSISTED LOADING OR UNLOADING OF ANY MOBILE PLATFORM

IS NOT RECOMMENDED.
1. Enter the platform, secure the safety gate.
2. Raise the main and jib booms to allow greater ground clearance so that the
platform will clear any obstacles as the machine goes up the loading ramp.
3. Carefully drive the unit onto the truckonrailer.
4. Ensure that the lower boom is fully lowered and that the upper boom is stowed
in the boom rest.
S. Tie down locations are located on all four corners of the chassis and on the
platform's skirt. Use four (4) 1/2 inch, "Grade 7" chains from each of the tie
down lugs.
Ratchet type load binders are recommended. Ifusing lever type load binders,
wire or strap them shut, or wrap chains around them to prevent <?pening.
TRANSPORTING THE UNIT
TOWING PROCEDURES
• If optional towing package is not installed, refer to "UNPOWERED EMERGENCY

MOVEMENT" in this section.
MANUAl92379-001
July 1998
EMERGENCY SYSTEM AND PROCEDURES
UNPOWERED EMERGENCY MOVEMENT
• Every attempt should be made to restore powerto the unit before using this procedure.
.. DANGER
THIS PROCEDURE REQUIRES RELEASING THE VEHICLE BRAKES,
WHICH RESULTS IN NO MEANS TO STOP THE UNIT'S TRAVEL.
TIME CONDOR RECOMMENDS USING THIS PROCEDURE ONLY IN
CASE OF EMERGENCY, AND ONLY A SHORT DISTANCE.
BE AWARE OF UNIT RUNAWAY ON SLOPING SURFACES. MOVEMENT

SPEED SHALL NOT EXCEED 1 M.P.H. (1.6 K.P.H.).
MANUAL92379-001
July19ga
• 1.
Secure the unit with chains or ropes.
The A38/42J is equipped with tie down lugs (front and rear of chassis) that can
beused fonowingtheunit. The chains or ropes must be of sufficient capacity to
move the unit.
A. WARNING
ALWAYS CHOCK THE WHEELS BEFORE YOU RELEASE THE
BRAKES TO PREVENT UNEXPECTED UNIT MOVEMENT ON SLOPES.
2 Chock wheels.
3. Disengage brakes.
A. WARNING
WHENEVER DISENGAGING THE BRAKES OR BEFORE
DISCONNECTION FROM TOWING VEHICLE, ENSURE THAT
THE UNIT CANNOT ROLL.
4. Disconnect steer cylinder.
5. Disconnect batteries.
After unchocking the wheels, the unit will be ready to be moved.
After power has been restored to the machine, engage brakes, reconnect
batteries, and connect the steer cylinder. The machine is now ready for
normal operation.
MANUAL 92379-001
July 1998
EMERGENCY LOWERING
In case of total power loss, the upper and lower booms can be lowered manually
usingtheauxiliaryvalveslocatedontheboom'sliftcylinder. Tolowerthebooms
using auxiliary valves, follow the following procedures:
1. Open auxiliary valve on the lower boom lift cylinder (counterclockwise) and
allow boom to lower until it stops. Control boom speed by opening and closing
valve.
2. Close auxiliary valve (clockwise) to resume normal operation.
3. Open auxiliary valve on upper boom lift cylinder (counterclockwise) and allow
boom to lower until it stops. Control boom speed by opening and closing
valve.
It is not possible for us to foresee every emergency situation that could arise
during operation of this machine.
When faced with an emergency,above all please remember:
• Staycalm.
• Think through the situation before operating the machine.
• Get help if necessary.
IMPORTANT: Any incident involving personal injury must be immediately

reported to the local Time Condor Corporation.
MANUAL9Z379-0D1
July 1998
MACHINE SPECIFICATIONS
A38 A42J
Working Hght. 13.40m 14.60m
Platfonn Hght. . .··38'
..........
11.60m 12.80m
Stow. Height {)'$">. 2.03 m .6. 9'1 . 2.06m
1
.. 15'8" 4.78 m ·"1&'"

Stow. Length ....... ....
:: : ::: :
5.49m
Overall Width 5'~)'!<. 1.75 m<5'9" 1.75 m
Platfonn Cap. /SOrlbs 225 kg~(}Oib~ . •• 225 kg
Platfonn Size 6()'1x':19 IJ 1.5OXO.8m6Qi' x.3p f' l.50x0 .8m
Up/Over .<~()t19tt 6.53 mQ.QiIQrt. 6.35 m
Horiz. Reach 19'/ 5.80m23'9" 7.25 m
Tail Swing ZERO-_ ..... •. ZERO <ZERO
.. .....
- -.- ..........
ZERO
In. Tum Rad. A~?~'1 1.38 m 4'(i~1I 1.38 m
Out.Tum Rad. :.: ....10'2,,'··
:::: .. ::" .... ::: ...
3.10m >1<)'2"'.
. .... . ....
" -
3.10m
Gradeability '·30%> 30% .·• •• 25%. 25%
Travel Speed 2.4mph. 3.8kmh ·.2.,4fuPh .'. 3.8 kmh
Ground Clear. ... 5',< 12.7 em ·.·S'.< 12.7 em
Tire Size 6.()Ox9 6.00 x 96;O()x.9 6.00 x 9
Jib Length ONJAd N/A4'< 1.20m
Jib Rotation N/l\. NIA <• .I3tjO 1300
Turret Rotat. 360°·N/C 360 N/C $(J()"}NiC360° N/C
0
Plat. Rot.l~P6If 120 Hl~Oo.l-I. 1200 H

0
Power Source 4,8VJl)O 48 VDC4-8YPC< 48 VDC

Gross Weight lO,5001bs 4763kg12;50qlbs 5670kg
Wheel Base ..·.·6'3/t
.........
1.90 mG')"> 1.90 m
Hyd. Tank Cap. 55gal. 20.821 J.5gal 20.821
Tire PressureqQp$i 120ttO . 120
(pneumatic tire
option)
MANUAL 92379·001
July 1998
MACHINE DIAGRAM
... - ............ - .... - "',--- --- ............ , ..................... -- - r" .............. _ .. - .. -,- _ ................... --. .. _ .. - -_ ............ r" _ .. __ ....... _ .. --r ........ _....... ---.,
50' 1 I I I I I I I
--:------L
; '- .-.---........~ ,
: .......... ;..... I ; I
45' ..... _. . _.. -:- .......................... i" '".It....t:.;:: ..... ............. ; ........................... -:- .................... _ ..... ~
--------~.-..
;
I
...............,.,
I
."'"', ,
...........:
\\1
: :
40' ·1I--I!-4 .............. '" _ .. _ .. -:I .. _ ...................

'"
.:~I ........ - ................... :~ ... _ ............ _ .. ................................ _ "'"
",
,,,
,,
,,
,
35'
\!
3~'
/:
I /
~1\
1\ I
( I,1: :, '
,,
,
25'
~
:-
I:
\:
\
,.,\---........ .~~------~----~~--~~.
. 1.". t" • • >~::...I"'"I""--~:
.
'
20' : .-
",""IIUl"'*=1...
.,
r·· .. '
1
I
.j
J;' :i
. .: .,
).
/
15' .' "." , "
, ,
," ,
10' "., .',
5' ., . ,.
------ .. --- ---_ .. _-- .. ---1 ..... --------_ .. "'"
~~~~~d::t--l-"l---r---------)
__ .. I _ _ ....... / ! F,
~- .
O· L-______ ~_~~ __ ~ __ ~~~_~~ ~.lJ~~~i-------------~--------·-

__ _____ ____
~ ~
./. ~, _____ ~ ____ ~
10' 0' 5' 10' 15' 20' 25' 30'

A381A42J Working Range Diagram
MANUAL92379-001
July1998
SERVICE MANUAL
ARTICULATING
MODEL A38/42J
~===========r ·
MANUAL92379-002
May1998
Revised 11198
TABLE OF CONTENTS
Introduction '" ............................................................................................................................ .
Service Information ... .... ........ ...... ...... .... .......... ...... ...... .... ............ .... ........ ............ ............ ........ ... ii
WaITanty ............... .......................................................................................................... ....... iii
Introduction ............................................................................................................................................ 3
MachineSpecifications .............................................................................................................................. 5
Machine Component Locator .................................................................................................................. 7
Lubrication Chart ..................................................................................................................................... 8
Section 1: Transporting and Emergency Procedures
Transportingthe Unit ............................................................................................................................. 13

TruckandTrailerTransport ................................................................................................................... 13
Unloading Procedure ............................................................................................................................. 14
UnpoweredEmergencyMovement ....................................................................................................... 14
Emergency Lowering ..................•.......................................................................................................... 16
Section 2: Hydraulic System
HydraulicFluid ...................................................................................................................................... 20
HandlingPrecautions ........................................................................................................................ 20
FluidRecommendations ................................................................................................................... 20
Fluid Contamination Checks ................................................................................................................... 21
Main Hydraulic Pump ....................................................................................................................... 22
MainHydraulicControl Valve ........................................................................................................... 24
BoomLiftSystem ............................................................................................................................ 26
Boom Lift Valve Segment ......................................................................................................... 26
Lift Cylinder .............................................................................................................................. 26
Boom Telescope (Extend) System ..................................................................................................... 26
Boom Extend Valve Segment .................................................................................................... 26
Pressure Relief Valve .................................................................................................................. 26
Telescope (Extend) Cylinder ...................................................................................................... 26
JibBoomSystem ............................................................................................................................. 26
Jib Boom Valve Segment ........................................................................................................... 27
JibCylinder ............................................................................................................................... 27
PlatformRotateSystem .................................................................................................................... 27
Rotary Actuator ........................................................................................................................ 27
Platform Levelling System ................................................................................................................. 27
Master Levelling Cylinder ........................................................................................................... 27
Slave LevellingCylinder ............................................................................................................. 28
Steer System ..................................................................................................................................... 28
Selector Valve Segment .............................................................................................................. 28
Steer Cylinder ............................................................................................................................ 28
SteerSystemMaintenance .......................................................................................................... 28
MANUAL92379-002
May 1998
Revised 11198
• Section 3: Electrical System
TABLE OF CONTENTS
Battery Charger ...................................................................................................................................... 32

Battery Service ...................................................................................................................................... 42
Cable Wiring Diagram ........................................................................................................................... 50
LimitSwitches ....................................................................................................................................... 51
5° Slope Alarm ...................................................................................................................................... 52
DriveSystem-SevconBoomController ................................................................................................ 53
General .......................................................................................................................................... 53
Inputs/Outputs ................................................................................................................................ 53
Brake .......................................................................................................................................... 54
Modes of Operation ........................................................................................................................ 54
TractionMode .......................................................................................................................... 54
Pump Mode ............................................................................................................................. 55
FeaturesinPumpMode ............................................................................................................ 55
Features in Traction Mode ......................................................................................................... 55
TroubleshootingwithFlashCodes ............................................................................................. 57
Sevconcontroller -Handheldcalibrator .......................................................................................... 58
Featuresandlliustration ............................................................................................................. 58
Condorfactorysettings .............................................................................................................. 59
TroubleshootingwithSevconcontroller ..................................................................................... 60
Sevcon to Drive Motors power wiring .............................................................................................. 61
Drive Controller ........................................................................................................................ 63
Section 4: Maintenance
Maintenance ......................................................................................... '" .............................................. 66

General Maintenance Tips ...................................................................................................................... 66
First Three Months of Operation ............................................................................................................ 67
RoutingServicing ................................................................................................................................... 67
Shift Operational Checklist ..................................................................................................................... 70
Weekly Operational Checklist ................................................................................................................. 73
MonthlyOperational Checklist ................................................................................................................ 74
Semi -Annual Operational Checklist ....................................................................................................... 76
BoltTorqueChart(Standard) ................................................................................................................. 78
Bolt Torque Chart (tv1etric) ..................................................................................................................... 79
MANUAL92379-002
May 1998
Revised 11/98
INTRODUCTION
This Service Manual is designed to provide you with the instructions needed to properly maintain the
Time Condor Corporation A28/32J A38/24J. When used in conjunction with the Operators and Parts
manuals (provided separately) this Service Manual will Assist you in making necessary adjustments or
repaIrs.
Time Condor Aerial Platforms are designed and built to provide many years of safe, dependable
service. To obtain full benefits from your A28/32J A38/42J, always follow the proper operating and
maintenance procedures. Only trained, authorized personnel should be allowed to operate or service
this machine. Service personnel should read and study the Operators, Service and Parts Manuals in
order to gain a thorough understanding of the unit prior to making any repairs. Exercise all necessary
safety precautions when performing maintenance not covered in this manual.
To help you recognize important safety information, we have identified warnings and instructions that
directly impact on safety with the following signals:
A. DA.NGER
"DANGER" INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF
NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY. THIS SIGNAL
WORD IS TO BE APPLIED TO THE MOST EXTREME SITUATIONS.
A. WARNING
"WARNING" INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH,
IF NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY.
A. CAUTION
"CAUTION" indicates a potentially hazardous situation which, if not avoided, may result
in minor moderate injury. It is also used to alert against unsafe practices which could
lead to property-dam age-only accidents.
MANUAL92379-002
May 1998
Revised 11/98
Service personnel and machine operators must understand and comply with all warnings and
instructional decals on the body of the machine, and at the ground controls and platfonn
control console.
A. DANGER
MODIFICATIONS OF THIS MACHINE FROM THE ORIGINAL DESIGN
AND SPECIFICATION WITHOUT WRITTEN PERMISSION FROM CONDOR
ARE STRICTLY FORBIDDEN. A MODIFICATION MAY COMPROMISE THE
SAFETY OF THE MACHINE, SUBJECTING USERS TO SERIOUS INJURY
OR DEATH. ANY SUCH MODIFICATION WILL VOID ANY REMAINING
WARRANTY.
Condor reserves the right to change, improve, modify or expand features of its equipment at any
time. Specifications, models or equipment are subject to change without notice, and without incurring
any obligations to change, improve, modify or expand features of previously delivered equipment.
Any procedures not found within this manual must be evaluated by the individual to assure
himself that they are "proper and safe", because all possible procedures cannot be covered.
All Condor manuals are periodically updated to reflect changes that occur in the equipment.
Please contact the factory with any questions you may have regarding your machine, or
the availability of more recent manuals.
MANUAL92379-002
May 1998
Revised 11198
MACHINE SPECIFICATIONS
•
A28 A32J
. . - ..... , ....... .
WorkingHght. •.•• .34L ... 1O.36m ................ 11.58m

PlatformHght.<2S!
::::::::::,: ::::::>-: . 8.53 m32.'
":. ::.; .... : ":.:: 9.75 m
Stow.Height?'g"> 2.06m()I~IIC 2.06m
15,U ii n
Stow. Length .:.:":"':::::;;";':::;:;:;" 4.85mI8 : :.: : : :.
i
(j1l
... .....
5.64m
.. .. ..
OverallWidth5:!~!tH 1.75 m L Si9 ! . 1.75 m

1
PlatformCap.$QQI~$ 226.8kg?OQI6s. 226.8 kg

Platform Size 48"%$0'1 1.2xO.8m4-$~'~39" l.2xO.8m
Up/OveriS'9" "::':-':':':::.::;.::::::::>
4.80mL$t9'~
.. ::.::: ... ;::::;:;.,.: ...... .
4.80m
Horiz.Reachiri'su/ 4.17m ··ls'2 Ii
':;:-::::"::'.:::::.:::.::'
5.54m
TaiISwing~l£l{Q ZERO?;ER.() ZERO
In. TumRad.~'?~~' 1.38m41.!§~" I.38m
Out. TumRad.l0'2,i'H 3.1 0 m)()I~'~ 3.10 m
Gradeability~Q%.< 30%.~$~ 25%
Travel Speed~.@~p~ 5.15 kmh3.2-#lpg 5.15 kmh
GroundClear.5 '?. 12.70cm > 5'!· · ·• • ··12.70cm
t
TireSize6:QQ*Q 6.00 x 96.0Qx9 6.00x 9

Jib Length.'NfA NIA/4' . 1.22 m
Jib Rotation ·N/A N/A . 13()? 130°
TurretRotat.360~N/C360° N/C 36()~N)C360° N/C
Plat. Rot. >hO~M 130° Mi36 M BooM 0
Power Source 48V.DC 48 VDC48vDC 48 VDC

Gross W eight ~,3QQlbs 2404 kg (),900)bs 3 13 0 kg
WheelBase . •• 6'311 1.91 m.6'3" . . 1.91 m
Hyd. Tank Cap.?5ga.l 20.821 5,5 gal 20.821
MANUAL 92379-002
May 1998
Revised 11198
• MACHINE DIAGRAM
40' ··
---------~----,---~----------~r--------------~--------
I
I
I
. I
-------r-----------~--,---------------r--------------1
I I I I
·
··
·· ,,
,,,
, ·
I
.
I __ J I _______________ I~ ______________ ~I
35' --------------~---------------~, ,
--------~-----------
,I
I
·I
I
I
I I I
I I I
30' I
--------------,------- 9f~~ca~--------------~--------
I
------r--------------, I
·,, ... ____________ ~, _______________ L

.
• ______________ ~I
25' --------------~-----
I
, , I
I
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··,
20' .. I I ,
r--------------,---------------r--------------~-
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,
--------------., ·
···
15' ····
--------------~------
______________ ..J
··
··
·
10' ·
--------------,------------ ·
--------r--------------,
··.
··
_________ L ______________
..
·
~
5'
·
I
I
0'
10' 5' a' 5' 10' 15' 20' 25'
MANUAL92379-002
May 1998
Revised 11198
PLATFORM
PRIMARY MACHINE COMPONENTS
PLA TFORM CONTROLS
•
JIB BOOM
JIB CYLINDER
UPPER BOOM
LIFT CYLINDER
MID-800M
LOWER 800M
LIFT CYLINDER
GROUND CONTROLS
TURRET
CHASSIS
MANUAL92379-002
May 1998
Revised 11/98
LUBRICATION CHART
SPECIFICATION FREQUENCY OF
NO. ITEM AND QUANTITY LUBRICA TION
l. Hydraulic Reservoir Texaco Rando HDZ32 to Check level & condition each shift.
"Full" mark with all Analye 6 months or 500 hours.*+
cYlinders retracted. Change yearly or 1000 hours. *+
Change after first 50 hours then
2. Hydraulic Filters Filter elements. every 6 months or 500 hours. *+
3. Swing Bearing Lithium N.L.G.I. #2 EP. Weekly or every 25 hours.*+

(standard open style) Purge old grease.
4. Exposed Swing Bearing Dry moly lube spray. Every six (6) months or 500
Gear Teeth hours.*+
5. Swing Drive Gear Box Fill to plug. SAE 140 EP Check monthly or every 100
or N.L.G.I. #00 EP oil. hours.*+ Change every two (2)
years or 2,000 hours.*
6 Wheel Bearings Lithium N.L.G.I. #2 EP. Change every six (6) months or 500
Clean and repair. hours.*+
7 Drive Wheel SAE 90, half full. Change after first 50 hours. Check
Power Hubs monthly or every 100 hours.*+
Change yearly or 1,000 hours.*+
* Whichever occurs first.

+ Different requirements for severe duty applications. See check list.
MANUAL92379-002
May 1998
Revised 11!98
LUBRICATION DIAGRAM
1
2
3
4
5
MANUAl92379-Q02
May 1998
Revised 11/96
SECTION 1:
TRANSPORTATION
AND
EMERGENCY PROCEDURES
MANUAL92379-002
May 1998
Revised 11198
TABLE OF CONTENTS, SECTION 1
Transponingthe Unit ............................................................................................................................. 13

TruckorTrailerTranspon ..................................................................................................................... 13
Unloading Procedures ............................................................................................................................ 14
UnpoweredEmergencyMovement ....................................................................................................... 14
Emergency Lowering ............................................................................................................................. 16
MANUAL92379-002
May 1998
Revised 11198
FACTORY RECOMMENDED
TRANSPORTATION DIAGRAM
LlL.1f==i=li:::=dJ woo DE N
,----"¥"..,UJ PALLETS
76546
MANUAL92379-002
May 1998
Revised11198
TRANSPORTING THE UNIT
TRUCK OR TRAILER TRANSPORT
A WARNING
UNASSISTED LOADING OR UNLOADING OF ANY MOBILE PLATFORM
IS NOT RECOMMENDED.
1. Enter the platfmm, secure the safety gate.
2. Raise the main and jib booms(if so equipped) to allow greater ground clearance so that the
platform will clear any obstacles as the machine goes up the loading ramp.
3. Carefully drive the unit onto the truck or trailer.
4. Ensure that the lower boom is fully lowered and that the upper boom is stowed
in the boom rest.
5. Tie down locations are located on all four comers of the chassis and on the
platform's skirt. Use four (4) 112 inch, "Grade 7" chains from each of the tie
down lugs.
Ratchet type load binders are recommended. Ifusing lever type load binders,
wire or strap them shut, or wrap chains around them to prevent opening.
TOWING PROCEDURES
• If optional towing package is not installed, refer to "UNPOWERED EMERGENCY

MOVEMENT" in this section.
MANUAL92379-002
May 1998
Revised 11198
• MOVING JOB SITE TO JOB SITE
• Inspect the outside of the unit for damage (including the underside).
Inspect all hoses, boom sections and cables for chafing or road damage.
Confirm that all wheel lug nuts and swing bearing bolts are tight
(refer to specifications).
UNLOADING PROCEDURES
Remove all machine tie downs. Remove wheel chocks, ifused. Switch the
"GROUNDIPLATFORM" key switch to "PLATFORM".
Enter the platform, and test all platform functions.
Raise the boom and the jib so that the platform will clear any obstacles as the
machine is driven down the loading ramp.
Carefully drive the unit off the truck or trailer.
Before placing the unit into service, all operators must read and understand
the contents of this Operator's Manual.
Upon initial unloading of the machine the "Pre delivery Inspection Report"
must be completed and returned in order to activate the Time Condor
Limited Warranty.
EMERGENCY SYSTEM AND PROCEDURES
• Every attempt should be made to restore power to the unit before using this procedure.
A. DANGER
THIS PROCEDURE REQUIRES RELEASING THE VEHICLE BRAKES,
WHICH RESULTS IN NO MEANS TO STOP THE UNIT'S TRAVEL.
TIME CONDOR RECOMMENDS USING THIS PROCEDURE ONLY IN
CASE OF EMERGENCY, AND ONLY A SHORT DISTANCE.
BE AWARE OF UNIT RUNAWAY ON SLOPING SURFACES. MOVEMENT

SPEED SHALL NOT EXCEED 1 M.P.H. (1.6 KP.H.).
MANUAL92379·002
May 1998
Revised 11198
l. Secure the unit with chains or ropes.
The A28/32J -A38/42J is equipped with tie down lugs (front and rear of chassis) that can
be used for towing the unit. The chains or ropes must be of sufficient capacity to
move the unit.
A WARNING
ALWAYS CHOCK THE WHEELS BEFORE YOU RELEASE THE
BRAKES TO PREVENT UNEXPECTED UNIT MOVEMENT ON SLOPES.
2. Chock wheels.
3. Disengage brakes by tightening the three sets of nuts against brake. See below.
Brake release nut
A WARNING
WHENEVER DISENGAGING THE BRAKES OR BEFORE
DISCONNECTION FROM TOWING VEHICLE, ENSURE THAT
THE UNIT CANNOT ROLL.
4. Disconnect steer cylinder.
5. Disconnect batteries.
After unchocking the wheels, the unit will be ready to be moved.
After power has been restored to the machine, engage brakes, reconnect
batteries, and connect the steer cylinder. The machine is now ready for
normal operation.
MANUAL9Z379·002
May 1998
Revised 11198
EMERGENCY LOWERING
In case oftotal power loss, the upper and lower booms can be lowered manually
using the auxiliary valves located on the boom's lift cylinder. To lower the booms
using auxiliary valves, follow the following procedures:
1. Open auxiliary valve on the lower boom lift cylinder (counterclockwise) and
allow boom to lower until it stops. Control boom speed by opening and closing
valve.
3. Open auxiliary valve on upper boom lift cylinder (counterclockwise) and allow
boom to lower until it stops. Control boom speed by opening and closing
valve.
It is not possible for us to foresee every emergency situation that could arise
during operation of this machine.
When faced with an emergency, above all please remember:
Stay calm.
Think through the situation before operating the machine.
Get help if necessary.
IMPORTANT: Any incident involving personal injury must be immediately

reported to Time Condor Corporation.
MA NUAL 9Z379-002
May 1998
Revised 11198
SECTION 2:
HYDRAULIC SYSTEM
MANUAL92379-002
May 1998
Revised 11198
TABLE OF CONTENTS, SECTION 2:
HydraulicFluid ...................................................................................................................................... 20
HandlingPrecautions ........................................................................................................................ 20
FluidRecommendations ................................................................................................................... 20
Fluid Contamination Checks ................................................................................................................... 21
Main Hydraulic Pump ....................................................................................................................... 22
Main Hydraulic Control Valve ........................................................................................................... 24
BoomLiftSystem ............................................................................................................................ 26
Boom Lift Valve Segment ......................................................................................................... 26
Lift Cylinder .............................................................................................................................. 26
Boom Telescope (Extend) System ..................................................................................................... 26
Boom Extend Valve Segment .................................................................................................... 26
Pressure Relief Valve .................................................................................................................. 26
Telescope (Extend) Cylinder ...................................................................................................... 26
JibBoomSystem ............................................................................................................................. 26
Jib Boom Valve Segment ........................................................................................................... 27
JibCylinder ............................................................................................................................... 27
Platform Rotate System .................................................................................................................... 27
Rotary Actuator ........................................................................................................................ 27
Platform Levelling System ................................................................................................................. 27
Master Levelling Cylinder ........................................................................................................... 27
SlaveLevellingCylinder ............................................................................................................. 28
Steer System ..................................................................................................................................... 28
Selector Valve Segment .............................................................................................................. 28
Steer Cylinder ............................................................................................................................ 28
Steer System Maintenance .......................................................................................................... 28
MANUAL92379-002
May 1998
Revised11198
HYDRAULIC FLUID
HANDLING PRECAUTIONS
A WARNING
PERSONS IN REGULAR CONTACT WITH MINERAL - BASED
HYDRAULIC FLUID NEED TO BE AWARE OF THE IMPORTANCE
OF THOROUGH HYGIENE, AND THE PROPER METHODS FOR
HANDLING MINERAL OILS IN ORDER TO AVOID POTENTIAL
HAZARDS TO HEALTH.
Ifmineral-based hydraulic fluid is SPLASHED INTO THEEYES, it must

be WASHED OUTlliOROUGHLYusing abundant quantities ofwater.
If irritation persists, medical advice should be sought
Mineral oils act as solvents on the natural oils in the skin. FREQUENT AND
PROLONGED SKIN CONTACT CAN CAUSE DERMATITIS OR
SEVERE IRRITATION. Mineral-basedhydraulicfluidsnormallypresent
no health hazard when used properly. Protective clothing and proper
washing facilities should be provided or be accessible.
A WARNING
HYDRAULIC FLUID UNDER PRESSURE CAN PENETRATE AND BURN
THE SKIN, DAMAGE EYES, AND MAY CAUSE SERIOUS INJURY,
BLINDNESS, AND EVEN DEATH.
FLUID LEAKS UNDER PRESSURE MAY NOT ALWAYS BE VISIBLE.
IF MINERAL - BASED HYDRAULIC FLUID HAS PENETRATED THE SKIN,

IT MUST BE MEDICALLY TREATED, BY A DOCTOR FAMILIAR WITH
THIS TYPE OF INJURY, WITHIN A FEW HOURS.
FLUID RECOMMENDATIONS
We strongly recommend the use of TEXACO RANDO HDZ32 HYDRAULIC FLUID. An

EQUIVALENT substitute can be used if absolutely necessary. Mineral - based hydraulic
fluids produced by different companies will USUALLY mix with each other satisfactorily,
but this IS NOT RECOMMENDED. When in doubt, consult your supplier.
MANUAl92379-002
May 1998
Revised11!98
FLffin CONTAMINATION CHECKS
Use the following as a guide to determine when analysis of the hydraulic fluid is necessary.
Any time the hydraulic pump is replaced.
If fluid discoloration is noticed in the hydraulic reservoir sight tube.
If, after the first 50 hours of operation, the hydraulic filter elements are plugged.
Any time the hydraulic filter elements show signs of metal content.
• Once every six months, under normal operating conditions.
• Every 3 months, in extremely dusty or dirty operating conditions.
The hydraulic fluid analysis must be done by a qualified laboratory. To ensure that you receive
accurate recommendations about the fluid being analyzed, always provide the following
information with the test sample.
Type of hydraulic fluid. (See Lubrication Chart)
• Model and serial number of unit from which sample was taken.
Purpose of analysis: i.e. pump failure, discoloration, etc.
Type of analysis: i.e. complete to show additive breakdown, acid buildup, viscosity, type
and percent of contaminants. Comparison to new fluid and recommendations.
Comply with contamination analysis and recommendations to achieve a clean, contamination free
hydraulic system.
Following the above guide will prevent premature failure of pumps, cylinder seals and drive
motors, and unnecessary down time.
MANUAL92379-002
May 1998
Revised 11198
Hydraulic Pump
The hydraulic pump is a fixed displacement type pump. The speed, or rate ofthe hydraulic
functions are controlled by the speed of the electric motor driving the pump. The control of this
speed is done with the "Pump Mode" of the Sevcon controller. The rheostat on the platform
control box sets the speed from the platform. The speed is 100% from the ground control box
using the ramping feature to smooth the operations.
The pump pressure can be checked by adding a 0-3000 PSI gauge to test port gauge. Now
bottom-out lower boom function from lower control box and adjust for 2500PSL
For more detailed information on the pump control see page 58 of the Electrical System,
Section Three.
MANUAL92379-002
May 1998
Revised 11/98
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Main Hydraulic Valve
The main hydraulic valve is distributed as shown below.
eeeee H= HF970826
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~~~~~
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Pump Main ;j;}
Pressure
Tank
CD - Ann Lift Retract Cylinder

CU - AnnLiftExtend Cylinder
BD - Boom Lift Retract Cylinder
BU - BoomLiftExtend Cylinder
M2 - Turret Swing Left
Ml - Turret Swing Right
R - Steer Right
L - Steer Left
B - Jib Extend Cylinder
A - Jib Retract Cylinder
MANUAL92379-002
May 1998
Revised 11/98
\.J°PER 800M
CYLINDER STEERINC
7$039 CYLINDER
51170
tURRET ROTAtOR
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• BOOM LIFT SYSTEM
The boom lift system consists of a hydraulic valve segment on the ground valve bank, a lift
cylinder with a counterbalance valve, a lift toggle switch on the ground control and a toggle
switch on the platform console.
BOOM LIFT VALVE SEGMENT
When the boom control lever on the platform console or the boom control toggle switch on
the ground control is activated, an electrical signal is transmitted to the valve cartridge in the
boom lift valve segment. This allows hydraulic fluid at the correct pressure to be sent to the
proper end of the lift cylinder to raise or lower the boom.
LIFT CYLINDER
The boom lift function is controlled by a double acting cylinder. The cylinder contains
a counterbalance valve, which will prevent unintended movement of the cylinder should
a hose or fitting develop a leak. When the boom is lowered, fluid flows to the rod end cylinder
port and to the counterbalance valve, and allowing fluid in the base end of the cylinder to flow
back to the hydraulic reservoir. When the boom section is raised, fluid flows to the base end
cylinder port and to the counterbalance valve, opening this valve and allowing fluid in the
rod end of the cylinder to flow back to the hydraulic reservoir.
BOOM TELESCOPE SYSTEM ( A381 A42J)
The boom telescope system consists of a hydraulic valve segment on the ground valve bank,
a pressure relief valve, a double telescope cylinder with two counterbalance valves, an extend
toggle switch on the ground control and a toggle switch on the platform console.
BOOM TELESCOPE VALVE SEGMENT
When the boom telescope control lever on the platform console or the boom telescope
control toggle switch on the remote control pendant is activated, an electrical signal is
transmitted to the valve cartridge in the boom telescope valve segment. This allows hydraulic
fluid at the correct pressure to be sent to the proper end of the telescope cylinder to extend
or retract the boom.
PRESSURE RELIEF VALVE
The pressure relief valve limits the pressure on the base end ofthe cylinder to 2000 PSI to
prevent the cylinder rod from buckling. The pressure relief valve is factory set and needs no
adjustment.
TELESCOPE CYLINDER
The telescope cylinders control the extending and retracting of the boom.
JIB BOOM SYSTEM ( A32JI A42J)
The jib boom system consists of a hydraulic valve segment on the ground valve bank, a cylinder
with a counterbalance valve, and a toggle switch on the platform console and a toggle switch on
the ground control.
MANUAL92379-002
May 1998
Revised 11/98
JIB BOOM VALVE SEGMENT
When the jib boom control lever on the platform console or ground control station is activated, an
electrical signal is transmitted to the valve cartridge in the jib boom valve segment. This allows
hydraulic fluid at the selected flow to be sent to the proper end of the cylinder to raise or lower jib
boom.
JIB ARTICULATION CYLINDER
The jib boom function is controlled by a double acting cylinder. The cylinder contains a
counterbalance valve, which will prevent unintended movement of the cylinder should a hose or
fitting develop a leak. When the boom is lowered, fluid flows to the rod end cylinder port and
the counterbalance valve, opening this valve and allowing fluid in the base end ofthe cylinder
to flow back to the hydraulic reservoir. When the jib boom section is raised, fluid flows to the
base end cylinder port and to the counterbalance valve, opening this valve and allowing fluid in
the rod end of the cylinder to flow back to the hydraulic reservoir.
PLATFORM ROTATE SYSTEM
The platform rotate system consists of a platform rotate toggle switch and valve, a double pilot
operated check valve, a rotary actuator and a platform rotator manifold. The platform rotate
system can onlybe operated from platform console.
ROTARY ACTUATOR
The rotary actuator is a helical gear type. Hydraulic fluid enters the actuator from either side
depending on the control valve direction, and moves the rack which causes the pinion shaft to
rotate.
PLATFORM LEVELLING SYSTEM
The platform levelling system automatically keeps the platform level, using a master/slave cylinder
arrangement. As the boom is raised or lowered, fluid is forced from one cylinder to the other in a
closed loop, which keeps the platform parallel to the ground in any boom position. Due to slight
internal leakage, there is a manual override that controls fluid through the platform level control
valve.
The platform levelling system in only controlled from the platform console.
MASTER LEVELLING CYLINDER

The master levelling cylinder is a double acting cylinder located between the upper frame of the
superstructure and the boom. Whenever the boom is raised or lowered, the master cylinder is
forced to extend or retract. The fluid displacement from the master cylinder is in tum sent up
the boom to the slave cylinder. This forces the slave cylinder to move the same distance as the
master levelling cylinder; thereby keeping the platform level.
MANUAL92379-002
May 1998
Revised 11 /98
SLAVE LEVELLING CYLINDER
The slave levelling cylinder is a double acting cylinder located between the jib boom and the
platform. This cylinder controls the position of the platform relative to the tip boom.
The slave levelling cylinder contains two counterbalance valves. The counterbalance valves
prevent platform movement in the event of hose failure.
STEER SYSTEM
The steering system consists of a steer valve segment, in the ground valve bank, a steer cylinder, a
steer rocker switch on the drive lever atthe platform console. Refer to "Component Locators" in
the introduction of this manual.
STEER VALVE SEGMENT
When the steer control lever on the platform console is activated, an electrical signal is transmitted to
the valve cartridge in the steer valve segment. This allows hydraulic fluid to be sent to the steer
cylinder.
STEER CYLINDER
The cylinder is double acting and is directly connected to the steering linkage assembly. This cylinder
powers all steering movements.
STEER SYSTEM MAINTENANCE

Check all pins on steering linkage and steer cylinder for excessive play, and ensure that all
retaining rings are in place and secure.
Lubricate linkage as required (see Lubrication Chart).
MANUAL92379-002
May 1998
Revised11t98
SECTION 3:
ELECTRICAL SYSTEM
MANUAL92379-002
May 1998
Revised 11198
TABLE OF CONTENTS, SECTION 3
BatteryCharger ...................................................................................................................................... 32
Battery Service ...................................................................................................................................... 42
Cable Wiring Diagram ........................................................................................................................... 50
Limit Switches ....................................................................................................................................... 51
SO Slope Alarm ...................................................................................................................................... 52
DriveSystem-SevconBoomController ................................................................................................ 53
General .......................................................................................................................................... 53
Inputs!Outputs ................................................................................................................................ 53
Brake .......................................................................................................................................... 54
Modes of Operation ........................................................................................................................ 54
TractionMode .......................................................................................................................... 54
Pump Mode ............................................................................................................................. 55
Features in Pump Mode ............................................................................................................ 55
Features in TractionMode ......................................................................................................... 55
Troubleshooting with Flash Codes ............................................................................................. 57
Sevconcontroller -Handheld calibrator .......................................................................................... 58
Featuresandlliustration ............................................................................................................. 58
Condor factory settings ............................................................................................................. 59
T roubleshootingwith Sevcon controller ..................................................................................... 60
Sevcon to Drive Motors power wiring .............................................................................................. 61
DriveController ........................................................................................................................ 63
MANUAL92379-0D2
May 1998
Revised 11198
115VACBATTERYCHARGER
TROUBLESHOOTING GUIDE
To be able to use the troubleshooting guide effectively, itis importantto read this guide completely
before beginning any tests.
CAUTION
REPAIRS BY QUALIFIED PERSONNEL ONLY.
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 willvoid 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 of 2 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 indi cate the charge rate.
If the charger does not turn on properly, refer to Part A, B, or C for specific test procedures.
Do not operate the charger if it is malfunctioning. Personal injury or

property damage could result.
MANUAL92379'()02
May 1998
Revised 11198
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.
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.
Dis connect 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 shouldbe the same as the battery terminal voltage and mustbe between 24 and 5ovolts
DC in order to close the relay. Ifthe 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 5ovolts DC) inside
the charger where the white and black wires ofthe DC cord attach. Ifthe battery DC voltage measured
inside the charger is now below the above limits ornotpresent, the DC plug or cordsethas an internal
break and must be replaced. If the charger is wired correctly and a satisfactory battery DC vol tage
is measured inside the charger, a malfunction in the Electronic TimerKithasprobablyoccurred. Due
to its complexity, do not attempt to make field repairs to any part of the Electronic Timer Ki t. If a
malfunction exists, simply remove the entire Electronic Timer Kit andreplaceitwithanewone. 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 amalfunction exists. First disconnect
the charger power supply cord from its outlet and the DC output from the battery. Place aj umper 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 cordis connected to alive 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. Ifnormal charging currentis indicated on the ammeter the Electronic
Timer Kit is defective and must be replaced.
MANUAL92379-002
May 1998
Revised 11198
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.
If AC 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. If the 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 of the power supply cord,
transformer primary coil and relay.
PART C - RELAY CLOSES AND TRANSFORMER HUMS BUT AMMETER DOES NOT
REGISTER
If the relay closes and the transformer hums, the charger AC circuit and Electronic Timer Kit are
functioning properly. If the 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, referto Section
2 - "Charger Fuse Blows" for further tests. If the 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. If the
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. Ifthe 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.
MANUAL92379-002
May 1998
Revised 11198
6)
2. Ifthe charger DC circuit test is good, a check ofthe capacitoris necessary. Disconnect the power supply
cord from its outlet and the DC output connector from the battery connector. Then disconnect
both transformer coil leads from the capacitor terminals. Use care when disconnecting the capacitor
leads so the wires do not break. Using an ohmmeter, setthe scale to R X 10K ohms and testthe capacitor
as follows:
DANGER
HIGH VOLTAGE: With the charger operating, the charger capacitor voltage is
approximately 650 volts AC. Use extreme caution when working near the capacitor terminal
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.If the 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 of the 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, 3/8" 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 of the 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 tenninal 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 92379-002
May 1998
Revised 11198
• Connectthe black lead of the power supply cord to tenninal #1 on the Electronic Timer Kit
and the white lead of the 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 tum when tightening the
nut. Reconnect the green wire of the Electronic Timer Kit along with the transfonner secondary
lead to the diode lead terminal.
CAUTION
Be sure all connections are clean and tight. Also check to be sure all wires
and tenninals 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 Electroni c 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. Ifthe 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 offproperly.
DANGER
Lead acid batteries generate highly explosive hydrogen gas especially
during the charging cycle. To AVOID the possibility ofan explosion,
charge batteries ONLY in a well VENTlLATED 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.
SECfION 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 electricall y
test the fuse to determine if one 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.
MANUAL92379-002
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PART A-SINGLE FUSE LINK BLOWS
This conditionisnonnally caused by a short circuit failure ofone 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 alowvoltage continuity tester, connect
one tester lead to the diode mounting plate and the other tester lead to a diode tenninaL
Note the reading and then reverse the tester leads and check each diode again. If a diode conducts
current in both directions, it is "shorted" and the complete Heat Sink Ass embly with Diodes (Part No.
09653 S) 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 isnonnally caused by areversepolarity 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. Ifpossible, check the voltage and polarity at the battery connector with aDC
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. If a
reverse polari ty 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 ofboth 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.
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.SECfION 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 of the 6 volt batteri es in a 24
volt batterypackreversepolarity. Using asuitableDCvoltmeter, testto be sure all batteries ina battery
pack are correctly wired and also test the battery pack voltage at the charging connector. After
charging for 3 0 minutes atthis 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.
SECfION 4 - CHARGER OUTPUT IS LOW
The most probable cause oflow output is a single fuse link blowing as the result ofa short circuit failure
of one diode. Refer to Section 2 - "Charger Fuse Blows" for troubleshooting procedures. On rare
occasions a short circuit failure ofthe transformer coils may cause the 0 utputto be low. Refertosection
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.
SECfION 5 - CHARGER TURN OFF MALFUNCTIONS
The Electronic Timer Kittums the charger off as well as on. Proper charge time is determined by many
factors, butthe main elements are: (1) battery size, (2) depth ofbattery 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 ofbatteries and
the original set of batteries on another charger.
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PARTA-CHARGERTURNSOFFTOOSOON
Checkto be sure the power supply cordis securely connected to alive outlet. Ifthe power supply outlet
is live, proceed with the next step.
To determine ifthe 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. Theammeterneedlejumps 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 performing properly.
2. The ammeter needle jumps smartly to between 20 and 25 amps, but does nottaper below 14 amps within
15 minutes. Ifthe batteries have been properly maintained and charged regularly, this generally indicates
that the batteries were not fully charged. Ifpossible, use a hydrometer to check the specific gravity of
several battery cells. Ifthe specific gravity readings are more than 30 points (.030) lower than normal
full charge readings, the electronic timer has malfunctioned and the complete Electronic Timer Kit must
be replaced. Referto Section 1, PartD - "Electronic Timer Kit Replacement" for correctprocedures.
Ifthe batteri es have notbeen used or charged regularly, they maybe sulfated and will not produce their
full capacity. Repeated cycles (atleast 5) ofalight discharge followed by a full charge will generally
result in the recovery ofmost ofthe battery's capacity. Do notinterpretthis 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 normal. 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 areductionin battery capacity. This condition
normally results in a finish charge higher than 10 Amps and less time is required to fully charge the
batteries. Do notinterput 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 perform as required, they should be replaced.
PART B - CHARGER DOES NOT TURN OFF
New batterieswith all good cells should rise to atleast2. 5volts 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 fmish charge rate of8 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.
If the charger remains on longer than the specified maximum time, check to see ifthe charger turns
on immediately when the DC output cord is connected withoutthe normal 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 ofmalfunction generally results in the chargernotturning off and the
complete Electronic Timer Kit must be replaced. Refer to Section 1, PartD - "Electronic Timer Kit
Replacement" for correct procedures.
MANUAL92379-002
May 1998
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If the charger remains on longer than the maximum time specified and the two to five second delay
is present, verify that the green wire from the Electroni c Timer Kit and the secondary transformer coil
lead are securely connected to the diode lead as shown. The charger will NOT tum off ifthe 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 vol tmeter is available, a test to verify that the Electronic Timer has
malfunctioned can be made. Connect the charger to the batteries and allowto charge normally. After
the 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 .0 12 volts, or ifthe battery vol tage
decreases between successive hourly readings, the charger should tum 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. TocheckforACpowerinterruptions,pluganelectricclockintothesameoutlet
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
If this 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. If the circuit is complete, check the relay contacts to be sure they are open
and have notwelded closed. Ifthe 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. Referto Section
7 - "Transformer Short or Burnout" for test procedures.
SECTION 7 - TRANSFORMER SHORT OR BURNOUT
Failure ofthe transformer can be the result ofnatural aging, premature shorting ofadj acent coil turns
or overheating damage. The most common cause of transformer overheating and premature burnout
is the result of misuse, connecting the charger to a battery system oflowervoltage than specified on
the charger (See Section3). Darkening ofall the transformer secondary coil windings is anindication
ofpossible overheating damage. Aloworcomplete lack ofoutput would be observed on the ammeter,
however, the transformer may hum ortheAC 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 disconnectthe transformer capacitor coil leads from the
capacitor terminals. Use care when disconnecting the capacitor lead so the wires do not break.
MANUAL92379-002
May 1998
Revised 11 /98
DANGER
HIGH 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 1, Part Afor by-pass procedures. With the Electronic Timer Kit bypassed
take caution in connecting the power supply cord to an outlet. If the AC line fuse or circuit breaker
blows, the transformer is shorted internall y and must be replaced. If this does not occur, check the
transformer secondary and capacitor coil voltages as shown in Figure 6, using asuitableACvoltmeter.
Ifthe measured voltages are substantially lower than those shown, the transformer is shorted internally
and must be replaced.
Ifthe 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 reconnectthe capacitor coil leads to the capacitor terminals. Then, take caution when
reconnecting the power supply cord to an outlet and measure the transformer secondaryvoltageagain.
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 orthe capacitor coil terminals may not be making proper electrical contact.
Refer to Section 1, Part C, Item 2 for capacitor test procedures. If the voltage readings are correct,
both the transformer and capacitor are good, refer to Section 1, Part C, Item 1 for further tests of the
DC circuit.
Ifitshould become necessary to replace a terminal on one of the transformer leads, the new terminal
must be crimped AND soldered. N01E: Some transformer leads may be aluminum wire and a solder
mustbeusedonthesewiresthatisintendedforuseonaluminum,suchasAlcoa#807solderwithAlcoa
#69 flux. Ifthese materials are not available locally, contact the Lester factory.
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BATTERY SERVICE
CAUTION
Low battery voltage (discharged) requires higher current draw
to do the same work. This high current draw WILL DAMAGE the
electric motor, relay contacts and the batteries. DO NOT OPERA
the CONDOR® with a battery DISCHARGED or that has a specifi
gravity of 1.130 or LESS.
BATTERY CHARGING
A. DO NOT charge batteries unless the electrolyte level has been checked.
B. Operate charger in accordance with the battery charging instructions.
C. Make sure the charger INPUT A.c. VOLTAGE is the same as the voltage
rating of the battery charger.
D. Avoid ARCING battery conditions. Protect batteries from sparks or open

flame.
E. Use protective face and eye equipment when checking the condition of
charging batteries.
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-levelling 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.
BA TTERY 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
MANUAL92379-002
May 1998
Revised 11198
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.
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. If any 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. Then 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 of conventional batteries is to check the electrolyte level in all
cells. If necessary, 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 112" (l3mm) 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.
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STEP 2 - HYDROMETER TEST
Using the hydrometer, measure and record the specific gravity, corrected to 80 degrees F (26.7 C) of
the electrolyte in each cell. If the range (highest-lowest) is 50 points (0.050 sp.gr.) or greater or the
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. lfno 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.
The average state of charge of the cells in a battery can be determined by measuring the stabilized
voltage of the battery. The voltage is stabilized if the 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. If the cell connectors are accessible for voltage measure-
ments, a range of 0.05 volts between the highest and lowest cells corresponds to a 50 point variation in
specific gravity. A cell voltage of2.07 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.
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TESTING WITH FIXED LOAD TESTER AND OPEN CIRCUIT
For testing batteries with a fixed load tester and an open circuit voltmeter, refer to "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.
STEP 2 - FIXED LOAD TEST
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 manufacturer's
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% of the Cranking Performance rating or 3 times to 20 ampere-hour capacity of
the 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.
MANUAL92379-002
May 1998
Revised 11198
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 of charge from the following chart (Battery temperature
60-100 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 with an expanded scale. If the state of charge is 75% or
greater and the battery failed the test, it should be replaced. If the state charge 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.
MANUAL92379·002
May 1998
Revised 11198
DETERMINING CAUSES OF BATTERY FAILURE
Whether the battery passes or fails either of the above tests, the result must be delivered.
If the battery passed the load test only after a recharge, the cause of the discharge condition
should be determined. If the 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 discharge 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, turn 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.
Dsing a DC ammeter with a resolution of at least 0.1 amp, measure the
current between the disconnect cable and the battery terminal. (DO NOT
CONNECT AMMETER ACROSS BATTERY TERMINALS!) A leakage
current measurement of O.lamp or more indicates the equipment electrical
system should be tested and repaired.
B. Ohmmeter -Disconnect the positive cable at the battery. Connect an

ohmmeter to the 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 (100 ohms -see Note I) 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 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.
MANUAl92379-002
May 1998
Revised11198
FIGURE: X
SA TTERY TESTING CHART
STEP1 VISUAL INSPECTION

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

I REPLACE BATTERY I I CHECKELECTROLYTE LEVEL I
BELOW TOP OF PLATES IN ONE OR I
MORE CELLS
I ELECTROLYTE LEVEL ABOVE TOP OF
PLATES INALLCELLS-PROCEDTO STEP
ADD WATER TO JUST ABOVE SEPA- 2
RATORS. CHARGE FOR lSMINUTESAT
lS-2SAMPS. PROCEEDTOSTEP2
STEP2 I HYDROMETER TEST J

I I
SPECIFIC GRAVITY LESS THAN 1.22S OR SPECIFIC GRAVITY 1.225 OR GREATER
CELL VARIATION SO POINTS OR GREATER. ORCELLVARlAllONLESSTHAN50POINTS.
I
I RECHARGE I I
DISCHARGE AT 150 AMPS FOR 151
SECONDS
I
SPECIFIC GRAVITY LESS THAN 1.225 OR I
CELL VARIATION SO POINTS OR GREATER.
I CONTINUETOSTEP3
I
I
I REPLACE BATTERY I
STEP 3 I LOAD TEST I
I
1. PLACE THERMOMETER IN CENTER CELL.
COVER BATTERY WITH A DAMP CLOTH.
2. CONNECTVOLTMETERANDAMPERELOAD
EQUAL TO 1/2THE COLD CRANKING AMPERES
ATO°F (-18°C) RATING OFTHE BATTERY FOR
15SECONDS.
3. OBSERVE VOLTAGE AT 15 SECONDS WITH
LOAD ON.
4. REFERTOVOLTAGECHARTBELOW.
I
I I
I
I VOLTAGE BELOW CHART VALUE
I
I REPLACE BATTERY I
I
VOLTAGE EQUAL TO OR ABOVE CHARTI
VALUE-RETURN TO SERVICE I
VOLTAGE CHART
ESTIMATEDELECTROLYTE TEMPERATURE MINIMUM REQUIRED VOLTAGE UNDER lSSEC. LOAD

(USE 1/2 THESE VALVES FOR 6-VOLT BATTERIES)
70°F (21°C) & ABOVE 9.6

60°F (16°C) 9.S
SO°F (10°C) 9.4
40° F{4° C) 9.3
30°F(-1°C) 9.1
20° F(-7" C) 8.9
10°F (-12°C) 8.7
OaF (-18°C) 8.S
MANUAl92379-002
May 1998
Revised 11/98
FIGURE: Y
BATTERY TESTING CHART
STEP 1 VISUAL INSPECTION

CHECK FOR OBVIOUS DAMAGE SUCH AS
CRACKED OR BROKEN CASETHATSHOWS
LOSS OF ELECTROLYTE. ALSOCHECKFOR
TERMI NAL 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 INCORRECT
POLAITY - USUALLY RED TO POSITIVE (+) AND BLACK TO NEGATIVE (-).
2. SET SELECTOR SWITCH ON LOAD TESTER TO 1/2CRANKING AMPERAGE
RA TI NG OF BATTERY (AT O'F, -18'C).
3. IFTESTERDOESNOTHAVEANAUTOMATlCBATTERYTEMPERATURE
COMPENSATOR, PLACEA THERMOMETER IN CELL, READ ANDSETTEMP-
ERATURE DIAL ON TESTER. WITHOUT ANYTEMPERATURE 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
I BATTERY FAILS LOAD TEST I I
I
I PROCEEDTOSTEP3 I
IBATTERY PASSES LOAD TEST
RETURN TO SERVICE. I
STEP 3 I OPENCIRCUITVOLTAGETEST I
I
1. ALLOW 10 MI NUTES FOR BA TTERY VOLTAGE TO STABI LlZE
AFTER LOAD TEXT.
2. READ OPEN CIRUITVOLTAGE.
I
UNDER 12.4VOLTS-BATTERYSHOULD BE 12.4VOLTSORABOVE-IFBATTERYDID

CHARGED AND LOAD TESTED AGAIN (RE- NOTPASSTHE LOAD TEST, ITSHOULD BE
PEAT STEP2).IF BATTERY AGAIN FAILS REPLACED- THEN PROCEED TO STEP 4.
THE LOAD TEST, REPLACE IT. IF IT PASSES,
RETURNTOSERVICEAFTERPROCEEDING
TOSTEP4.
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 ALLACCESORIES TURNED
OFF:
A) DISCONNECTTHE BATTERY GROUND CABLE AND CONNECT ASUITABLE VOLTMETER
BETWEEN DISCONNECTED BATTERY POST AND GROUND (A READING OVER 6 VOLTS
INDICATES AN EXCESSIVE LEAK).
OR
B) DISCONNECTTHE BATTERY CABLE THATGOESTO THE STARTER AND CONNECT AN
OHMMETERBETWEENTHECABLEANDTHEGOUND(ARESISTANCEOFUNDER1000HMS
WILL DRAIN THE BA TTERY).
3. CHARGING SYSTEM SHOULD ALWAYS BE CHECKED AFTER CHARGING OR REPLACING A
BATTERY.
MANUAL92379-002
May 1998
Revised 11198
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MANUAL92379-002
May 1998
Revised11J98
LIMIT SWITCH
The lower elevation limit switch should be adjusted to change state when the boom is 4' to 6' high.
The upper elevation limit switch should be adjusted to change state when the boom is horizontal or
just above.
Upper Elevation
Limit Switch
Lower Elevation
Limit Switch
MANUAL92379-002
May 1998
Revised 11/98
• TILT ALARM
The tilt alarm gives an audible warning when the machine is 4-1/2° or more out oflevel. It is located in
the platform control console. To replace the tilt alarm, open the platform control console, disconnect the
wires and remove it from the platform control console.
TIL T ALARM TEST
The alarm can be tested by manually tipping the alarm sensor. This "Push-to Test" feature enables tilt
alarm to be tested without losing its adjustment. Select "Platform" at the ground key (selector) switch.
With the boom raised above horizontal, individually push down on each of the three fastened corners of the
tilt alarm. On the tilt alarm, there are three LED's. The green LED indicates the unit has power. The red
LED indicates the sensor is tilted beyond 4-1/2°. The yellow LED indicates the sensor is tilted beyond 4-
1/2° and the 3 second delay has expired (tilt alarm should sound at the platform).
TIL T ALARM ADJUSTMENT
The tilt alarm can be adjusted. Before attempting to adjust the alarm, park the machine on a flat, level
surface.Level the base of the alarm by adjusting each of the three flange nuts until the level bubble is
centered.
CIRCUIT BREAKER
There is one 20 amp circuit breaker mounted on the face of the ground control box.
If the breaker is tripped, reset it by pushing in the button. If the breaker trips again, the cause of the high
current draw must be corrected prior to further operation.
LIMIT SWITCH
There are limit switches for the boom telescope and boom lift. The (boom telescope) limit switch is
located on the lower left side of the base boom. The boom lift limit switch is located on the center post of
the turret. Unless the boom lift and (telescope) limit switches are closed as shown on the machine
electrical schematic at the end of this manual, the machine will only be able to travel at creep speed from
platform.
EMERGENCY STOP BUTTON
There is an emergency stop button on the ground control console and on the platform control console.
When the emergency stop buttons are pressed, all functions stop immediately and the wheel brakes are
automatically applied. To replace the emergency stop button, open the ground control console or platform
control console to gain access for button removal. Remove the appropriate button mounting screws and
Wires.
MANUAL9237~02
May 1998
Revised11i98
DRIVE SYSTEM SEVCON BOOM CONTROLLER
General Comments/Scope
A boom controller is a device which will provide TRACTION and PUMP control to a boom lift vehicle,
operating at 24 to 48 volts. The TRACTION and PUMP control functions are incorporated into the device such
that either mode of operation can be selected by an advantage ofthis system being that both TRACTION and
PUMP drives can be incorporated into a single controller.
The FORWARD and REVERSE contactors are wired to enable PLUG-BRAKING. A tachometer is present
to measure speed and is used in a closed loop fashion to provide CONSTANT SPEED CONTROL (CSC).
The accelerator input is used to select a 'cruise' speed, which the controller will attempt to maintain by varying
the percentage on and/or utilizing PLUG-BRAKING. The controller remains in CSC at all speeds.
This specification outlines the modes of operation, inputs and outputs, and essential features proposed for the
boom controller.
Inputs and Outputs
The following sections define the required 110 forthe boom controller.
Power Inputs and Outputs

The following power connections shall be provided:
Battery positive
Battery negative
2 Motor connections
Control Inputs
The following control inputs shall be provided:
OnJOffEmergency SW in series with Foot SW, applying battery voltage to controller.

TRACTION Acc. 5K to OK, min to max speed or 3.5+ 0.05 to <0.2v.
PUMP Acc. same as above with external pull up resistor.
FORWARD select
REVERSE select
PUMP select
TRACTION Speed cutback 1 (interlock with boom extension)*
TRACTION Speed cutback 2 (interlock with off-level switch)*
Tachometer input
* Speed cutback is: SW close = no cutback
SW open = speed cutback applies
Lowest selected speed has priority.
Control Outputs
The following control outputs shall be provided:
FORWARD contactor drive

REVERSE contactor drive
PUMP/TRACTION select contactor drive
PUMP (STEER) motor override direct battery connection contactor
MANUAL92379-002
May 1998
Revised 11198
DRIVE SYSTEM SEVCON BOOM CONTROLLER Cont.
Electric Brake
The ELECTRIC BRAKE will be supplied from the positive side through the emergency switch and from the
negative side through the FWD and REV driver. Therefore, the ELECTRIC BRAKE will be applied when no
DIRECTION contactoris energized (i.e. in NEUTRAL, during PUMP mode, or if a fault condition is forcing
neutral).
The brake time constant should be slow enough that it will not operate during direction contactor changeover
(of the order of 0.25 Seconds).
The ELECTRIC BRAKE must be rated at the same voltage as the contactor coils. The current consumption
of the brake should be such that the 3 amp overcurrent limit is not exceeded by the contactor coil and brake
current, combined. If the combined current consumption ofthe coil and brake will exceed 3 amps, an auxiliary
relay will be needed to drive the brake.
Modes of Operation
The following sections define the required modes of operation:
TRACTION Motor Drive
Drive in either FORWARD or REVERSE will start only if the following

conditions are satisfied:
PUMP switch off.

No procedure or diagnostic faults present.
FWD or REV selected as appropriate.
Once in TRACTION mode activating the PUMP switch shall not cause TRACTION mode
to be exited, the PUMPITRACTION contactor drive shall not be energized (shall be left at the
TRACTION position). If the PUMP switch is selected during TRACTION, a procedure fault will
occur when NEUTRAL is selected, remaining until the PUMP switch and both DIRECTIONS are
no longer selected.
When NEUTRAL is selected the controller will control smooth stopping of the vehicle, using PLUG
BRAKING, before the ELECTRIC BRAKE is allowed to operate.
If the PUMP switch is activated in NEUTRAL, when the vehicle has stopped and the BRAKE is
applied, then PUMP mode will become operational.
PUMP Motor Drive
PUMP motor drive will start only if the following conditions are satisfied:
FWD and REV switch off.

Traction mode off (brake applied)
No procedure or diagnostic faults present.

PUMP switch selected.
MANUAL92379-002
May 1998
Revised 11198
PUMP drive shall only be enabled when the DIRECTION selector inputs in NEUTRAL and
the truck is stationary. Once PUMP drive mode has been entered then the status of the
DIRECTION selector inputs shall no longer interlock PUMP operation. If a
DIRECTION switch is selected during PUMP drive, a procedure fault will occur when the
PUMP switch is no longer selected, remaining until both DIRECTIONS and the PUMP switch
are no longer selected.
Features in PUMP Mode
• Proportional control of PUMP motor speed when upper control is selected.

The PUMP motor speed shall be controlled by varying the percentage on of the switching
element in relation to a separate PUMP accelerator input. The accelerator input is wire number
60 from the speed control potentiometer. When PUMP mode is enabled a variable offset speed
shall be applied to the PUMP motor at zero demand. This shall be adjustable in the range of
0% ON to 30% ON using the handheld calibrator. Displacement ofthe accelerator input shall
result in a linear increase in percentage on from the offset speed to 100% ON over the full
range of accelerator input. When lower control is selected, the input is connected to ground
for 100% output through wire #60 any time a function is activated.
• Wire off detect

In the event ofthe accelerator input becoming detached, the fitted external pull up resistor will
cause pulsing in PUMP mode at the offset speed. No fault diagnostic will be reported.
• Pump Accell
The PUMP motor speed control shall incorporate a "soft start" facility by applying acceleration
delay to changes in the applied percentage on of the switching element. The duration of the
acceleration delay shall be variable between 0.5 seconds and 5 seconds with a resolution of
0.1 seconds, using the hand held calibrator.
• Pump Decel
The PUMP motor speed control shall incorporate a "soft stop" facility by applying deceleration
delay to changes in the applied percentage on of the switching element. The duration of the
deceleration delay shall be variable between 0.5 seconds and 5 seconds with a resolution of
0.1 seconds, using the hand held calibrator.
NOTE: Both Soft Start and Soft Stop share a common adjustable parameter.
Features in Traction Mode
Maximum speed control
The controller shall incorporate a function to limit the maximum possible speed. This function
shall operate in such a manner as to control vehicle speed by limiting the percentage on of the
switching device to keepthe vehicle speed below the maximum permitted valve or, if required,
to apply variable PLUG BRAKING to restrict vehicle speed when traveling down a gradient.
In any case maximum permitted valve should not be exceeded by more than 15%.
The maximum permitted speed shall be computed from the accelerator input percentage such
as that the maximum acceleratorinputpercentageis equivalenttothe maximum allowed speed.
The maximum permitted speed shall vary linearly with accelerator input percentage according
to the following relationship.
MANUAL 92379-002
May 1998
Revised 11198
• MAX SPEED = Percentage speed as defined by calibrator personality (0% to 100%).
ACCEL. SPEED = MAX. SPEED * Accelerator input percentage.
Where control speed is the speed at which the controller will drive the truck, in the manner
described above.
NOTE: Minimum control speed is set by the speed personality.
The actual vehicle speed shall be measured using a suitable tachometer, to be agreed with
Sevcon, which shall supply 20V DC for 1000 RPM with a maximum speed of 2500 RPM
(50V). The polarity indicates the vehicle direction.
If the actual vehicle speed is greater than the CONTROL SPEED the controller shall employ
an algorithm which will limit the percentage of the switching device or, if necessary, initiate
PLUG BRAKING to ensure that the CONTROL SPEED is not exceeded by more than the
specified tolerance.
The SPEED CONTROL function shall also compensate (to an accuracy of 15910) for positive
gradients by increasing the percentage ofthe switching device, to alimitoffull battery voltage.
Speed Cutbacks
If either speed cutback is selected, the MAX SPEED above is reduced to the appropriate
cutback (provided that it is lower), and the accelerator input is rescaled to the new MAX
SPEED.
A four second lag is applied to the off-level switch when it is de-selected to compensate for
switch bounce.
Off-Level Control
When the off-level cutback is selected, in addition to reducing the MAX. SPEED, various
algorithms are activated to give greater vehicle control on a hill.
The TRACTION acceleration delay is reduced to a very short delay, so that it is

possible to quickly compensate for roll-back when the vehicle is going up hill.
The Plugging level range increases to 400A versus 200A when on-level.
Accelerator Input
The TRACTION accelerator is controlled with wire #45 from the Drive Joystick Control.
Direction in controlled as follows, wire #43 is Forward and wire #44 is Reverse.
Wire Off Detect
In the event of the accelerator input becoming detached, pushing in TRACTION mode will
occur so that the vehicle drives at minimum speed. A 6-flash fault diagnostic will also be
reported.
MANVAL92379·002
May 1998
Revised11198
TractionlBraking Hysteresis
So that the vehicle behavior is smooth, a hysteresis curve will be implemented on changeover
between pulsing of the switching device to drive the vehicle, and PLUG BRAKING.
When pulsing, the braking requirement must be high enough to justify changeover to PLUG
BRAKING. When braking, the pulsing requirement must be high enough to justify changeover
from PLUG BRAKING.
Troubleshooting With Flash Codes
The following is a list of flash codes that are displayed on the Sevcon unit. The number of
flashes identify one of several conditions possible in a fault condition.
LED on - Controller operational
LED off - Internal fault
2 flash - Procedure fault

This includes DIRECTION os PUMP selected at power on, or DIRECTION and PUMP
selected together.
3 flash - Motor permanently low.

This includes MOSFET short circuit. This fault only shuts down TRACTION mode, not
PUMP mode, though PUMP mode cannot be selected if this fault occurs during TRACTION
mode.
4 flash - Motor permenently high.

This includes DIRECTION or PUMPffRACTION contactor welded. This fault only shuts
down TRACTION mode, not PUMP mode, though PUMP mode cannot be selected if this
fault occurs during TRACTION mode.
5 flash - Motor neither low nor high.

This includes DIRECTION or PUMPffRACTION contactor open circuit, MOSFET open
circuit and hardware failsafe trip. This fault onlt shuts down TRACTION mode, not PUMP
mode.
6 flash - Faulty TRACTION accelerator.

This includes TRACTION accelerator greater than 30% at power on, and wire off. Note that
the PUMP accelerator in not fault detected.
NOTE: 6 Flash is normal when lower control is selected
7 flash - Low battery voltage.

This includes battery voltage below 13 volts.
8 flash - Thermal cutback.

This includes MOSFET temperature above 80°.
10 flash - Tachometer fault detected.
11 flash - Tachometer input out of range.

MANUAL9237g.002
May 1998
Revised 11198
The Sevcontrolleris a hand held unit that plugs directly into the Sevcon Boom Controller through a seven
pin connector. It can be used to view and change system parameters as well as for troubleshooting.
, /
V -~
AMP Max Plug Current
o!
SEC Traction Aceel Delay
SEC Traction Decel Delay
% Creep Speed
% Max Speed
% Elevation Cutback Speed
% Slope Cutback Speed
O~
SEC Pump Delay
% Pump Threshold
SELECT
0
Batt
Motor
Motor Calibrator
Temp
Test
Sevcontrol
MANUAL 92379-002
May 1998
Revised 11198
CONDOR FACTORY SEVCON SETTINGS
MODEL
A28/A32J A38/A42J
L Max Plug Current amps 400 600

2. Traction Accel sec 2.0 2.0
3. Traction Decel sec .50 .50
4. Traction Creep % 10 10
5. Max Speed % 100 100
6. Elevation Cutback % 10 10
7. Slope Cutback % 50 50
8. Pump Delay sec 3.0 3.0
9. Pump Threshold % 10 10
10. Onlevelplugging amps 400 750
1) MAX CONTROLLER CURRENT

a. 50 Amps to 400 Amps
DEFAULT 270A
b. 50 Amps to 600 Amps
DEFAULT 600A
2) ACCELERATION DELAY l.0 Seconds to 3.0 Seconds

DEFAULT 2.0 Seconds
3) DECELERATION DELAY 0.5 Seconds to 3.0 Seconds

DEFAULT l.5 Seconds
4) TRACTION CREEP 0% to 10%

DEFAULT 0%
5) MAX ALLOWED SPEED 0% to 100%

DEFAULT 70%
6) CUTBACK SPEED 15% to 20% (Boom Up)

DEFAULT 10%
7) CUTBACK SPEED 25% TO 60% (Off-Level)

DEFAULT 50%
8) PUMP SOFT START DELAY 0.5 Seconds to 5.0 Seconds

DEFAULT 3.0 Seconds
9) PUMP CREEP SPEED % on 0% -> 30%

DEFAULT 10%
10) ON LEVEL PLUGGING CURRENT

a. 50 to 400 Amps
b. 50 to 750 Amps
MANUAL92379-0OZ
May 1998
Revised 11 198
Troubleshooting
,
Diagnostics using hand held calibrator
V ~
GRAPHIC
D +
Sequence
OF HAND - Number
CALIBRATOR
D
D Select
Button
Temp
.--
rest
Select ~
~
Test Mode
Sequence No. Test Display Input #
- Accelerator o to 100% 14 &13

Input
1 FOlWard CLiOP 8
Switch
2 Reverse CLiOP II
Switch
3 Tachometer o to 100% 12
Input
4 Elevation CLiOP 4
Upper & Lower
Switch
5 Level CLiOP 7
Switch
6 Pump 16
Switch
7 Actual 2
Direction
8 Not Used
9 Not Used
10 Not Used
NOTE: CL = Switch CLOSED

OP = Switch OPEN
MANUAL92379-002
May 1998
Revised 11/98
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MO.NUAL92379-002
May 1998
Revised 11198
AMP MATE-N-LOK
CONNECTOR
~
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2,60- }H~MB ROC~ERr.
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PLUG# 1-480706-0 r I -I v--
_~-cD-_~~
PIN# 350690-1 RED C D
,20 QRN
,21 DIA THRU OPTIONAL ~rVjG\t ,---

ELECTRONICS ARE
EPQ):Y £NCAPSUlA1£D
MOUNTING HOLE - 2 PL / BRN I SPEEDSiGNAL-~---1
1,70
1,51 DIA THRU ~ f-- 2,281.14 I ~5AMP)'(AX
ORCIOW
I SOUD S1 A TE
DRIWR
j
!
I
I---- WT!ORG l~cCWM/0I"_ MOTOR CONTROL
3.40 - -
PANEL CUTOUT
TERM
I
COLOR
BLKGROUND
FUNCTION
~ I CIRCUIT
I
I
30' MAX-4-~30' MAX 2

3
ERN MOTOR CONTROL SIG
SPARE
BLU : V SUPPLY I !
I
,\-" HANDLE
A ( " TRAVEL
HANDLE
TRAVEL"""" B
4 BLU V SUPPLY
i I
~~D
BLK GROUND
5 ORG CW OUTPUT DIGI TAL
6 WT!ORG CCW OUTPUT DIGiTAL
:~ :
2 6 ~_l--------0
7
S
GRN
YEL
ROCKER "D"
ROCKER "c"
llLj~
i'i !!O i'i
________ .J
9 RED HANDLE SUPPLY
/ ~ WT IRED ~ L WT !BLK
J BRN
5,00 ROCKERJ ELECTRICAL CONNECTION
18"
PIGTAIL
SWITCH 0)
GRIP
NOTES: 1) VOLTAGE SUPPLY IS TO BE 28-60VDC,
2) CONTROL HANDLE IS SPRUNG TO CENTER POSITION,
I 3) SPEED SIGNAL: NEUTRAL 3,9-4,2VDC, =
CW & CCW TRIP 3,3- 3,6VDC. =
CW & CCW MAX = O.OVDC,
owe:. NO. ~EV.
~
CUSTOMER COpy P-O Confrol" Inc.
3,85 95 Dolphin Rd. B-09944 A
Thl'S AutQCAQ' dotobost! ;!!I (l Bristol, CT 06010 SHEH I'SC.o.tE
copy of the oriqlnol P-Q PHONE: (S60) 5B~-6994
~::'QJn,~$~~~~~lJt;;e right to ,--!~~~FA~X,-,~(8~60~)-,5::8,",3-:::6~O'-"'-_L_ _ _ _-L_':..::.::2~
:;;:f~~;,'~~tl~~·'"a' datobo,. M 115-1634 INSTALLATION DWG
Further copyiM9 Qnd distribution
of thl. dotobose without MOTOR CONTROL (MOS 90)
9
~:~e'C o~~~~~~o:'"'~o ~ """"""'''';'''''''';''--=-':''0''''''''''''-=-'-:''':'1""',Q,J;',,,,,,,';tN<Co"""''''''-'' 1"''''''.----
prohibited. JCH ! 11-10-97
10 76012-110 I PINION GEAR 8-04506 10

9 76012-109 1 500 OHM POTENTIOMETER A-00ISS-5000 VENDOR: P-Q CONTROLS, INC,
8 76012-108 1 MNT PLT 5115 POT & S\I1TCH 8-02476 VPN: M11S-1634
7 76012-107 1 ELEG, ASS'Y FOR M115-1634 E-115-1634
6 76012-106 1 ROCKER SWiTCH ACTU ATOR 8-04740 m.1[
~
COl'lll{l1'l CQRPCf/ATION
5 76012-105 1 CAP FOR ROCKER SWiTCH 8-04742 SPECIFICATIONS: ,

", CII.!!l"S
-"
a 0 0 8;300 IMP[F!IAl DRIVE
WACO. 10AS 76712
4 76012-104 1 SWITCH SEPARATOR 8-04741 30 DEGREE MAX HANDLE TRAVEL .~fx ! :g~ohT~"'~E-------==----------1
3 76012-103 2 SWITCH FOR ROCKER A-05029-01 HANDLE HAS ROCKER SWITCH ON TOP OF JOYSTICK
JOYSTICK, DRIVE CONTROL
10 CONTROL STEERING FUNCTIONS,
2 76012-102
1 76012-101
1
I
GRIP HALf ASS'Y RSG
BOOT (,31 SHAFT)
0-07853
8-02305-02
THE JOYSTICK CONTROL MODEL IS TO BE USED WiTH THE
MOS 90 SEVCON MOTOR CONTROLLER,
l1R O.C.N. NO.
PM"
DArt S KASER 9/2/97
BIORA~NGNO 76012 'EV,
A
ITEM CONDOR P!N OTY DESCRIPTION P-Q CONTROLS P!N l '!fl. D.R.N. NO. tl,ol Tt ftPPA'. ",!'PROVED JHe 9/4/91 SCAlE 1/1 .rs. rn 1 Of 1
SECTION4:
MAINTENANCE
MANUAL92379-002
May 1998
Revised 11 /98
Table of Contents, Section 4
Maintenance .......................................................................................................................................... 66
General Maintenance Tips ...................................................................................................................... 66
First!hree~~nthsofOperation ............................................................................................................ 67
RoutlngServlclng ................................................................................................................................... 67
Shift Operational Checklist ..................................................................................................................... 70
Weekly Operational Checklist ................................................................................................................. 73
MonthlyOperational Checklist ................................................................................................................ 74
Semi-Annual Operational Checklist ....................................................................................................... 76
Bolt Torque Chart (Standard) ................................................................................................................. 78
BoltTorqueChart~etric) ..................................................................................................................... 79
MANUAL92379-002
May 1998
RevSed 11198
• MAINTENANCE
The A28/32J is designed to require a minimum amount of maintenance. However, it is essential thathe
specified services be performed at the indicated intervals, and that instructions contained in this manual
are followed to ensure safety and reliability.
~ DANGER
DEATH OR SERIOUS INJURY MAY RESULT IF MACHINE IS OPERATED IN
AN UNSAFE CONDITION. DO NOT OPERATE ANY MACHINE IF IN UNSAFE
OPERATING CONDITION.
GENERAL MAINTENANCE TIPS
• ALWAYS clean the surrounding area before opening hydraulic components.
Never open a hydraulic system when there are contaminants in the air.
Never leave components or hoses open. They must be protected from contamination (including
rain) at all times.
Use only recommended lubricants. Improper lubricants or incompatible lubricants may be as

harmful as no lubrication.
Watch for makeshift "fixes", which can jeopardize safety as well as lead to more costly repairs.
Any work platform found not to be in safe operating condition should be removed from service
until repaired. All repairs should be made by authorized personnel in conformance with the
manufacturer's operating, maintenance, and repair manuals.
MANUAl92379-002
May 1998
Revised 11/98
FIRST THREE MONTHS OF OPERATION
As with any new machine, minor fluid leaks may occur until the various hydraulic components and
pipe fittings are fully seated.
It is particularly important that, for the first three months of operation, all hydraulic components,
hoses and pipe fittings be checked regularly for leaks and tightness, and corrective action taken as
required.
The hydraulic pump, electric motor, cylinders and pressure valves are self-lubricating.
ROUTINE SERVICING
NOTE: The following recommendations are based on advice of our component suppliers,
and the requirements of various safety regulations. They should be followed with discretion
based on factors such as amount and type of machine usage, environmental conditions, and
local safety regulations.
IMPORTANT: Make certain that the unit is inspected per the operational checklist at the
end of this section.
SHIFT SERVICE
Hydraulic System
Before checking the hydraulic fluid level, ensure that the machine booms are stowed in the
traveling position, and the machine is standing on level ground. Fluid level must be to full mark
on dipstick, located under filler cap. Refer to Lubrication Chart for correct grade of hydraulic
fluid. Ensure that the filler cap is secure to prevent entry of water or other impurities into the tank.
Tire Condition
Check that the tires are not damaged.
Platform Rails and Safety Gate
Check security of platform and safety gate.
Steering
Check the steer cylinder for fluid leakage. Inspect steering linkage for signs of wear.
Batteries
Check the electrolyte level in battery cells. Replenish with distilled water, ifnecessary.
Pivot Pins
Examine all pivot pins on booms and cylinders to ensure that they are positively secured in position.
Test All Machine Systems
Test the operation of the drive assembly, including drive motor and steering. Test the operation of all
machine boom functions.
MANUAl92379-002
May 1998
Revised 11198
Checklist
Perform all items on the Shift Checklist found later in this section.
WEEKLY SERVICE
Swing Bearing and Drive Pinion Gear
Lubricate standard open swing bearing and drive pinion gear.
Checklist
Perform all items on the Weekly Checklist found later in this section.
MONTHLY SERVICE
Hydraulic System
Pressurize the hydraulic circuit and inspect the system for any signs of leakage, particularly at flexible
hoses, connections and hydraulic components. Check hydraulic fluid color. If the hydraulic fluid does
not appear clear amber, but has a cloudy appearance, it is usually an indication that water is present.
A dark brown color, accompanied by a strong ''burnt'' smell, indicates that the fluid has overheated. If
either condition occurs, a complete hydraulic fluid and filter change will be necessary.
Chassis Bolts
Check all bolts for signs oflooseness. Refer to individual items in the Monthly Checklist.
Cylinders
Check all cylinders for hydraulic fluid leakage.
Pivot Pins and Grease Fittings
Lubricate all pivot pins and grease fittings.
Platform Mounting
Check that platform weldments and platform frame members are in good condition.
Checklist
Perform all items on the Monthly Checklist found later in this section.
SEMI-ANNUAL SERVICE
Boom Cylinders
Fully retract, then extend the boom lift cylinder. After each extreme position, check that there is no
movement between cylinder rod and bearing housing, or between cylinder cap and tube.
MANUAL9237~002
May 1998
Revised 11/98
Hydraulic Filter
Change the return filter element.
In severe use applications, more frequent filter changes will be necessary.
Checklist
Perform all items on the Semi-Annual Checklist found later in this section.
ANNUAL SERVICE
Note: Machine Annual Inspection Report Forms are available from TIME CONDOR.
Flexible Hoses
Inspect all hoses over their complete length. Replace any hoses showing looseness or corrosion at the
end fittings. Replace hoses with cracking, blistering or excessive wear of outer protective covering.
Hydraulic Fluid
If the hydraulic system has been properly maintained, the fluid should only need to be changed
once each year. This, of course, will depend on machine application, amount of use, temperature,
atmospheric conditions and other factors.
Hydraulic Fluid Tank
Carefully check the condition of the fluid inside the tank to ensure that it flows easily and is of clear,
amber color. In cases of gross contamination, it will be necessary to completely drain and refill the
entire hydraulic system.
Structural Examination
A thorough examination of the machine should be carried out for signs of corrosion, misalignment,
material fractures, and other damage. Particular attention should be given to the condition of
welded joints.
FOUR YEAR INTERVAL SERVICE
Pivot Pins and Bearings
Remove the pivot pins for examination. Check the pivot pin bearings with the pivot pins removed.
Replace with the correct type of pins and bearings, as necessary.
MA NUAl 92379·002
May 1998
Revised 11/98
SHIFT OPERATIONAL CHECKLIST
All checks must be completed before operation of the unit.
These checklists can be copied as needed to aid in performing these inspections.
DATE: INSPECTED BY: - - - - - - - - - -
MODEL NUMBER: ____________ SERIAL NUMBER:
GENERAL INFORMATION
1. Keep inspection records up-to-date.

2. Record and report all discrepancies to your supervisor.
3. A dirty machine cannot be properly inspected.
KEEP YOUR CONDOR MACHINE CLEAN!!!
A WARNING
THIS CHECKLIST MUST BE USED AT DAILY INTERVALS OR AFTER
EVERY 6 TO 8 HOURS OF USE, WHICHEVER IS SOONER. FAILURE
TO DO SO COULD ENDANGER THE LIFE OF THE OPERATOR. ALWAYS
REMEMBER, A LITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH
MORE THAN IT COSTS.
INITIAL DESCRIPTION
1. Check unit for any prior-shift or transportation damage, i.e. missing

parts, torn or loose hoses, hydraulic fluid leaks, torn or disconnected
wires, flat or damaged tires etc.
2. Check for machine damage, broken welds, improper or makeshift

repaus.
3. Check hydraulic system for leaks, examine hoses for signs of

excessive wear, chafing or twisting.
MANUAL9237S-002
May 1998
Revised11198
INITIAL
SHIFT OPERATIONAL CHECKLIST (Continued)
DESCRIPTION
•
6. Check battery electrolyte leveL Check battery terminals for tight
connections and cleanliness.
7. Check hydraulic fluid level. The level should be at the line

marked on the sight gauge with the unit in stowed position. Inspect
condition of hydraulic fluid in the reservoir. Fluid should be a clear
amber color.
8. Check tires proper inflation pressure.
9. Check if wheel lug nuts are tight.
10. Inspect safety equipment as required by OSHA, government and

local rules.
11. Inspect the work platform and boom structure for signs of damage
and broken welds. Check platform gate latch for damage.
12. Check pivot pins for security.
13. Check that no attempt had been made to override the drive interlock
system by a previous operator.
14. Check that all warning and instructional decals are legible and
secure.
15. Check that the tilt alarm is working properly.
16. When all pre-inspection checks have been completed, test the
ground controls for proper operation.
MANUAL92379·002
May 1998
Revised 11198
SHIFT OPERATIONAL CHECKLIST (Continued)
INITIAL DESCRIPTION
21. With the main boom raised, check for the smooth operation of drive,
creep speed.
ADDITIONAL MAINTENANCE REQUIREMENTS FOR HARSH ENVIRONMENTS
INITIAL DESCRIPTION
Inspect cylinder bolts, valve spool boots, etc., for cuts or other
damage after every eight (8) hours of service. Repair if necessary.
Check hydraulic system for leakage after every eight (8) hours of
operation.
MANUAL92379-Q02
May 1998
Revised 11198
WEEKLY OPERATIONAL CHECKLIST
DATE:-------------- INSPECTED BY:
MODEL NUMBER: - - - - - - - - SERIAL NUMBER: _ _ _ _ _ _ __
GENERAL INFORMATION
1. Keep inspection records up- to-date.

Keep your Condor machine clean!!
A. WARNING
THIS CHECKLIST MUST BE USED AT WEEKLY INTERVALS OR EVERY
25 HOURS, WHICHEVER OCCURS FIRST. FAILURE TO DO SO COULD
ENDANGER THE LIFE OF THE OPERATOR. ALWAYS REMEMBER, A
LITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH MORE THAN
IT COSTS.
INITIAL DESCRIPTION
1. Perform all checks listed on Shift Operational Checklist.
2. Check wheel lug nut torque.
3. Check hydraulic connections for leaks, corrosion and wear.
4. Lubricate swing bearing and drive pinion gear.
5. Apply lubricant swing to exposed swing bearing and drive

pinion gear .
Check lubricant in optional oil bath swing bearing case, if so

equipped, for proper level, and check for dirt or mental
contamination.
MANUAL92379-002
May 1998
Revised 11198
MONTHLY OPERATIONAL CHECKLIST
DATE:-------------------- INSPECTED BY:
MODEL NUMBER: ------------- SERIAL NUMBER: - - - - - - - - -
GENERAL INFORMATION

A WARNING
THIS CHECKLIST MUST BE USED AT MONTHLY INTERVALS OR EVERY
100 HOURS, WHICHEVER OCCURS FIRST. FAILURE TO DO SO COULD
ENDANGER THE LIFE OF THE OPERATOR. ALWAYS REMEMBER, A
LITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH MORE THAN
IT COSTS.
INITIAL DESCRIPTION
1. Perform all checks listed on Shift and Weekly Operational

Checklists.
2. Lubricate all grease fittings.
3. Lubricate all hydraulic valve spool linkages .
4. Check hose and electrical wire routed from the main boom,
through the jib boom and to the platform for any damage.
5. Check torque of swing bearing bolts.
MANUAL92379-002
May 1998
Revised 11 /98
MONTHLY OPERATIONAL CHECKLIST (CONTINUED)
INITIAL DESCRIPTION
8. Check adjustment and security of swing drive motor assembly.

There should be a slight amount of backlash between the turret
and chassis when properly adjusted. Check torque of mounting
bolts.
9. Check oil level in swing drive gear box.
10. Check oil level in power hubs.
11. Check that tires are not leaning in or out.
12. Check that wheel spindles turn freely, with no end play.
13. Check drive wheel power hub mounting bolt torque.
14. Check that neither the main boom nor jib boom drift with a full load,
when there is no hydraulic pressure.
15. Check to make sure boom sections are not dented or bent.
16. Check that all adjustable flow valves are locked. Check settings if
any are not locked.
MANUAL92379.002
May 1998
Revised 11198
• SEMI-ANNUAL OPERATIONAL CHECKLIST
DATE:-------------------- INSPECTED BY:
MODEL NUMBER: ------------- SERIAL NUMBER: - - - - - - - - -
GENERAL INFORMATION

A WARNING
THIS CHECKLIST MUST BE USED AT SIX MONTH INTERVALS OR
EVERY 500 HOURS, WHICHEVER IS SOONER. FAILURE TO DO SO
COULD ENDANGER THE LIFE OF THE OPERATOR. ALWAYS REMEMBER,
A LITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH MORE THAN
IT COSTS.
INITIAL DESCRIPTION
1. Perform all checks listed on Shift and Weekly Operational

Checklists .
2. Have hydraulic fluid sample analyzed at a test laboratory.

Comply with test results and recommendations to ensure
long, trouble free operation.
NOTE: Ifhydraulic fluid has been regularly maintained, it

should only require changing once every year, depending
on maintenance, temperature, application, duty cycle, and
atmospheric conditions.
3. Inspect the entire machine for signs of structural damage and

broken welds, and worn or damaged components. Replace
as necessary.
4. Clean and lubricate all electrical switches with an electrical

contact cleaner and ensure that the switches operate freely
in all positions.
5. Check the electrical mounting and hardware connections

for security.
MANUAl92379·Q02
May 1998
Revised 11/98
SEMI-ANNUAL OPERATIONAL CHECKLIST (CONTINUED) •
INITIAL DESCRIPTION
6. Replace retum filter element.
7. Clean and lubricate the exposed swing bearing gear teeth with dry
moly lube spray (not required for oil bath swing bearing option).
8. Repack front wheel bearings.
EVERY YEAR
9. Drain and replace fluid from hydraulic reservoir. Drain and replace
fluid from drive wheel power hubs. Ifbadly contaminated, it may be
necessary to disassemble and inspect components.
EVERY TWO YEARS
10. Drain and replace fluid from swing drive motor assembly. Ifbadly
contaminated, it may be necessary to disassemble and inspect
components.
MANUAL 92379-002
May 1998
Revised 11/98
APPENDIXA
BASIC STRESS
MAJOR AREA SAE GRADE 8
NOMINAL DlA SQ. IN
lllREADS INCH
NOTES:
I.TIllS CHART SHOWS RECOMMENDED BOLT TORQUES.
2.TORQUE =RX DXT

R = .150 FOR UJB 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
MANUAL92379-002
May 1998
Revised 11198
APPENDIXB
BOL T 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 ACCEPT ABLE

FOR ANY THREAD PITCH IN THAT DIAMETER
DIAMETER DRY LUBRICATED DRY LUBRICATED DRY LUBRICATED DRY LUBRICATED

THREADS THREADS THREADS THREADS THREADS THREADS THREADS 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
M12 67 40 73 44 92 55 127 76
M14 107 64 116 69 146 89 203 122
M16 167 100 181 108 230 138 316 190
M20 325 195 352 211 449 269 617 370
M24 562 337 609 386 775 465 1066 640
M30 1117 670 1210 726 1540 924 2188 1271
MANUAL92379-002
May 1998
Revised 11/98
PLATFORM ROTAlE SlEERlNG BooM EX1ENO/RElllACT .
AC1\JATOR C'IUNOER C'rUHOER
UPPER 900II 3Il480 S1170 76040
CYUNIl£R
76130
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. x I
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1
lURRET ROTATOR
:-~
MOTOR
J :
76000
PtAlFORI« I.£VEL PtA1l'ORII I.£VEL
.18 LOiI£R BOOII MAS1ER CYUNDER SLAIIE C'tUNOER
C'lUHDER C'IUNOER
~.
76127 76'28
76040 78'29
,------ ------.
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HYORAUUC CONlROL
VALVE
78009
FR..TEA BREAtHER
WI 0IPS11CT<
5031.6-001
HYDRAULIC
TANK
76J98
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OM a"
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BOOM-SUPPORTED ELEVATING
AERIAL WORK PLATFORM
MODEL A38/42J
SERIAL NUMBER 425980 19 AND UP
ILLUSTRATED PARTS MANUAL
MANUAL 92379-003
July 1998
CONDOR® Model A38/42J
ILLUSTRATED PARTS BREAKDOWN
CONTENTS
•
FIGURE NO. DESCRIPTION PAGE
A ....................................... SERIALNUMBERLOCA TION ...................................... 2

B ........................................ HOW TO ORDER PARTS ............................................... 3
C ....................................... RECOMMENED SPARE PARTS LIST ............................ 5
1.1 ..................................... FINALASSEMBLY .......................................................... 6
21 ..................................... CHASSIS INSTALLATION .............................................. 8

2.2 ..................................... STEERIN"GINSTALLATION ......................................... 10
2.3 ..................................... BATTERY BOX INSTALLATION .................................. 12
2.4 ..................................... BATTERY CABLE KIT .................................................... 14
25 ..................................... ELECTRIC MOTOR ........................................................ 16
2.6 ..................................... WfIEELDRIVE ............................................................... 17
3.1 ..................................... HOSE KIT ........................................................................ 18
4.1 ..................................... TURRET INSTALLATION .............................................. 20

4.2 ..................................... HYDRAULIC FILTER ASSEMBLY ................................. 22
4.3 ..................................... TURRET WIRING ASSEMBLY ....................................... 23
4.4 ..................................... TURRET BOX ASSEMBLY .............................................. 24
4.5 ..................................... UPPER-LOWER BOX CABLE ASSEMBLY .................... 26
5.1 ..................................... BOOMINSTALLATION ................................................. 28

5.1 ..................................... BOOMINSTALLATIONS/N 42598019 &UP ............... 32
5.2 ..................................... CYLINDER ASSEMBLY ................................................. 34
5.3 ..................................... REGENERATIVE MANIFOLD ASSEMBLY ................. 35
5.4 ..................................... HOSE CARRIER INSTALLATION ................................. 36
6.1 ..................................... JIB INSTALLATION ........................................................ 38
7.1 ..................................... PLATFORM INSTALLATION ........................................ 41

7.2 ..................................... PLATFORM BOXASSEMBLY A38 ................................. 42
7.3 ..................................... PLATFORM BOX ASSEMBLY A42J ................................ 46
7.4" ..................................... 110VOLTLINETOPLATFORM ................................... 51
8.1 ..................................... DECAL KIT ..................................................................... 52
MANUAL 92379-003
July 1998
Revised 11f98
• FIGUREA:SERIALNUMBERLOCATION
. ·.
O
TheCONDOR®ModelA38/42] Serial Number is stamped in two locations on the machine.
1. Thefirst place the serial number is located is on the right hand side,
stamped on the top of the rear axle housing.
2 The second place the serial number is located is on the right hand side
at the rear of the turret.
The Data Plate is located at the right hand side in front of the axle.
MANUAL 92379-003
July 1998
Revi<edlll98
FIGUREC-RecornrnendedSparePartsList •
CONDOR®MODELA38/42J (1 UNIT-1 YEAROPERATION)
QIY PARTNUMBER DESCRIPTION QIY PARTNUMBER DESCRIPTION
Electricallnstallation Hydraulic lnstallation

11 2060000100 ........ Diode 1 33430 .................. Filter Assembly
2 51913 .................. OperatorRedPIPuIl 1 110-1 .................. Element-Filter
2 51914 .................. Base + 1 NC Contact 1 110-2 .................. FilterHead-Return
12 40880 .................. Toggle Switch Guard 1 50316-OO1 ........... FilterBreather/Dipstick
6 40874 .................. Switch, Toggle 1 76021 .................. Pump/Motor Assy DC
6 50075 .................. Switch, Toggle 1 76021-104 ........... Motor Assembly
I 52671 .................. Operator 3 Pos Keyed 1 76021-101 ........... Pump Assembly
1 52029 .................. Base + 2 NO Contact 1 34814 .................. Regenerative Manifold
3 34383 .................. ContactBlockNO 1 34799 .................. RegManifoldOnly
6 34542 .................. Jumper 2 34369 .................. CartridgeLogicNO
3 76386 .................. DiodeJumper 2 35033 .................. Counterbalance Cart.
1 65355 .................. Resistor2.2KOHMS 1 38167 .................. CavityBlockingPlug
1 67939-003 ........... Fuse Bussman
1 65360 .................. Level Sensor Decal Installation
2 81164 .................. LimitSwitchAssembly 1 76412-A38 .......... DecalKit
1 51036 .................. LimitSwitchBodyOnly 1 76105 .................. ControlBoxDecaIGround
1 51037 .................. OffsetHeadLimit Switch 1 76102 .................. ControlBoxDecalPlatform
1 51039 .................. Ann Adjustable
1 76011 .................. PotentiometerCOntrol Manual Installation
1 76012 .................. JoystickDrive Control 1 A630-A38-1 ....... Opr,Parts, Service Manual
2 65356 .................. Relay SPDT 48VD C Fig. Mt. 1 92379-001 ........... Operator's Manual
1 65354-005 ........... Circuit Breaker Ther. 5A 1 76393 .................. Electric Schematic
1 34644-648 ........... Alann 1 76493 .................. Hydraulic Schematic
1 34552-010 ........... TenninalStrip
2 67869 .................. Socket Relay
1 66751 .................. Foot Switch
4 76346 .................. QuickDisconnect48110
1 76013 .................. Charger,Battery48V
1 76363 .................. PlatfonnCOntrolBoxA38
1 76362 .................. PlatformCOntroIBoxA42J
1 76006 .................. SevconController
Drive Installation
2 76003 .................. Motor,Electric6HP
2 76004 .................. Brake, 37LB Saer
2 76018 .................. DrWheeIPlanetary
2 76019 .................. Torque Hub
4 76397 .................. CompressionRing
Steering lnstallation
1 76036 .................. Knuckle WeldmentLH
1 76037 .................. Knuckle WeldmentRH
4 76081-001 ........... Pin We1dment 1.25 Dia
4 813680532 .......... Bearing1.25x1.50x2"L
1 76047 .................. Tie Rod
2 34341 .................. RodEnd-Male.75RH
4 34342 .................. Bushing Self Lube
2 66770-125 ........... Bearing, Thrustl-1I4
1 76502 .................. Cylinder, Steering
2 76017 .................. Hub Assembly, 6 Bolts 6" Dia.
4 76016 .................. Tire Assembly, 600-9x4.00
MANUAL 92379·003
July 1998
Revised 11198
• FIGURE 1.1: Final Assernbly
0
I
(X)
1'0
<C
10Cl
:21')
U~
(fl--'
_w
0
~
ZO
5:2
0
~
:ro::
(flO
0
'1~5
~mo
~~ 0
z"":
MANUAL 92379-003
July 1998
Revised 11/98
FIGURE 1.1: Final Assembly •
ITEM PART Nl JMBER DESCRIPTION QTY

Ref. M-A38/42J-Ol ............. CondorModeIA38/42J-01 .................................................... Ref.
-1 76369 .......................... FinalAssemblyDWG;M-A38-01 ............................................... 1
76370 .......................... FinaIAssemblyDWG;M-42J-01 ................................................. 1
2 76413 .......................... ChassisInstallation;A38/42J ....................................................... 1
3 A38-Turret ................... TurretInstallation ........................................................................ 1
A42J-Turret ................. TurretInstallation ........................................................................ 1
4 76483 .......................... BoomInstallation ....................................................................... 1
76484 .......................... BoomInstallation ....................................................................... 1
5 A42J-Jib ...................... Jib Installation ............................................................................. 1
6 A38-Platform ............... Platform Installation .................................................................... 1
A42J-Platform ............. Platform Installation .................................................................... 1
-7 76412-A38/42J ............ DecalInstallation ........................................................................ 1
-8 76393 .......................... ElectricSchematic ....................................................................... 1
-9 92379-001 .................... Operator'sManuaIM-A38/42J-01 .............................................. 1
-10 A630-A38-01 ............... Operator/Service/PartsManualA38/42J .................................... 1
11 76465-001 .................... HoseKit,A38 ............................................................................ 1
76465-002 .................... HoseKit,A42J ........................................................................... 1
MANUAL 92379-003
July 1998
Revised 11/98
• FIGURE 2.1 :Chassis Installation; A38/42J
18
MANUAL 92379-003
July 1998
Revised 11/98
FIGURE 2.1 :ChassisInstallation;A38/421 •
ITEM PARTNlJMBER DESCRIPTION QIY
Ref. 76413 .......................... ChassisInstallation;A38/42J ................................................... Ref.
1 76413-DWG ............... InstallationDWG,A38/42JChassis .............................................. 1
2 76078 .......................... MainChassisWeldment;A38/42J ............................................... 1
3 76359 .......................... SteeringInstallation,A28/32J ...................................................... 1
4 76414 .......................... BatteryBoxlnstallation,A38/42J ................................................ 2
5 76487 .......................... Angle, Battery Box ...................................................................... 2
6 BOW30054 .................. Bolt .38-16UNC x 1.00" GR5 Hex ............................................. 4
7 BOW31433 .................. Washer,Flat3/8SAE ................................................................. 4
8 76358-002 .................... CableKit;A38/42JBattery ......................................................... 1
9 76358-DWG ............... DWG,A38/42JBatteryCableInstallation ................................... 1
10 ~ ... ~.ttQ.H.f....... TireAssembly,600-9x4.00 ........................................................ 4
11 76001 .......................... Tachometer Kit, DC ElecMotor ................................................ 1
12 65009-001 .................... Bolt .63-11UNCx 4.50 GR9 Hex ............................................. 16
13 76003 .......................... ElecDrive Motor, 6 HP ............................................................. 2
14 BOW30054 .................. Bolt .38-16UNC x 1.00" GRS Hex ............................................ 8
15 76004 .......................... Brake, 37LB Static Torque ......................................................... 2
16 BOW30105 .................. Bolt .50-13UNCx 1.25 Hex ....................................................... 4
17 76006 .......................... Controller ................................................................................... 1
18 BOW30281 .................. Bolt, Hex .50-20UNF x 1.500 ................................................... 24
19 76017 .......................... HubAssembly,6BoltsOn6" DIA ............................................. 2
20 76019 .......................... TorqueHub,50.29:1 ................................................................... 2
21 76397 .......................... CompressionRing,ITL .............................................................. 4
22 BOW36615 .................. NutHex.50-20UNF ................................................................ 18
23 76334 .......................... Strap, Static ................................................................................. 1
24 76346 .......................... Quick Disconnect, 48V 1/0AWG .............................................. 4
25 BOW30007 .................. Bolt .25-20UN C x 1.75" Hex ...................................................... 8
26 76345 .......................... CoverWeldment,DriveTube ..................................................... 1
27 CLY020000-001 .......... Trim-Seal,.56wx.0620pening101"L .......................................... 1
28 67928-240 .................... O-Ring 11.75 ID x 4.03 OD ....................................................... 1
29 65409-021 .................... Bumper, Rubber 1" OD x 1/2 H ............................................... 1
30 BOW36717-HD .......... Washer,Flat.63IDHeavyDuty ................................................. 18
31 76498 .......................... Stop Bracket, Turret .................................................................... 1
MANUAL 92379-003
July 1998
Revised 11198
• FIGURE 2.2 :Steering Installation; A28/38
5
6
15
3------+t-
8
9
11
MANUAL 92379·003
July 1998
Revised 11198
FIGURE 2.2 :Steering Installation; A28/38 . ,
ITEM PART NIJMBER DESCRIPTION QTY

Ref. 76359 .......................... SteeringInstallation;A28/38 ................................................... Ref.
-1 76359-DWG ............... SteeringlnstaliationDWG;A38/42J ............................................ 1
2 76036 .......................... KnuckleWeldment;A38/42JLH ................................................ l
3 76037 .......................... Knuckle Weldment;A38/42J RJI ............................................... 1
4 76081-001 .................... Pin Weldment; l.25"DIA ........................................................... 4
5 BOW30052 .................. Bolt .38-16 x .75 GR5 Hex ......................................................... 4
6 BOW31433 .................. Washer Flat, 3/8 SAE ................................................................. 4
7 76047 .......................... TieRod;A28/38 ........................................................................ 1
8 34341 .......................... Rod End - Male .75 RJI R#67821 .............................................. 2
9 BOW36176 .................. Bolt .75-10UNCx3.00GR8 Hex ............................................... 2
10 BOW31438 .................. Washer .75x 1.50D GRS SAEFlat ............................................. 2
11 BOW34278 .................. Nut - 3/4-10 Elastic Stop ........................... ;.r ............................ 2
12 76502 .......................... Cylinder; ArticulatedSteering ..m~.~f..l~.§UJ.Q........... 1
13 34342 .......................... Bushing,SelfLub ........................................................................ 4
14 81368-05-32 ................ Bearing; 1.25ID x 1.500D x 2"L ................................................ 4
15 66770-125 .................... Bearing - Thrust 11/4 ................................................................ 2
16 76489 .......................... Washer, Modified ....................................................................... 1
17 BOW2506 ................... Hitch Pin, 3/16 x 35/8 .............................................................. 1
MANUAL 92379-003
July 1998
Revised 11198
fa FIGURE2.3:Battery Box Installation; A38/42J
12
10
MANUAL 92379-003
July 1998
Revised Ui98
FIGURE 2.3 :Battery Box Installation; A38/421 fJ)
ITEM PARTNUMBER DESCRIPTION QTY
Ref. 76414 .......................... BatteryBoxlnstallation;A38/42J ............................................ Ref.
-1 76414-DWG ............... DWG;BatteryBoxInstallation ................................................... 1
2 76064 .......................... BoxWeldment,Battery ............................................................... 1
3 76065 .......................... Cover,Battery ............................................................................ 1
4 76347 .......................... Insulation;BatteryCover ............................................................. 1
5 54048 .......................... Latch - Door .............................................................................. 1
-6 BOW30004 .................. Bolt .25-20UNC x 1.00" GR5 Hex ............................................. 2
-7 BOW31431 .................. Washer.25IDx.630DFlat ........................................................ 4
8 50554 .......................... J- Bolt 5/16 x 13 114 - Battery ................................................... 2
9 BOW34324 .................. Nut-5/16-18UNCWing ........................................................... 2
10 52793 .......................... Battery;6V305AH165RCM ....................................................... 4
-11 BOW34272 .................. Nut-25-20UN"CNylonLock ................................................... 2
12 76470 .......................... Angle, A38/42J Battery Clamp .................................................... 1
MANUAL 92379-003
July 1998
Revised 11198
• FIGURE2.4:BatteryCableKit
CHASSIS
@ 2 PL
POWER UNIT
TURRET
MANUAL 92379-003
July 1998
Revised 11198
FIGURE 2.4: Battery Cable Kit . ,

Ref. 76358-002 .................... BatteryCableKit ..................................................................... Ref
1 76358-DWG ............... InstallationDWG,A38BatteryKit .............................................. 1
2 76356-043.00 ............... Cable Assembly-43.0" Large Battery ........................................... 2
3 76356-038.00 ............... Cable Assembly-38.0" Large Battery ............................................ 2
_-- 4 54247-007.00 ............... CableAssembly-6.5" LargeBattery ............................................. 6
54247-016.00 ............... Cable Assembly-16.0"LGBattery ................................................ 6
5 54247-082.00 ............... CableAssembly-16.0" Large Battery ........................................... 1
12 76361-026.00 ............... CableAssembly-26.0" Large BAttery .......................................... 1
13 54247-100.00 ............... CableAssembly-100.00" Large Battery ....................................... 2
-Indicates Items Not Shown
rr====jjm=========nn ~E VCON
/cON TROLLER
S2 A2 A1 Sl
51 A1 A2 S2
CHi\SSIS DRIVE
TUBE
MANUAL 92379-003
July 1998
Revised 11198
FIGURE 2.5:Motor, Elec6HP

Ref. 76003 .......................... Motor, Elec 6 Hp ................................................................... Ref.
-1 76003-101 .................... DriveEndhead ........................................................................... 1
-2 76003-102 .................... Bearing ....................................................................................... 1
-3 76003-103 .................... RetainingRing ............................................................................. 1
-4 76003-104 .................... Fan ............................................................................................. 1
-5 76003-105 .................... Armature & Fan Assembly .......................................................... 1
-6 76003-106 .................... Field Coil Kit .............................................................................. 1
-7 76003-107 .................... Brush ......................................................................................... 2
-8 76003-108 .................... Brush Spring ............................................................................... 2
-9 76003-109 .................... Brush Box Assembly ................................................................... 1
-10 76003-110 .................... Brush Lead Assemb ly Kit ............................................................ 1
-11 76003-111 .................... Bearing ....................................................................................... 1
-12 76003-112 .................... WavyWasher .............................................................................. 1
-13 76003-113 .................... CommutatorEndhead ................................................................ 1
-14 76003-114 .................... HeadbandAssembly(M:) ................................................ _............ 1

Drawing not available at this time
MANUAL 92379-003
July 1998
Revised II (98
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SEEClElC6lICIlISl
DRY. UNSEDOED STAllC TORQUE - 31lbf • fL
DRY, UNSEDOED D'rNAMIC TORQUE - 30 Ibf • ft.
111 8001430 1.00 7Il004-1111 o-RING

15 1.00 7Il004-115 o-RING
14 lEB4G-40D4 A 7Il004-114 SHIW
13 lE11-4O-4OO3 3.00 7Il004-113 IWIUAL. R£l. SUB-ASSY
12 8001113 1.00 7Il004-112 1N1ERHAL. aJP
11 8001301 1.00 7Il004-111 EXTERNAL aJP
113 8OO1to1 1.00 7Il004-1113 CALL. IlEMlNG
II SOO931\4 11.00 7Il004-109 COIiIPRESSICIII SPf!IHQ VENDOR: MATRIX ENGINEERING
--- ---
8 SClO8896 3.00 7Il004-108 soa<ET lID eN!' SCREW VPN: lEB40-14
5
7
II
1£840-1707
lEB+O-2II01
lEB+O-l~
3.00
2.00
3.00
7Il004-107
7Il004-1011
7Il004-105
SPACER
CJU1EIII PLATE
FRlCllON PI.ATE - SOlID
,_ - -
=-:11'" .. 6;i. ~ ---
-- .....
-- -- ----
_ _ '" Ac:
.
--..
4 lEB+O-21011 1.00 7Il004-104 NOOfI1\NG PLATE
B
3 lEB+O-1108 1.00 7Il004-103 SHAfT -._Oc:::J BRAKE, 37 LB SAER
A
2 lEB+O-I209 1.00 7Il004-102 ARMAlIlRE ...........
1 1£840-1812
ITEN 1lA11IX P
1.00
QTY
7Il004-101
CCIIlCft saNCI£ P
UAGNET " cat. ASSDIlI.Y
DESaaP1lON
I3L
-
I3L ...... tIL
"""" C 76004
.... 1 Ql'1
8
·
16 S001430 1.00 76004-116 O-RING
15 1.00 76004-115 O-RING
14 1E840-4004 AIR 76004-114 SHIM
13 1EB40-4003 3.00 76004-113 MANUAL REL SUB-ASSY
12 S001113 1.00 76004-112 INTERNAL CLIP
11 S001301 1.00 76004-111 EXTERNAL CLIP
10 S001901 1.00 76004-110 CALL BEARING
9 S009364 6.00 76004-109 COMPRESSION SPRING
8 S008895 3.00 76004-108 SOCKET HD C,A,P SCREW
7 1E840-1707 3.00 76004-107 SPACER
6 1E840-2501 2.00 76004-106 OUTER PLATE
5 1E840-1305 3.00 76004-105 FRICTION PLATE - SOLID
4 1EB40-21 06 1.00 76004-104 MOUNTING PLATE
-
3 1E840-11 08 1.00 76004-103 SHAFT
2 1EB40-1209 1.00 76004-102 ARMATURE
1 1E840-1812 1.00 76004-101 MAGNET & COIL ASSEMBLY
ITEM MATRIX PIN QTY CONDOR SERVICE PIN DESCRIPTION
=
;
~
J
)
J
j
,j
j
j
)
~
J
J
,]
)
J
j
J
FIGURE 2.6:WheeIDrive, 33.79: 1 Planetary •
RETAINING RING SELECTION

p X· RING THICKNESS PART NO C
.107-.111 .107-.105 14-00-139-041
112-.116 .112-.110 14-00-139-042
.117-.121 .117-.115 14-00-139-043
.12.2-.126 .122-.120 14-00-139-044
.12 -.1 .. 1 12 -.125 14-00-1 9-045
132-.136 .132- 130 14-00-139-046
.137-.141 .137-.135 14-00-139-047
15-45 LB n
16-21 l6 n
15-45 LB n 21 STAMP COVER ON GROUND SURFACE f'ROVlDED
LEGIBLY STAMP FINAL ASSEMBLER'S NAME ? 6J01166
II L
0/'1 MACHINED SURFACE Of fLANGE
DAY Of /¥IONTH
CODe >EAR (LAST O<01T)
MONTH (SEE $TO-l02 fOR coor)

Ref. 76018 .......................... WheelDrive,33.79:1Planetary ................................................ Ref.
1 6171101 ....................... Shaft-Output .............................................................................. 1
2 14-00-044-010 ............. Seal-Oil ...................................................................................... 1
3 04-01-101-35 ............... Bearing-Cone ............................................................................. 1
4 04-01-102-12 ............... Bearing-Cup ............................................................................... 2
5 04-01-101-17 ............... Bearing-Cone ............................................................................ 1
6 *** ............................... Ring-Retaining ............................................................................ 1
7 10-00-041-002 ............. Compound-Sealing ............................................................ 2PLCS
8 14-14-165-001 ............. Cover ......................................................................................... 1
9 03-04-101-01 ............... Plug-Pipe .................................................................................... 1
10 14-14-165-001 ............. Gear-PriSun .............................................................................. 1
11 95-04-115-01 ............... Washer-Thrust ............................................................................ 1
12 14-00-191-003 ............. Plug-Shipping ............................................................................. 1
13 0000179820 ................. Bolt-HexHead ........................................................................... 8
14 6659122 ....................... Assembly-Pri Carrier ................................................................... 1
15 616226 ......................... Gear-Ring .................................................................................. 1
16 665952 ......................... Assembly-SecCarrier .................................................................. 1
17 14-00-183-006 ............. Bolt-Wheel ................................................................................. 9
18 617946 ......................... Hub ........................................................................................... 1
19 14-00-047-002 ............. Washer-Flat .............................................................................. 12
20 6188315 ....................... Bolt-HexHead ......................................................................... 12
21 14-00-052-002 ............. Plug-Pipe .................................................................................... 1

MANUAL 92379-003
July 1998
Remed 11198
FIGURE 3.1 :HoseKit, A38/42J
~!
~I ~
@) I~ "(€)
-'\~ i' r~
I l/)~>'
~ ~J;:<~)
,,j
l,\. l\\ k \
(<::1
\'\ ,\.\ \ ~ l:~~,:-L. . . . ./~.----------------_v-----~----~---~.:,

'\ \
(~)
-I Gj" :
. \"; O@ :B] i
/t'('-~~3>-~=:=j!~tI~!'i::!~t~I-·
! ...(~ i !. @@ B \ i i
j . .......... .... j / ....._............... :0 @@·.... ·El·..·-, i j
i :
1 : ,--.------------------
0.
~)
1[@lll@I~~
/
-----------------------------_.-/
o.............. ....................·
~
MANUAL 92379·003
July 1998
Revised 11198
FIGURE3.1:HoseKit,A38/42J •

Ref. 76465 .......................... Hose Kit, A38/ 42J ................................................................. Ref.
1 76465-DWG ............... HoseKitlnstallationDWG;A38/42J .......................................... 1
2 66044-276.00 ............... Hose Assembly #04 67685 J37 ST-ST ......................................... 1
4 66848-087.00 ............... Hose Assembly #04 67685 J37 ST-90L ....................................... 1
5 66848-087.00 ............... Hose Assembly #0467685 J37 ST-90L ....................................... 1
8 66044-041.00 ............... Hose Assembly #0467685 J37 ST-ST ........................................• 1
9 66044-041.00 ............... Hose Assembly #0467685 J37 ST-ST ......................................... 1
66044-612.00 ............... Hose Assembly #04 67685]37 ST-ST ......................................... 1
66044-612.00 ............... Hose Assembly #04 67685 J37 ST-ST ......................................... 1
23 66044-576.00 ............... Hose Assembly #0467685]37 ST-ST ......................................... 1
MANUAL 92379·003
July 1998
Revised 11/98
• FIGURE4.1 :Turret Installation
3 10
11
12
9
MANUAL 92379-003
July 1998
Revised 11/98
FIGURE 4.1 :Turret Installation . ,

Ref. A38-Turret ................... TurretInstallation .................................................................... Ref.
Ref. A42J-Turret ................. Turret Installation .................................................................... Ref.
1 76000 .......................... Motor,Hydraulicl0CIPR(R#68697) .......................................... 1
2 76009 .......................... HydraulicControlValve .............................................................. 1
76010 .......................... Hydraulic Control Valve .............................................................. 1
3 76013 .......................... Charger;48VBattery .................................................................. 1
4 76021 .......................... Pump/Motor Assembly; DC ...................................................... 1
-5 76046" .......................... SwingGear;A38/42J ................................................................. 1
6 76108-001 .................... Cover;A38/42JTurretLH ......................................................... 1
7 76108-002 .................... Cover; A38/42J Turret RH ......................................................... 1
8 76109 .......................... Cover;A38/42JCounterweight .................................................. 1
9 76398 .......................... HydraulicTank;A38/42J ............................................................ 1
10 33430 .......................... FilterAssembly-Hydraulic ......................................................... 1
11 50316-001 .................... Filter Breather W/Dipstick .......................................................... 1
12 76259 .......................... TurretWeldment ........................................................................ 1
-13 76267-001 .................... Pin Weldment;2"DIAx 11.68"LG.............................................. 3
-14 76480 .......................... Pin Cap; For2" Pin ..................................................................... 3
-15 76392-003 .................... Turret WiringAssembly;A38 ....................................................... 1
76392-004 .................... Turret WiringAssembly,A42J ..................................................... 1
-16 76371 .......................... Closeout;A38/42JCenter ........................................................... 1
-17 76259-A42J .................. Turret Weldment;A42J .......................:;;.('i1;:: ....:;......,s,O/, ........ 1
-18 65009-001 .................... Bolt .63-11 UNC x 4.50 GR9 Hex .......f:b.ij;, ... ( .... /.... :.7 ......... 22
19 65009-003 .................... Bolt .63-11 UNC x 5.50 GR9 Hex ....c..s.. ....f€.::... !..~-:I:::l............ 2
-20 76486 .......................... Stop,A38/42JTurret ................................................................. 1
-21 BOW36717-HD .......... Washer,Flat.631DHeavyDuty ................................................. 24
MANUAL 92379-003
July 1998
Revised 11/98
• FIGURE 4.2:Filter Assembly-Hydraulic
ITEM
Ref.
PARTNUMBER DESCRIPTION
33430 .......................... Filter Assembly-Hydraulic ..................................................... Ref.

QTY
1 110-2 ........................... FilterHead-ReturnLine ............................................................. 1

2 110-1 ........................... Element-Filter ........................................................................... 1
MANUAL 92379-003
July 1998
Revised 11198
FIGURE 4.3 :Turret WiringAssembly; A38/42J 8)
ITEM PART NUMBER DESCRIPTION OTY
Ref. 76392-003/004 ............ TurretWiringAssembly;A38/42J ........................................... Ref.

-1 76374 .......................... Box Assembly; A38 Turret .......................................................... 1
76373 .......................... BoxAssembly;A42JTurret ......................................................... 1
-2 76386 .......................... DiodeJumper; 12" ..................................................................... 1
-3 76385 .......................... DiodeJumper; 8" ....................................................................... 1
-4 76384 .......................... DiodeJumper; 6" ....................................................................... 6
-5 76377-003 .................... CableAssembly;A38Upper-LowerBox .................................. 1
76377-004 .................... CableAssembly;A42JUpper-LowerBox ................................... 1
-6 76378-003 .................... Cable;A38 Upper Box To Chassis .............................................. 1
76378-004 .................... Cable;A28/42JChassis ............................................................... 1
-7 76380 .......................... Cable;A28/42JChassis ............................................................... 1
-8 65360 .......................... Level Sensor; 48 VDC ................................................................ 1
-9 54910-105 .................... StrainRelief-ST-21 .................................................................... 1
-10 66992 .......................... Plug-l0Contact ........................................................................ 1
-11 65358 .......................... Hood; Top Entry ....................................................................... 1
-12 81164 .......................... Limit Switch Assembly ...... 2
00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MANUAL 92379-003
July 1998
Revised 11198
• FIGURE4.4:BoxAssembly,A38/42JTurret
o o
o o
o
P
D
000
o D
«)
iII I I I I I I I l--0i
o e
MANUAL 92379-003
July 1998
Revised 11/98
FIGURE4.4:BoxAssembly,A38/42JTurret . ,

Ref. 76373 .......................... BoxAssembly,A38 Turret ...................................................... Ref.
Ref. 76374 .......................... Box Assembly, A42J Turret ..................................................... Ref.
1 76268 .......................... Box, Lower Control-Machined ................................................. 1
2 34552-012 .................... TerminalStrip-12Position ......................................................... 1
3 76075 .......................... Diode Circuit Board ................................................................... 1
4 76382 .......................... Decal,LowerBoxTags .............................................................. 1
5 76379 .......................... CableAssembly,LowerBoxToChassis ...................................... 1
6 Jr~ .1'~1~...... BatteryCondition/HourMeter ................................................... 1
7 51913 .......................... Operator, RedP-Pull ZB2-BT4 .................................................. 1
8 51914 .......................... Base + 1 NC Contact ZB2-BZI02 .............................................. 1
9 40874 .......................... ToggleSwitch-DPDT (A38) ..................................................... 3
40874 .......................... ToggleSwitch-DPDT (A42J) .................................................... 4
10 40880 .......................... Guard, Toggle Switch (A38) ....................................................... 3
40880 .......................... Guard, Toggle Switch (A42J) ...................................................... 4
11 52671 .......................... Operator,3POSRotkyZB2BG3 ............................................... 1
12 52029 .......................... Base + 2NO ContactsZB2-BZ103 ............................................ 1
13 34383 .......................... ContactBlock,NOZB2-BE101 ................................................. 3
14 67114-009 .................... Strain Relief 3/4NPT (.63-.75) ................................................... 1
15 67123-002 .................... Seal, Connector Elect. 3/4" ......................................................... 1
16 67124-002 .................... Locknut-3/4NPTConduit ....................................................... 1
17 BOW31231 .................. Nut #6-32 Hex Keps ................................................................. 2
18 34542 .......................... Jumper ....................................................................................... 1
19 65355 .......................... Resistor, 2.2K OHMS 2Watt ................................................... 1
20 206-00001-00 ............... Diode ........................................................................................ 1
21 BOW31071 .................. Mach ScrewFH #6-32NC x 1/2 ................................................ 2
22 BOW31070 .................. Mach ScrewFH #6-32NC x 1/4 ................................................ 4
23 BOW31529 .................. PlugButton.50DIA(A38) ......................................................... 4
30 76377-003 .................... Cable Assembly, Upper To Lower Box .................................. Ref.

76377-004 .................... Cable Assembly, Upper To Lower Box .................................. Ref.
31 76105 .......................... Decal, TurretControlBox ...................................................... Ref.
MANUAL 92379-003
July 1998
Revised 11198
flit FIGURE4.5:CableAssembly;A38/42JUpper-LowerBox
C1
MANUAL 92379·003
JulyJ998
Revised 11198
FIGURE 4.5:CableAssembly; A38/42JUpper-LowerBox •
ITEM PARTNUMBER DESCRIPTION OTY
Ref. 76377-003 .................... Cable Assembly; A38/42J Upper - Lower Box ...................... Ref.
Ref. 76377-004 .................... Cable Assembly; A38/42J Upper -Lower Box ...................... Ref.
1 51325 .......................... Cable 24 Conductor 16GA ......................................................... ..
2 66652-002 .................... Plug, Male 24 Contacts #1-24 ..................................................... 1
3 66655-010 .................... Hood; Top E ntry 24 Contacts .................................................... 1
66655-011 .................... Hood, Side Entry24 Contacts ..................................................... 1
4 54910-105 .................... StrainRelief,ST21 ....................................................................... 1
5 76377-DWG ............... CableAssemblyDWG;UpperToLowerBox ............................ l
MANUAL 92379-003
July 1998
Revised 11198 .
• FIGURE 5. l:BoomInstallation; A38/42JtoSN#42598019
MANUAL 92379-003
July 1998
Revised 11/98
FIGURE 5.1 :Boom Installation; A38 to SN #42598019 . ,

Ref. 76483 .......................... BoomInstallation;A38 ........................................................... Ref.
1 76066-006 .................... PinWe1dment; Slave Cylinder Base End ....................................... 1
2 76069 .......................... Pin Cap; l"DIAPin .................................................................... 1
3 76066-007 .................... Pin Weldment;MasterCylinder Rod End .................................... 1
4 76069 .......................... Pin Cap; l"DIAPin .................................................................... 1
5 76066-008 .................... PinWe1dment;MasterCylinderBaseEnd .................................... 1
6 76069 .......................... Pin Cap; l"DIAPin .................................................................... 1
7 76129 .......................... Lift Cylinder, Lower Boom ........................................................ 1
8 76130 .......................... Lift Cylinder, Upper Boom ......................................................... 1
9 76464 .......................... Cylinder Assembly;A38BoomExt .............................................. 1
10 76208 .......................... Bearing Pad; AD] 11/4-7 UNC ................................................. 4
11 76256 .......................... Base Boom Weldment; A38 ........................................................ 1
12 76267-001 .................... Pin Weldment,2"DIAx 11.68"LG .............................................. 2
13 76269 .......................... Pin Cap; 2" Pin ........................................................................... 2
14 76267-002 .................... Pin Weldment;2"DIAx 11.12"LG ............................................. 4
I
15 71983 .......................... RubberPad,S"x5 x1/4" ............................................................ 5
I
16 76267-003 .................... Pin Weldment;2 DIAx7.18"LG .............................................. 2
17 37398-002 .................... Wrap-Track/Boom .................................................................... 1
18 76274 .......................... Boom We1dment;A38 Lower ..................................................... 1
19 76275 .......................... Tension Link We1dment; Lower Boom ....................................... 1
20 76282 .......................... WearPad;A38 Tip/Base Top ..................................................... 1
21 76283 .......................... Wear Pad; A38 Tip/Base Bottom ............................................... 1
22 76294 .......................... Wear Pad; Base/Mid Boom Bottom ........................................... 1
23 76295 .......................... Wear Pad; Base/Mid Top ........................................................... 1
24 76308-001 .................... Pin; Ext CylinderRodEnd ......................................................... 1
25 76308-002 .................... Pin Ext Cylinder BaseEnd .......................................................... 1
26 76311 .......................... Wear Pad; .50 x 1.00 x 2.50 ......................................................... 2
27 76312 .......................... Mid-PostWeldmentA38 ............................................................ 1
28 76337 .......................... HoseCarrierInstallation;A38 ...................................................... 1
29 76127 .......................... Master Cylinder; Upper Boom .................................................... 1
30 76128 .......................... Slave Cylinder; Upper Boom ....................................................... 1
31 76257 .......................... Boom Weldment;A38 Tip .......................................................... 1
32 81494-002 .................... Cover - 86A Arm Hose 77112"LG ............................................ 1
33 76427 .......................... Retainer;A38HydraulicHose ...................................................... 1
34 BOW36835 .................. Bolt.38-16UNCx 1.25 Flat SOC ............................................... 2
35 BOW34272 .................. Nut-25-20UNC Nylon Lock .................................................... 6
36 76267-004 .................... Pin Weldment;2"DIAx 10.56"LG .............................................. 2
37 76471 .......................... CableClamp;A38 ...................................................................... 1
38 76472 .......................... Cover Base Boom, A38 .............................................................. 2
39 BOW36000 .................. Screw .25-20UNC .50"HD Cap Hex .......................................... 4
40 BOW36701 .................. Washer-l/4Flat ....................................................................... 4
41 BOW31325 .................. Washer-.25IDSplitLock ............................................................ 4
42 BOW36818 .................. Screw, Cap Flat Head .2S-20UNC 2L ......................................... 2
43 37398-004 .................... Wrap-Track3146/54 .................................................................. 3
MANUAL 92379-003
July 1998
Revised 11/98
• FIGURE 5.l:BoomInstallation;A42JtoSN#42598019
MANUAL 92379·003
July 1998
Revised 11/98
FIGURE 5.1:BoomInstallation;A38toSN#42598019 •

Ref. 76483 .......................... BoomInstallation;A38 ........................................................... Ref.
1 76066-006 .................... Pin Weldment; Slave Cylinder Base End ....................................... 1
2 76069 .......................... Pin Cap; l"DIAPin .................................................................... 1
3 76066-007 .................... Pin Weldment; Master Cylinder Rod End .................................... 1
4 76069 .......................... Pin Cap; l"DIAPin .................................................................... 1
5 76066-008 .................... Pin Weldment;MasterCylinder Base End .................................... 1
6 76069 .......................... Pin Cap; l"DIAPin .................................................................... 1
7 76129 .......................... LiftCylinder,LowerBoom ........................................................ 1
9 76464 .......................... CylinderAssembly;A38BoomExt .............................................. 1
10 76208 .......................... Bearing Pad; AD] 11/4-7UNC ................................................. 4
11 76256 .......................... Base Boom Weldment;A38 ........................................................ 1
12 76267-001 .................... Pin Weldment,2"DIAxl1.68"LG .............................................. 2
13 76269 .......................... PinCap;2"Pin ........................................................................... 2
14 76267-002 .................... Pin Weldment;2" DIAx 11.12"LG ............................................. 4
15 71983 .......................... Rubber Pad,5"x5"x1/4" ............................................................ 5
16 76267-003 .................... PinWeldment;2"DIAx7.18"LG .............................................. 2
17 37398-002 .................... Wrap-Track/Boom .................................................................... 1
18 76274 .......................... Boom Weldment; A38 Lower ..................................................... 1
19 76275 .......................... TensionLinkWeldment;LowerBoom ....................................... 1
20 76282 .......................... Wear Pad; A38Tip/BaseTop ..................................................... 1
21 76283 .......................... WearPad;A38 Tip/Base Bottom ............................................... 1
23 76295 .......................... WearPad;Base/MidTop ........................................................... 1
24 76308-001 .................... Pin; Ext Cylinder Rod End ......................................................... 1
25 76308-002 .................... Pin Ext Cylinder Base End .......................................................... 1
26 76311 .......................... WearPad;.50x1.00x2.50 ......................................................... 2
31 76257 .......................... BoomWeldment;A38Tip .......................................................... l
32 81494-002 .................... Cover _86A Arm Hose 77 112"LG ............................................ 1
33 76427 .......................... Retainer;A38 Hydraulic Hose ...................................................... 1
34 BOW36835 .................. Bolt.38-16UNCx 1.25 Flat SOC ............................................... 2
35 BOW34272 .................. Nut-25-20UNCNylonLock .................................................... 6
36 76267-004 .................... Pin Weldment;2"DIAx 10.56"LG .............................................. 2
37 76471 .......................... CableClamp;A38 ...................................................................... 1
38 76472 .......................... Cover Base Boom, A38 .............................................................. 2
39 BOW36000 .................. Screw .25-20UNC .50"HD Cap Hex .......................................... 4
40 BOW36701 .................. Washer-l/4Flat ....................................................................... 4
41 BOW31325 .................. Washer-.25IDSplitLock ............................................................ 4
42 BOW36818 .................. Screw, Cap FlatHead .2S-20UNC 2L ......................................... 2
43 37398-004 .................... Wrap-Track3146/54 .................................................................. 3
MANUAL 92379·003
July 1998
Revised 11/98
• FIGURE 5.1:Boomlnstallation;A38/42J SN#42598019andabove
35
37
3'
3J
o of!
il
,/ £
.'~------r--------L------',ii
( !(§~~J~~) )
,/:~ ~":::::-f'=~"~"","='7'l---~ V-.~

/ /oJY-'o- -- I I / /oJY'~o' ""
( (~( C \~)) : : ((~( () ):;) l
''--__:O~~_r--L..---- " L - __ ~<'~~~/
MANUAL 92379-003
July 1998
Revised II 198
FI GURE 5.1 :Boom Installation; A3 8/42J SN #425980 19 and above e
Ref. 76525 .......................... Boomlnstallation;A38-02 ...................................................... Ref.
1 76066-006 .................... Pin Weldment; Slave Cylinder Base End ....................................... 1
2 76069 .......................... PinCap;l"DIAPin .................................................................... 1
3 76066-007 .................... Pin Weldment;MasterCylinderRodEnd .................................... 1
4 76069 .......................... Pin Cap; l"DIAPin .................................................................... 1
5 76066-008 .................... Pin Weldment;MasterCylinderBaseEnd .................................... 1
6 76069 .......................... Pin Cap; l"DIAPin .................................................................... 1
7 76129 .......................... Lift Cylinder, Lower Boom ........................................................ 1
9 76464 .......................... Cylinder Assembly;A38BoomExt .............................................. 1
10 76208 .......................... Bearing Pad; ADJ 11/4-7 UN C ................................................. 4
11 76508 .......................... Base Boom Weldment;A38 ........................................................ 1
12 76267-001 .................... Pin Weldment,2"DIAx 11.68"LG .............................................. 2
13 76269 .......................... Pin Cap; 2" Pin ........................................................................... 2
14 76267-002 .................... Pin Weldment;2"DIAx 11.12"LG ............................................. 4
15 71983 .......................... RubberPad,5"x5"xl/4" ............................................................. 5
16 76267-003 .................... Pin Weldment;2" DIAx7.18"LG .............................................. 2
17 37398-002 .................... Wrap-Track/Boom .................................................................... 1
18 76274 .......................... Boom Weldment;A38Lower ..................................................... 1
19 76275 .......................... TensionLinkWeldment;LowerBoom ....................................... 1
20 76282 .......................... Wear Pad; A38 Tip/Base Top ..................................................... 1
21 76283 .......................... WearPad;A38 Tip/BaseBottom ................................................ 1
23 76295 .......................... WearPad;Base/MidTop ........................................................... 1
24 76308-001 .................... Pin; ExtCylinderRodEnd ......................................................... 1
25 76308-002 .................... Pin Ext Cylinder Base End .......................................................... 1
26 76311 .......................... Wear Pad; .50 x 1.00 x 2.50 ......................................................... 2
31 76257 .......................... Boom Weldment;A38 Tip .......................................................... 1
32 81494-002 .................... Cover-86AArmHose77112"LG ............................................ 1
33 76427 .......................... Retainer; A38 Hydraulic Hose ...................................................... 1
34 BOW36835 .................. Bolt .38-16UNC x 1.25 Flat SOC ................................................ 2
35 BOW34272 .................. Nut-25-20UNCNylonLock .................................................... 6
36 76267-004 .................... PinWeldment;2"DIAx10.56"LG .............................................. 2
37 76471 .......................... CableClamp;A38 ...................................................................... 1
38 76472 .......................... Cover Base Boom, A38 .............................................................. 2
39 BOW36000 .................. Screw.25-20UNC.50"HDCapHex .......................................... 4
40 BOW36701 .................. Washer - 1/4 Flat ....................................................................... 4
41 BOW31325 .................. Washer-.25IDSplitLock ............................................................. 4
42 BOW36818 .................. Screw, Cap Flat Head .25-20UNC 2L ......................................... 2
43 37398-004 .................... Wrap-Track3146/54 .................................................................. 3
MANUAL 92379·003
July 1998
Revised 11/98
• FIGURE 5.2:Cylinder Assembly
ITEM PARI NUMBER DESCRIPTION QIY

Ref. 76464 .......................... Cylinder Assembly .................................................................. Ref.
-1 76131 .......................... Extension Cylinder-Upper Boom ............................................... 1
-2 34814 .......................... ManifoldAssembly,Regenerative ................................................ 1
-3 76310 .......................... Wear Pad ................................................................................... 2
-4 BOW36815 .................. Bolt, Soc. Flat .25-20 UNC x 1.0 ................................................. 4
-5 02448 .......................... Straight,M]06M006 ................................................................. 2
-6 02298 .......................... Elbow, 90° M]06 F]06 ............................................................... 2

MANUAL 92379-003
July 1998
Revised 11(98
FIGURE 5.3:RegenerativeManifoldAssembly e
I I
CYL RETR
VALVE RETR
l
4 X 3
(
5
CYL EXT
VALVE EXT
C - ~
z
Ref. 34814 .......................... ManifoldAssembly,Regenerative ............................................ Ref.

1 34799 .......................... Manifold,Regenerative ................................................................ 1
2 34369 .......................... Cartridge, Logic NO .................................................................. 2
3 35033 .......................... Cartridge, Counterbalance ........................................................... 2
4 38167 .......................... Plug,SUNCavaityBlocking ........................................................ 1
5 02662 .......................... Elbow, 90° MJ06 M006 ............................................................ 2
MANUAL 92379-003
July 1998
Revised 11/98
• FIGURE 5.4:HoseCarrier Installation
ITEM
Ref.
PART NUMBER
76337 ..........................
DESCRIPTION QIY
Hose Carrier Installation .......................................................... Ref.
-1 76337-DWG ............... HoseCarrierInstallationDrawing ............................................... 1
-2 76335 .......................... TubeWeldment,HoseCarrierTip .............................................. 1
-3 76338 .......................... HoseCarrierTrack ..................................................................... 1
-4 76318 .......................... Bracket, Hose Carrier Wear Pad .................................................. 1
-5 71402 .......................... Wear Pad, Hose Tube Base Lower .............................................. 1
-6 71403 .......................... Wear Pad, Hose Tube Base Upper .............................................. 1
-7 71404 .......................... Retainer, Wear Pad ...................................................................... 1
-8 71471 .......................... Spacer, CatrackMounting ........................................................... 1
MANUAL 92379-003
July 1998
Revised 11198
•
This page intentionally left blank
MANUAL 92379·003
July 1998
Revised 11/98
• FIGURE 8.1 :Jib Installation
11 3,4
9
o
o
5,6
10
7,8
MANUAL 92379-003
July 1998
Revised 11/98
FIGURE 8.1 :Jib Installation e
Ref. A42J-Jib ...................... Jib Installation ......................................................................... Ref.

1
2 76040 .......................... LiftCylinder;Jib ......................................................................... 1
3 76066-003 .................... Pin Weldment;Jib Adapter .......................................................... 3
4 76069 .......................... Pin Cap; l"DIAPin .................................................................... 3
5 76066-004 .................... Pin Weldment;Jib Cylinder Rod .................................................. 1
6 76069 .......................... Pin Cap; l"DIAPin .................................................................... 1
7 76066-005 .................... PinWeldment;JibToBoom ....................................................... 1
8 76069 .......................... Pin Cap; l"DIAPin .................................................................... 1
9 76230 .......................... Jib Weldment; Upper .................................................................. 1
10 76237 .......................... Jib Weldment;Lower ................................................................. 1
11 76296 .......................... AdapterWeldment;Jib ............................................................... 1
MANUAL 92379-003
July 1998
Revised 11198
•
This Page Intentionally Left Blank
MANUAL 92379-003
July 1998
Revised 11198,.
FIGURE 6.1 :Platfonn Installation •

Ref. A38/42J-Platform ........ Platform Installation ................................................................ Ref.
-1
-2 76363 .......................... BoxAssembly,A38Platform ...................................................... 1
76362 .......................... Box Assembly, A42J Platform ..................................................... 1
-3 81368-36-16 ................ Gar-Max, 2.00 II) x 2.50 OD x 1" L .......................................... 1
-4 76348 .......................... MountingPlate,Relay&Breaker ................................................. 1
-5 76066-002 .................... Pin Weldment ............................................................................. 2
-6 76069 .......................... Pin Cap, 1" DiaPin ..................................................................... 2
-7
-8 76205 .......................... 30 x 60 Platform Weldment ........................................................ 1
-9 35460 .......................... Actuator ..................................................................................... 1
-10 76211 .......................... SkirtWeldrnent ........................................................................... 1
-11 76252 .......................... LowerSkirtBracketWeldment ................................................... 1
-12 76284 .......................... Bracket Weldment, UpperSkirt ................................................... 1
-13 66751 .......................... FootSwitchw/Guard + Cable ................................................... 1
-14 38335 .......................... 110VLinetoPlatformAssembly ................................................. 1
MANUAL 92379-003
July 1998
Revised Ilf98
BOX COMPONENT ASSEMBLY
2XI9J§
/-------,,," (l)
M4 X ,07 X !6mrn Le.
o
~
~
fA51
VIEW FROM TOP OF BOX LIP

'A'
...
TO LIM. SW.
CABLE ASSY
CONDOR PjN iliM'T
76378-001 528"
76378-002 '57r"
76378-003 -64r
76378-004 696"
o DO NOT STRIP THIS END

CUb=;:e;;=="LJ } TO CHASSIS
CABLE ASSY
TO UPPER
CONTROL BOX
~'ttt/
CONNECTOR Cl (10 PIN)
I I I I
PIN WIRE NO. FUNCTION ~::, (\'0 ~::, ~
1 BLU LIMIT SW. OUlPUT TO PUMP SP. CONT. ;;?Y ;; 4' ;; t"j ;; ~
1'\ 'f" 1'\ 'f" 1'\ 'f" "'f"
2 WHT INPUT FROM UMIT SWITCH
3 GRN DRIVE FORWARD R9 65358 1.00 1.00 1.00 1.00 EA HOOD, 10 CONTACT
4 ORG DRIVE REVERSE R8 66992 1.00 1.00 1.00 1.00 EA PLUG, 10 CONTACT
5 WHT/BU< TRACllON ACCELERATE R7 54910-105 1.00 1.00 1.00 1.00 EA STRAIN RELIEF, ST21
6 BU< GROUND
7 RED/BU< GROUND 65351-010 EA CABLE SEAL, GREEN
6 11.00 11.00 11.00 11.00
8 GRN/BU< GROUND
5 65351-134 11.00 11.00 11.00 11.00 EA TERMINAl, 16-14GA MALE
9 REO INPUT FROM LEVEL SENSOR WHEN LEVEL
10 ORG/BU< SPARE 4 65351-042 1.00 1.00 1.00 1.00 EA CONNNECTOR. SHROUD 2 C(
3 65351-044 1.00 1.00 1.00 1.00 EA CONNNECTOR. SHROUD 3 C(
2 65351-048 1.00 1.00 1.00 1.00 EA CONNNECTOR, SHROUD 6 C(
1 67295-023 58.00 54.00 48.00 44.00 LF CABLE. 16GA/l0C
ITEM PART NUMBER On' On' On' On' UM DESCRIPTION
r I I I lO<lESS 01I<ElrMSE """"" m£OONOtll 00
I I I 1~1".
0£aIIAlS
• + 1 ~ 8300 IYf'£RIAl. 0
WACO. TEXAS .,.
FIGURE 6.2:BoxAssemblY,A38 Platform •

Ref. 76363 .......................... BoxAssembly,A38Platform .................................................. Ref.
1 76253 .......................... Box, Upper Control-Machined ................................................... 1
2 76011 .......................... Speed Control Potentiometer ...................................................... 1
3 76012 .......................... DriveControlJoystick ................................................................ 1
4 67964-002 .................... Butt Connector, 16/14GA .......................................................... 2
5 51913 .......................... Operator,RedP-PullZB2-BT4 ................................................... 1
6 BOW31529 .................. Plug Button .50DIA ................................................................... 1
7 51914 .......................... Base + 1NC Contact ZB2-BZ102 ............................................... 1
8 50075 .......................... Toggle SwitchSPDT ................................................................. 6
9 40880 .......................... Guard, Toggle Switch ................................................................. 6
10 65356 .......................... Relay,SPDT48VDCW/Diode .................................................. 2
11 65354-005 .................... CircwtBreaker5A-50VDC ......................................................... 2
12 34644-648 .................... Alarm,48VDC ........................................................................... 1
13 34552-010 .................... Strip, Terminal10Position ......................................................... 1
14 66993 .......................... Receptacle, Female 10 Con 1-10 ................................................. 1
15 66995 .......................... Base,PanelMounted10Contacts ................................................ 1
16 76390 .......................... Decal, Upper Box Tags .............................................................. 1
17 66653-002 .................... Receptacle, Female 24 Contacts 1-24 ........................................... 1
18 66654-024 .................... Base, Panel Mounted 24 Contacts ............................................... 1
19 67869 .......................... Socket,Relay .............................................................................. 2
20 65353-004 .................... Connector Plug-6Pin ................................................................. 1
21 65353-006 .................... Connector Plug-9Pin ............................................................... 1
22 65353-052 .................... Pin For AMP Plug .................................................................... 13
23 67114-003 .................... Strain Relief -1I2NPT .371.5 .................................................... 1
24 67123-001 .................... Seal, Connector Elect 1/2" .......................................................... 1
26 34542 .......................... Jumper ....................................................................................... 5
27 BOW31145 .................. Machine Screw RH #10-32 x 3/4 .............................................. 2
28 BOW43602 .................. Machine ScrewRH4Mx 0.7 x 1Smm ......................................... 2
29 BOW31127-1 .............. Machine Screw RH #6-32 x 11/4 ............................................. 4
30 BOW31126 .................. Machine Screw RH #6-32 x 3/4 ................................................ 2
32 BOW31231 .................. Nut, #6-32 ................................................................................ 6
33 BOW31232 .................. Nut, #8-32 ................................................................................ 8
34 BOW31428 .................. Washer,Flat #6 ......................................................................... 4
35 BOW31429 .................. Washer,Flat #8 ......................................................................... 1
36 206-00001-00 ............... Diode ........................................................................................ 4
(Optional)
45 76102 .......................... Decal, Platform Control Box .................................................. Ref.
46 34836 .......................... Operator, WhiteP-ButtonZB2-BAl ....................................... Ref.
47 52672 .......................... Base + 1 NO Contact ZB2-BZ101 ......................................... Ref.
48 65354-005 .................... CircuitBreaker5A-50VDC ..................................................... Ref.
MANUAL 92379-003
July 1998
Revised 11/98
WIRING ASSEMBLY (STEP 1) WIRING ASSEMBLY (STEP 2)
" SPEED CONTROL POTENTlOME7ER 1. un FUNCTION S'MTCH(S
2 DRIIi£ CONTROL JOYOTiCK 2. TIL 1 AND ALARM RELAYS (S\\HCH SIDE ONLY)
3. TILT AND ALARM RELAYS (COILS ONLY) 3. TIL 1 ALARM
4, CIRCUI1 BREAKERS 4, rOmS\lVlTCH
5, EMERGENCY STOP AND HORN S'M1CHE'3.
y£wc:Ottll><>i. "'t{CCM~
IIII 1I11 I11I IIII
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IIII 1111 1111 IIII

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~
)
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1111 II1I
" "
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IIII ' - - - - - , 1
1111 o 111I IIII IIII
~.~,iJ
III>
1III r---c:==--, 1111

""L'''M~
--~~~' :E:~_:_)iJ
I ]_:,1: :'=1_
",.~. -:-42~
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vn
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"I ·----------------1
N01[, ::: : ___ ~J~L_ l
ALL WIRES 18 GA (WHilE) PiN 5B257 '" I l
USE WiRE MARKERS AT EACH END Or WIRE RUN,

l~\oo::oo~~oi~~:::~~:'oo'j",~
,,
• ________________ J
''
FIGURE 6.2:BoxAssembly,A38 Platform . ,

Ref. 76363 .......................... BoxAssembly,A38Platform .................................................. Ref.
6 BOW31529 .................. Plug Button .50DIA ................................................................... 1
7 51914 .......................... Base + INC Contact ZB2-BZI02 ............................................... 1
10 65356 .......................... Relay, SPDT 48VDC WIDiode .................................................. 2
11 65354-005 .................... CircuitBreaker5A-50VDC ......................................................... 2
12 34644-648 .................... Alarm, 48VDC ........................................................................... 1
13 34552-010 .................... Strip, Terminall0Position ......................................................... 1
14 66993 .......................... Receptacle, Female 10Con 1-10 ................................................. 1
15 66995 .......................... Base,PanelMountedl0Contacts ................................................ l
19 67869 .......................... Socket,Relay .............................................................................. 2
21 65353-006 .................... Connector Plug - 9 Pin ............................................................... 1
22 65353-052 .................... Pin For AMP Plug .................................................................... 13
23 67114-003 .................... StrainRelief-1/2NPT .371.5 .................................................... 1
25 67124-001 .................... Locknut-1I2NPT Conduit. ...................................................... 1
26 34542 .......................... Jumper ....................................................................................... 5
28 BOW43602 .................. Machine ScrewRH4MxO.7 x 15mm ......................................... 2
32 BOW31231 .................. Nut, #6-32 ................................................................................ 6
33 BOW31232 .................. Nut, #8-32 ................................................................................ 8
34 BOW31428 .................. Washer, Flat #6 ......................................................................... 4
35 BOW31429 .................. Washer,Flat #8 ......................................................................... 1
36 206-00001-00 ............... Diode ........................................................................................ 4
(Optional)
46 34836 .......................... Operator, White P-Button ZB2-BA 1 ....................................... Ref.
48 65354-005 .................... Circuit Breaker 5A-50VDC ..................................................... Ref.
MANUAL 92379-003
July 1998
Revised 11198
• FIGURE 6.3 :BoxAssembly, A42JPlatfonn
BOX COMPONENT ASSEMBLY
(2)
M4 X .1)7 X 16mrn lG.
(7 Plt>::.)
1
8
8
(1)
(!)
,
I
(1)
(!)
@
I'->_~_ (2 PLCS)
11
@ @
o o
VIEW FROM TOP OF BOX liP
MANUAL 92379-003
July 1998
Revised 1l/98
'A'
TO LIM. SW.
CABLE ASSY
CONDOR PIN DIM 'A'
76378-001 528"
76378-002 576"
76378-003 648"
76378-004 696"
o DO NOT STRIP THIS END

q!b==i!5;;==d...J } TO CHASSIS
CABLE ASSY
TO UPPER
CONTROL BOX
i~i~/
CONNECTOR Cl (10 PIN)
I I I I
PIN WIRE NO. FUNCTION ~') ~ ~') ~
1 BLU LIMIT SW. OUTPUT TO PUMP SP. CONT. ;;~
1'\ '!"
;;4' ;;:, ;;~
1'\ '!" 1'\ '!" 1'\ '!"
2 WHT INPUT FROM LIMIT SWITCH
3 GRN DRIVE FORWARD R9 65358 1.00 1.00 1.00 1.00 EA HOOD, 10 CONTACT
4 ORG DRIVE REVERSE RB 66992 1.00 1.00 1.00 1.00 EA PLUG, 10 CONTACT
5 WHT/BLK TRACTION ACCELERATE R7 54910-105 1.00 1.00 1.00 1.00 EA STRAIN RELIEF. ST21
6 BLK GROUND
7 RED/BLK GROUND
6 65351-010 11.00 11.00 11.00 11.00 EA CABLE SEAL. GREEN
8 GRN/BLK GROUND
5 65351-134 11.00 11.00 11.00 11.00 EA TERMINAL. 16-14GA MALE
9 RED INPUT FROM LEVEL SENSOR WHEN LEVEL
10 ORG/BLK SPARE 4 65351-042 1.00 1.00 1.00 1.00 EA CONNNECTOR, SHROUD 2 C(
1 67295-023 58.00 54.00 4B.OO 44.00 LF CABLE. 16GA/IOC
ITEM PART NUMBER QTY QTY QTY QTY UM DESCRlP1l0N _ _ 00
I I L J IM!SS . - s E - .
I I I 1~'Jul • +,
Il£a\IAI.S
~ IJ300 _AlP
WACO. lEXA!I 78
FIGURE 6.3 :BoxAssembly, A42J Platform •

Ref. 76362 .......................... Box Assembly, A42JPlatform ................................................. Ref.
2 76011 .......................... SpeedControlPotentiometer ...................................................... 1
4 206-00001-00 ............... Diode ........................................................................................ 4
5 51913 .......................... Operator, RedP-PullZB2-BT4 ................................................... 1
6 BOW18579 .................. TerminalPiggy-Back22/18GA .................................................. 2
7 51914 .......................... Base + lNC Contact ZB2-BZ102 ............................................... 1
10 65356 .......................... Relay,SPDT48VDCW/Diode .................................................. 2
11 65354-005 .................... CircuitBreaker5A-50VDC ......................................................... 2
12 34644-648 .................... Alarm,48VDC ........................................................................... 1
13 34552-010 .................... Strip, Terminal 10 Position ......................................................... 1
15 66995 .......................... Base, Panel Mounted 10 Contacts ................................................ 1
19 67869 .......................... Socket,Relay .............................................................................. 2
20 65353-004 .................... Connector Plug-6 Pin ................................................................. 1
21 65353-006 .................... Connector Plug-9Pin ............................................................... l
22 65353-052 .................... PinFor AMP Plug .................................................................... 13
26 34542 .......................... Jumper ....................................................................................... 5
28 BOW43602 .................. MachineScrewRH4Mx 0.7 x lSmm ......................................... 2
32 BOW31231 .................. Nut, #6-32 ................................................................................ 6
33 BOW31232 .................. Nut, #8-32 ................................................................................ 8
34 BOW31428 .................. Washer, Flat #6 ......................................................................... 4
3S BOW31429 .................. Washer,Flat #8 ......................................................................... 1
(Optional)
46 34836 .......................... Operator, WhiteP-ButtonZB2-BA1 ....................................... Ref.
48 65354-005 .................... Circuit Breaker SA-50VDC ..................................................... Ref.
. Indicates Items Not Shown
Revised August 1998

MANUAL 92379·003
July 1998
Revised 1J/98
WIRING ASSEMBLY (STEP 1) WIRING ASSEMBLY (STEP 2)
L SPEED CONTROL POTENTIOMETER I. lIri fUNCTION SI'<11CHES
2. DRIVE CONTROL JOYS1!CK 2. >Ill AND ALARM RELAYS (51\11CH SIDE ONLY)
3. lilt AND ALARM RELAYS (COILS ONLY) 3. TILT ALARM
4. CIRC\111 BREAKERS 4. [00151'<11CH
5. EMERGENCY SlOP AND HORN S\\HCHE5
""
" II
1111 IIII IIII

till
" II
IIII IIII IIII ~(lIanl"""
IIII
Hit
1111
II "
~
,j 1> II II
~
' 1111 1111
IV !III II II
cD
1111
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1111
""
jj
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" Ol(/R
,"
""
,"...
,
:·l "
" "
~W1E:
ALL ~RES 18 GA (~11E) PIN ,,8257
USE I\1RE MARKERS Al EACH END OF I'<1RE RUN.
lOMR t.lA$ [R S'Ml
"" LOMA IJASTER ~\'IIT()-f

FIGURE 6.3 :BoxAssembly, A42J Platform •

Ref. 76362 .......................... Box Assembly, A42J Platform ................................................. Ref.
4 206-00001-00 ............... Diode ........................................................................................ 4
7 51914 .......................... Base + lNC Contact ZB2-BZ102 ............................................... 1
10 65356 .......................... Relay, SPDT 48VDC WIDiode .................................................. 2
11 65354-005 .................... Circuit Breaker 5A-50VDC ......................................................... 2
12 34644-648 .................... Alarm, 48VDC ........................................................................... 1
13 34552-010 .................... Strip, Terminall0Position ......................................................... 1
15 66995 .......................... Base, Panel Mounted 10 Contacts ................................................ 1
19 67869 .......................... Socket,Relay .............................................................................. 2
21 65353-006 .................... Connector Plug-9Pin ............................................................... 1
22 65353-052 .................... Pin For AMP Plug .................................................................... 13
24 67123-001 .................... Seal, Connector Elect 112" .......................................................... 1
25 67124-001 .................... Locknut-1/2NPTConduit ....................................................... l
26 34542 .......................... Jumper ....................................................................................... 5
27 BOW31145 .................. Machine Screw RH #10-32 x 314 .............................................. 2
28 BOW43602 .................. Machine Screw RH 4M x 0.7 x lSmm ......................................... 2
29 BOW31127-1 .............. Machine Screw RH #6-32 x 1114 ............................................. 4
31 BOW31132 .................. MachineScrewRH #8-32 x 3/4 ................................................ 8
32 BOW31231 .................. Nut, #6-32 ................................................................................ 6
33 BOW31232 .................. Nut, #8-32 ................................................................................ 8
34 BOW31428 .................. Washer, Flat #6 ......................................................................... 4
35 BOW31429 .................. Washer,Flat #8 ......................................................................... 1
(Optional)
46 34836 .......................... Operator, White P-Button ZB2-BAl ....................................... Ref.
48 65354-005 .................... Circuit Breaker5A-50VDC ..................................................... Ref.
MANUAL 92379-003
July 1998
Revised 11/98
This Page Intentionally Left Blank
MANUAL 92379-003
July 1998
Revised 11/98
FIGURE 6.4: 110VoltLinetoPlatfolm •

Ref. 38335 .......................... 110VoltLinetoPlatform ........................................................ Ref.
-1 40956 .......................... Box, Rain Tight Single-Gang ....................................................... 1
-2 67295-017 .................... Cable, 3 Conductor 12 GA .................................................. 60LF.
-3 66357 .......................... Receptacle, GroundFault ............................................................ 1
-4 66358 .......................... Cover, Weatherproof .................................................................. 1
-5 67114-003 .................... StrainRelief1/2NPT .37/.5 ........................................................ 1
-6 67123-001 .................... Seal, Connector Elect 1/2" .......................................................... 1
-7 BOW23075 .................. Connector, 12-10GA WireButt ................................................... 2
-8 BOW31146 .................. Screw, #10-32UNF x 1.00 Round Sit .......................................... 4
-9 BOW31430 .................. Washer,#10IDFlat ................................................................... 8
-10 BOW31362 .................. Washer, #10ID Split Lock ......................................................... 8
-11 52710 .......................... Plug, 110Volt ............................................................................. 1

MANUAL 92379-003
July 1998
Revised 11/98
48 FIGURE 7.1:DecalKit,A38/42J 24
f 17
MANUAL 92379-003
July 1998
Revised 11/98
FIGURE 7.1:DecaIKit,A38/42J G
Ref. 76412-A38 ................... DecalKit,A38/42J ................................................................. Ref.
*1 76412-DWG ............... InstallationDWG,DecalA38/42J ............................................... 1
*2 76105 .......................... Decal, Turret Control Box .......................................................... 1
""3 21882-001 .................... Decal, EL Hazard Keep Clear ..................................................... 2
*4 37958-500 .................... Decal, 500LB Rated Work Load ................................................. 1
*5 38176 .......................... Decal-AuxHydraulicValveLowering(A38) ............................... 2
38176 .......................... Decal-AuxHydraulic Valve Lowering(A42J) .............................. 3
*6 38533 .......................... Decal, Lower Caution Boom ...................................................... 1
"'7 38550 .......................... Decal, Platform Fall Arrest .......................................................... 2
*8 52759 .......................... Decal- Stand Clear ..................................................................... 2
""9 54182 .......................... Decal-BatteryCharger Plug ....................................................... 1
*10 54652-005 .................... Decal,BatteryService Caution ..................................................... 2
11 54940-023 .................... Decal, Time Condor Sticker ........................................................ 2
*12 54984-004 .................... Decal, Lift And Tie Down .......................................................... 4
*13 54984-006 .................... Decal, 110 Volt EXT To Platform .............................................. 1
*14 54984-007 .................... Decal, Hydraulic Fluid ................................................................. 1
*15 56024 .......................... Decal, 2.50" High" Forward" .................................................... 2
*16 56023 .......................... Decal, 7.00" High Arrow ............................................................ 2
17 56033 .......................... Decal, 3.5" High Twin Stripes .......................................... 12.23LF.
*18 56034-500 .................... Decal, 500LBS RAted Work Load .............................................. 1
19 55941-017 .................... Decal, 17x2.5" Condor Bird ..................................................... 1
*20 58399 .......................... Decal- Tire Replacement Solid ................................................... 4
67938-100 .................... Decal- Tire Pressure 100 PSI .................................................. Ref.
*21 69573 .......................... Decal, Boom Upper Caution ...................................................... 1
*22 71615 .......................... Decal Panic Stop .................................................................... Ref.
*23 76102 .......................... Decal, Platform Control Box ...................................................... 1
*24 76407 .......................... Decal, A38 ................................................................................. 2
76408 .......................... Decal,A42J ................................................................................ 2
*25 54984-003 .................... Decal, Operators Manual ............................................................ 1
26 55940-023-G ............... Decal, Condor ............................................................................ 1
*27 76496 .......................... Tag,DescendingSlopeCaution ................................................... 1
*28 76412-100 .................... DecaIKit,A38Essential .......................................................... Ref.
29 76412-101 .................... DecaIKit,A42JEssential ........................................................ Ref.
50 15843 .......................... Nameplate,BoomIdentification .................................................. 1

:}Indicates Essential Decals
MANUAL 92379·003
July 1998
Revised 11198
• FIGURE 7.1:DecalKit,A38/42J
/=
to
N
l.()
o o
MANUAL 92379-003
July 1998
Revised lli98
FIGURE 7.1 :Decal Kit, A38/421 G
Ref. 76412-A38 ................... DecaIKit,A38/42J ................................................................. Ref.
*1 76412-DWG ............... InstallationDWG,DecalA38/42J ............................................... 1
""2 76105 .......................... Decal, Turret Control Box .......................................................... 1
*3 21882-001 .................... Decal, EL Hazard Keep Clear ..................................................... 2
*4 37958-500 .................... Decal,500LBRatedWorkLoad ................................................. 1
*5 38176 .......................... Decal-AuxHydraulic Valve Lowering(A38} ............................... 2
38176 .......................... Decal-AuxHydraulicValveLowering(A42J) .............................. 3
*6 38533 .......................... Decal, Lower Caution Boom ...................................................... 1
>'7 38550 .......................... Decal, Platform Fall Arrest .......................................................... 2
*8 52759 .......................... Decal- Stand Clear ..................................................................... 2
*9 54182 .......................... Decal-BatteryChargerPlug ....................................................... 1
*10 54652-005 .................... Decal, BatteryService Caution ..................................................... 2
11 54940-023 .................... Decal, Time Condor Sticker ........................................................ 2
*12 54984-004 .................... Decal, Lift And TieDown .......................................................... 4
*13 54984-006 .................... Decal, 110 Volt EXT To Platform .............................................. 1
*14 54984-007 .................... Decal, Hydraulic Fluid ................................................................. 1
""15 56024 .......................... Decal, 2.50" High" Forward" .................................................... 2
*16 56023 .......................... Decal, 7.00" High Arrow ............................................................ 2
17 56033 .......................... Decal, 3.5" High TwinStripes .......................................... 12.23LF.
*18 56034-500 .................... Decal, 500LBS RAted Work Load .............................................. 1
19 55941-017 .................... Decal, 17x2.5" Condor Bird ..................................................... 1
'~20 58399 .......................... Decal- Tire Replacement Solid ................................................... 4
67938-100 .................... Decal- Tire Pressure 100 PSI .................................................. Ref.
*21 69573 .......................... Decal, Boom Upper Caution ...................................................... 1
*22 71615 .......................... DecalPanicStop ................................................................... -.Ref.
>'"23 76102 .......................... Decal, Platform Control Box ...................................................... 1
*24 76407 .......................... Decal,A38 ................................................................................. 2
76408 .......................... Decal,A42J ................................................................................ 2
*25 54984-003 .................... Decal, Operators Manual ............................................................ 1
*26 76412-100 .................... Decal Kit, A38 Essential .......................................................... Ref.
27 76412-101 .................... Decal Kit, A42J Essential ........................................................ Ref.
50 15843 .......................... Nameplate,Boomldentification .................................................. 1

)~Indicates Essential Decals
MANUAL 92379-003
July 1998
Revised 11/98
Notes
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the state of
California to cause cancer, birth defects,
and other reproductive harm.
WARNING: Battery posts, terminals, and

related accesories contain lead and lead
compounds, chemicals known to the
State of California to cause cancer and
reproductive harm. Wash hands after
handling.
_DE_T_R_O_IT_D_IE_S_E_L_ _
CORPORATION
@\..\....~
CALIFORNIA PROPOSITION 65 INFORMATION

TO CALIFORNIA CUSTOMERS AND
TO COSTOMERS SELLING DIESEL ENGINE EQUIPMENT
INTO OR FOR USE IN CALIFORNIA
Proposition 65, a California law, requires warnings on products which expose individuals
in California to chemicals listed under the law, including certain chemicals in diesel
engine exhaust.
Obligations of Manufacturers of Diesel-Powered Off-Road Equipment. The California
Superior Court has approved either of the following two methods of compliance with
Proposition 65 requirements by manufactures of off-road equipment containing diesel
engines. (The court order containing these provisions may be furnished on request.)
1. On-Equipment Warning. Place the warning pictured in attachment 1 on all equipment
shipped by you into or for sale in California after January 1, 1996. The warning
must be in a location where it is easily visible to the operator of the equipment when
(s)he is operating the equipment. The warning must be secured to the equipment. If
warnings or operating instructions are provided through a digital display, you may
use that method of providing the warning.
2. Operator Manual Warning. When the operator manual is next revised or by
December 31, 1995, whichever is earlier, place the warning in attachment 2 in the
operator manual. The warning may be either printed in the manual or a sticker.
The warning must appear in one of the following locations.
* Inside the front cover
* Inside the back cover
* Outside the front cover
* Outside the back cover
* As the first page of text
Under either alternative, the warning must appear in the same size, print and format as
the attachment selected or be of equally conspicuous size and format. If the warning
is provided in an on-screen display, the warning must contain the language in the attach-
ment and must be provided at the time of or in connection with ignition in the same man-
ner as other safety warnings electronically communicated on screen.
Obligation of Resellers of Diesel Engines. This letter must accompany any loose diesel
engine sold in California.
Should you have any questions, please call Detroit Diesel Corporation, Mr. John F.
Farmer on (313) 592-7111, Fax (313) 592-5014.

Condor A38 A42j 92379

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OPERATOR'S, SERVICE AND

BOOM-SUPPORTED ELEVATING WORK PLATFORM

THIS MANUAL MUST BE RETAINED ON THE UNIT AT ALL TIMES.

DO NOT ALTER OR MODIFY THIS UNIT WITHOUT PRIOR WRITTEN

SERVICE & MAINTENANCE

4. TII\1E CONDOR Corporation Service School TrainingManuals are availableforpurchasethrough

TIME CONDOR Corporation

8300 ImperialDrive, P.O. Box21447, Waco, Texas76702-1447'254-420-5200,254-666-4544FAX

FormNo.513-3M-392 Effective Date 9/1/90

BOOM-SUPPORTED ELEVATING WORK PLATFORM

TABLE OF CONTENTS ........................................................................................................... 1

A Safety Symbols ........................................................................................................... 3

II. MACHINE OPERATION ................................................................................................ 12

III. MOVING FROM JOB SITE TO JOB SITE ..................................................................... 28

IV. EMERGENCY PROCEDURES ....................................................................................... 31

VI. MACHINE SPECIFICATIONS ................................................................................... 34

VII. MACHINEDIAGRAM ................................................................................................. 35

ANSIISIA 92.5-1992 MANUAL OF RESPONSIBILITIES

You must maintain CLEARANCE OF AT LEAST 10 FEET (3.05 M) between any

DEATH OR SERIOUS INJURY will result from contact with, or inadequate

• DO NOT block the foot switch or anyfunctioncontrolin the operating position.

• The "UNPOWERED EMERGENCY MOVEMENT" procedure (described later

• DO NOT attempt to open any hydraulicline orcomponent without first relieving

• DO NOT alter, modify or disable any safety devices or interlocks.

• Limit travel speed according to conditions of the ground surface, congestion,

• DO NOT sit, stand or climb on platform rails.

• DO NOT indulge in stunt driving or horseplay while operating this machine.

• Whenever disengaging the brakes or before disconnecting from towing

• Immediately report any erratic noises, vibrations or malfunctions of the unit to

• DONaT exceed the maximum platform horizontal pulloflOOlbs. (45.4 kg).

21882-001 - Decal, Electrocution Danger

• DO NOT OPERATE THIS CONDOR ® UNTIL YOU HAVE BEEN

• PRIOR TO EACH DAY'S USE, CHECK TO MAKE SURE ALL

• DO NOT USE THIS CONDOR® IF IT IS MALFUNCTIONING OR

• RAISE PLATFORM ONLY WHEN CONDOR ® IS ON FIRM,

• AL WA YS LOOK IN THE DIRECTION IN WHICH THE PLATFORM IS

• DO NOT MAKE ANY MODIFICATIONS TO THIS CONDOR@

38533 - Decal, Lower Boom Caution

RAISE PLATFORM ONLY WHEN CONDOR® IS ON

i • ALWAYS LOOK IN THE DIRECTION IN WHICH THE'

, • NORMAL TRAVEL POSITION IS WITH BOOM

DO NOT DRIVE ON A SLOPE UNLESS BOOM IS

69573 - Decal, Upper Boom Caution

RATED WORK LOAD

If any of these items are damaged or missing, replace them immediately.

Right Hand Side

Left Hand Side

ITEM PART NUMBER DESCRIPTION QTY

Ref. 76412-A38/A42J ......... DecalInstallationM-A38-01M-A42J-Ol ................................. Ref.

- Indicates Items Not Shown

,..-,11------ PLA TFORM CONTROLS

\'\¢&,¥---------- JIB BOOM

LOWER BOOM --------------1

1------------- LIFT CYLINDER

GROUND CONTROLS , - - - - - TURRET

Item Control Location Description

Turn key left (counterclockwise) one position to turn

With key switch "OFF", the key may be removed to

3. EmergencyStop On Ground Used to stop all functions in an emergency. Push for

Item Control Location Description

Boom Extend/ OnPlatform Switch controls the Boom Extend/Retract function.

Lever controls forward and reverse travel of machine

WITH PLATFORM SWUNG OVER STEERING

O· L-______ ~_~~ ~ ~_ ~.lJ~~~i-------------~--------·-