Operation, Service Parts Models T60 T66J: AND Manual

TIME CONDOR Corporation
OPERATION, SERVICE
AND PARTS MANUAL
MODELS T60 & T66J

BOOM-SUPPORTED ELEVATING WORK PLATFORM
Beginning With Serial Number P3469800 1
(~~~)
o 0
SHIPPING ADDRESS MAILING ADDRESS

CONDOR® CONDOR®
TIME CONDOR Corporation TIME CONDOR Corporation
8300 IMPERIAL DRIVE P.O. Box 21447
VVAco,TEXAS76712 VVAco,TEXAS76702-1447
(254)420-5200 (254)420-5200
MANUAl. 92375-001
April 1998
\
OPERATOR'S MANUAL
MODELS T60 & T66J

(~~~)
o 0

CONDOR® CONDOR®
(254)420-5200 (254)420-5200
MANUAL92375-001
April 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 befor~ 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, and/or delete certain design
features of its products without any obligation to incorporate new features into products previously
sold. Our manuals are continually updated to reflect these changes.
DO NOT ALTER OR MODIFY THIS 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 of the CONDOR®.
MANUAL92375-001
April199B
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. Range Of Operation ................................................................................................................ 14
C. GroundControls ...................................................................................................................... 16
D. Platform Controls .................................................................................................................... 20
E. Start Up Procedures ................................................................................................................ 26
1. Shift Check ......................................................................................................................... 26
2. Machine Start Up ............................................................................................................... 28
3. Ground Operation and Checks ........................................................................................... 29
4. Platform Operation and Checks ......................................................................................... 31
5. Cold Weather Operation ..................................................................................................... 34
E. General Operation ................................................................................................................... 35
1. Boom Operation ................................................................................................................. 35
2. Drivers and Steering ........................................................................................................... 38
3. Braking ............................................................................................................................... 38
4. Gas Engine Operation ......................................................................................................... 39
5. Diesel Engine Operation ..................................................................................................... 39
F. Shut Down Procedures ........................................................................................................... 40
III. MOVING FROM JOB SITE TO JOB SITE ....................................................................................... 40
A. Unloading ................................................................................................................................. 40
B. Loading .................................................................................................................................... 41
C. Tie Down ................................................................................................................................. 41
D. Towing Procedure ................................................................................................................... 41
IV. EMERGENCY PROCEDURES ....................................................................................................... 43
V. MACHINE SPECIFICATIONS ........................................................................................................ 48
ANSIISIA 92.5-1992 MANUAL OF RESPONSIBILITIES
MANUAL92375-001
Apoi11998
•
This Page Intentionally Left Blank
MANUAL9237!XJ01
April 1998
SAFETY SYMBOLS
This manual contains important information on the safe use ofyour CONDOR T 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 ofthose around you, you must operate your aerial platform
as instructed in this manual.
You the operator, are the single most important factor for safety when using any piece of equipment. Learn
to operate your work platform in a safe manner.
To help you recognize important safety information, we have identified warnings and instructions that directly
impact on safety with following signals:
.. DANGER
"DANGER" INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT
AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY. THIS SIGNAL WORD IS
LIMITED 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 OR MODERATE INJURY. IT IS ALSO
USED TO ALERT AGAINST UNSAFE PRACTICES, AND FOR PROPERTY-DAMAGE-
ONLY SITUATIONS.
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 start until you are satisfied that it is safe to proceed.
MANUAL92375-001
April 1998
· .SAFETY RULES AND PRECAUTIONS
~ 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
electrically charged conductor.
You must AVOID CONTACT between any part 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

part of the machine, or its load, and any electrical line or apparatus carrying over 300
volts 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 electrically charged conductor.
• 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 harness 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 harness 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 any function control in the operating position.
• DO NOT exceed the platform capacity ofthe unit in any configuration. Review the
section titled "MACHINE SPECIFICAnONS", later in this manual, regarding this
model's capacities and dimensions.
MANUAl92375-001
April 1998
SAFETY RULES AND PRECAUTIONS (Continued)
•
.. 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 torque hubs, 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 only for a short distance. Be on guard against unit runaway
on sloping surfaces. Movement speed shall not exceed 1 M.P.H. (1.6 K.P.H.).
• DO NOT attempt to open any hydraulic line or component without first relieving all
system pressures and shutting off fluid flow from the tank.
• DO NOT allow anyone to tamper with, service or operate the machine from 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 refuel the unit near sparks or open flames. Gasoline and propane vapors,
and Diesel fuel fumes are highly explosive.
• 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.
MANUAl92375-001
April 1998
• SAFETY RULES AND PRECAUTIONS (Continued)
.& 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 mobile platform is clear of personnel and
equipment before: driving the unit; or raising, lowering or extending the boom; or
swinging the superstructure; or, rotating or tilting the platform.
• Maintain a safe distance from overhead and ground obstacles, debris, drop-offs,
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.
A WARNING
• Complete the "Operational Checklists" found in this manual (see Table of Contents)
at designated intervals.
• Ensure thatthe machine is in "LOW' drive speed while unloading from a truck or trailer.
• Always attach the unit to a winch when loading or unloading from a truck or trailer.
TIME CONDOR does not recommend unassisted loading or unloading of any aerial
work platform.
• With the superstructure 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 undercarriage of
the unit or the location of the superstructure lockpin hole for travel orientation.
MANUAl9237MlO1
April 1998
SAFETY RULES AND PRECAUTIONS (Continued) •
A WARNING
• Check fuel system for leaks or damaged fuel lines before operating unit. If any damage
is found, contact your supervisor immediately. Machine must be removed from service
until diagnosis and any necessary repairs have been completed.
• Actuation of the red "EMERGENCY STOP" button will apply brakes immediately,
causing unexpected platform movement as the machine comes to a sudden stop. Brace
yourself.
• Whenever disengaging the drive torque hubs or before disconnecting from towing
vehicle, ensure that the 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 completed.
• Operating this equipment without all safety and control decals in place can be
hazardous.
A CAUTION
• For transporting the 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.
• DO NOT exceed the maximum platform horizontal pull of 100 lbs. (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 lower the 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 or tow the 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.
MANUAl9237S-001
April 1998
• SAFETY RELATED DECALS
ELECTROCUTION HAZARD
KEEP CLEAR
DEATH OR SERIOUS INJURY CAN
RESULT FROM CONTACT WITH TillS
EQUIPMENT OR VEIllCLE IF IT SHOULD BE
ELECTRICALLY CHARGED
21882-
21882-001 - Decal, Electrocution Danger
• DO NOT OPERATE THIS MACHINE UNTIL YOU

HAVE BEEN PROPERLY TRAINED & HAVE
COMPLETELY READ & UNDERSTOOD THE
OPERATOR'S MANUAL.
• PRIOR TO EACH DAY'S USE, CHECK TO MAKE

SURE ALL FUNCTIONS ARE OPERATING
PROPERLY & PERFORM ALL INSPECTIONS
IDENTIFIED IN THE OPERATORS MANUAL .
.. • DO NOT USE THIS MACHINE IF IT IS DAMAGED

; OR MALFUNCTIONING IN ANY WAY, OR IF THE
illND SPEED IS ABOVE 25 MPH.
• RAISE PLATFORM ONLY WHEN ON FIRM, LEVEL

GROUND.
• AL·NA YS LOOK IN THE DIRECTION IN WHICH THE

PLA TFORM IS MOVING. WATCH FOR & AVOID
OVERHEAD CBSTRUCTIONS & ANYTHING ELSE
THA T MAY STRIKE PLATFORM, PERSONNEL,
PERSONNEL, OR CON TROLS.
, • THiS MACHINE is NOT ELECTRICALLY INSULA TED.

SEE OPERATOR MANUAL FOR SAFE APPROACH.
DISTANCES TO ENERGIZED POWER LINES.
• DO NOT MAKE ANY MACHINE MODIFICATIONS

\\HHOUT WRITTEN APPROVAL FROM CONDOR.
• DO NOT FORCE THE BOOM, PLATFORM, OR

SKIRT INTO THE GROUND .
• IN CASE OF EMERGENCY, PUSH RED

"EMERGENCY STOP" BUTTON.
7161B
71618 - Decal, Lower Boom Caution
MANUAl92375-001
April 1998
I LL CAUr~ON I
•
SAFETY RELATED DECALS
• BEFORE OPERATI~G, ALL PERSONS IN

PLATFORM MUST HAVE APPROVED FALL
PROTECTION SYSTEMS ATTACHED.
• THIS MACHINE IS NOT ELECTRICALLY

INSULA TED. SEE OPERA TOR'S MANUAL
FOR MINIMUM SAFE APPROACH DISTANCES
TO ENERGIZED POVVER LINES.
• RAISE PLATFORM ONLY WHEN MACHINE IS

ON FIRM, LEVEL GROUND.
• ALWAYS LOOK IN THE DIRECTION IN WHICH

THE PLATFORM IS MOVING. WATCH FOR,
AND AVOID OVERHEAD OBSTRUCTIONS AND
ANYTHING ELSE THAT MAY STRIKE
PLATFORM, PERSONNEL OR CONTROLS.
• 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 & LEVEL OR LOWER.
• IF SLOPE ALARM SOUNDS, THE MACHINE IS

OUT OF LEVEL. REVERSE DIRECTION OF
TRAVEL & REPOSiTION ON FIRM, LEVEL
GROUND.
• DO NOT FORCE THE BOOM, PLATFORM OR

SKIRT INTO THE GROUND.
• IN CASE OF EMERGENCY, PUSH RED

"EMERGENCY STOP" BUTTON.
71614
71614 - Decal, Upper Boom Caution
RATED \.JORK LOAD
LB
37958-500
37958-500 - Decal, Rated Work Load
MANUAl 92375-001
April 1998
.,
SAFETY AND CONTROL DECAL LOCATIONS
A WARNING
OPERATING TIDS EQUIPMENT WITHOUT ALL SAFETY AND CONTROL
DECALS IN PLACE CAN BE HAZARDOUS.
If any ofthese items are damaged or missing, replace them immediately.

Decals are shown for standards machine. Optional equipment may change
the decal locations.
14
Front
Rear
5,6
\
7
8THRU 11,20 INSIDE
Right Hand Side

Left Hand Side
MANUAL92375-001
April 1998
SAFETY AND CONTROL DECAL DESCRIPTIONS
CD
ITEM PART NUMBER DESCRIPTION QTY

Ref. 71491 ............................ InstallationDWG ..................................................................... Ref.
1
2 71419-DWG ................. Decal Installation DWG. T60-01 ................................................... 1
3 67938-080 ..................... Decal, 80 PSI Tire Pressure .......................................................... 4
4 54984-004 ..................... Decal, Lift and Tie Down .............................................................. 4
5 56023 ............................ Decal, Arrow ................................................................................. 2
6 56024 ............................ Decal, Forward .............................................................................. 2
7 21882-001 ..................... Decal, Electrocution Danger ......................................................... 2
8 21849 ............................ Decal, Unleaded Gas Only ............................................................ 1
9 54984-007 ..................... Decal,HydraulicFluid ................................................................... 1
10 71618 ............................ Decal, Boom Lower Caution ......................................................... 2
11 54984-006 ..................... Decal, 110 Volt Ext To Platform ................................................... 1
12 21079 ............................ Decal, Lube Fitting ........................................................................ 1
13 38805 ............................ Decal, Do Not Lift Wheels (T66J) ................................................ 3
14 71614 ............................ Decal, Boom Upper Caution ......................................................... 1
15 37958-500 ..................... Decal, 500 LB Rated Work Load ................................................. 2
16 56034-500 ..................... Decal, Rated Work Load .............................................................. 1
17 71615 ............................ Decal, Panic Stop .......................................................................... 1
18 38550 ............................ Decal, Platform Fall Arrest ........................................................... 2
19 71369 ............................ Decal, Platform Control Box ......................................................... 1
20 71370 ............................ Decal, Turret Control Box ............................................................. 1
21 71589 ............................ Decal, Error Code Lower Controls ............................................... 1
22 71617 ............................ Decal, Ground Board Lights .......................................................... 1
23 56033 ............................ Decal, Twin Stripe ............................................................ 12.23LF.
24 55940-060 ..................... Decal, 9.00 x 60.00 CONDOR ..................................................... 1
25 55941-017 ..................... Decal, "Bird" ................................................................................. 1
- Indicates Items Not Shown
MANUAL92375-001
April 1998
MACHINE OPERATION
MANUAl 92375-001
April 1998
PRIMARY MACHINE COMPONENTS
CD
PLATFORM
CONlROLS
PLATFORM
JIB BOOM
SLAVELEVELING
CYLINDER
MASTER
~ MAlNBOOM
lEVEl1NG ASSEMBLY
CYLINDER
- / - - - - - LIFT
CYLINDER
lURREf
IIC~ag~~)
o 0
GROUND
CONTROLS CHASSIS
LEFT HAND SIDE
MANUAl92375-001
April 1998
T60 wORKING RANGE DIAGRAM
-10 10 20 30 40 50
(-105M) 0.051·1) (6.09M) (914M) (J219M) (JS.24M)
80
(209M)
70
(213414)
AUTOMA TIC SLO\v' SPEED
7
BOOM DO\v'N ZONE
AUTOMA TIC RETRACT TO FOLLO\v'
CURVE \v'HEN BOOMING DO\v'N
60
(J829M)
AUTOMATIC
SLO\v' SPEED
BOOM UP
ZONE
50
(JS.24fD
40
0219I-D
30
(9WI)
20
(6091·1)
10
GOSI-D
-10
(-305M)
MANUAL92375-001
April 1998
T66J wORKING RANGE DIAGRAM
-10 10 20 30 40 50
(-3.0Sfl) GOSH) (609M) (9.14M) (12.J9M) OS.24M)
80
(24.39fll
70
(21.34M)
AUTDMA TIC RETRACT

TO FDLLOVI CURVE
7
VlHEN BOOMING DOVIN '
60
(J829M)
AUTOMATIC
SLOVI SPEED
BOOM UP
ZONE
I 50
05 24M)
40
02.J9M)
30
(9.J4M)
\
20
(609fD
10
GOSH)
)
\\JL!L--A.--.'J
-10
MANUAl9237!HJ01
(-3.0SM)
April 1998
OPERATOR CONTROLS DESCRIPTION
(GROUND CONTROLS)
7
~--------------------~
./ ~
8
'\
o
( ,
11--0 LP GAS
6 --~7---------------~
o
10 3
ENGINE RPM
~11D SPEED
.... iJI
IDLE
,
"0
GLOW PLUG
,
<9J
2
1--I---r---------------------:~
.~
4
~-----i0
0, CIRCUIT
BREAKER
START 0
~ "
u ~
5 --------~~------~4
(\ ("'\1.,
~ .. .. \J
( \ (,,('\,\/
~~~
UP
(,,\,
SWING DONN
BOOM
OPERATE
FUNCTIONS UP EXTEND
,~ ~ 1 \I
U U
!
~
DOWN RETRACT
EMERGENCY JIB BOOM
PUMP
\
\ COMJ'II! ./
/
/
MANUAl92375-001
April 1998
(GROUND CONTROLS)
Item Control Location Description
1. Circuit Breaker On Ground Pops out when the 12 Volt electrical circuit is
Console Panel overloaded. Push in to reset.
2. Choke/ On Ground Choke button for gas or dual fuel engines. Press
Glow Plug Button Console Panel and hold while starting a cold engine.
Glow plug button for some Diesels. Press and hold

(if so equipped) to preheat combustion chamber
before starting a cold engine.
3. 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.
4. Engine Start On Ground Press push button to engage engine starter. Re-
Button Console Panel lease button immediately upon engine start.
NOTE: Main power key switch must be in

"GROUND" position.
S. Axle Not On Ground When lit, the light indicates that the axles are not
Locked Console Panel locked. This is a danger light that boom has
extended or raised and the axle lock cylinders have
not locked the axle.
6. Hour Meter On Ground Indicates that elapsed time that the engine has been
Console Panel operated in hours and tenths.
7. Volt Meter On Ground Indicates electrical system voltage.

Console Panel
MANUAl92375-001
ApriI199B
(GROUND CONTROLS, CONTINUED)
7
8
11--0
n
LP GAS
0
6
10
ENGINE RPM
~ 3
MID SPEED
2
.... if'
IDLE
,
~
GLOW PLUG
'
~,
1 -+---t------O
~\
CIRCUIT
BREAKER
4 --+-~_ _ _ _~I~
I STt.RT ( )
d"
I
I .:J. d:1
U u
(\ ~.. CCW
UP
5 -----r-....L.------I-\' \ CW',
~
SWING
CDOWN
BOOM
OPERATE
o o
FUNCTIONS UP EXTEND
~
~ )
~
DOWN RETRACT
EMERGENCY JIB BOOM
PUMP
COMJ'II!. ./
/
/
MANUAl9237!HlO1
April 1998
(GROUND CONTROLS, CONTINUED)
8. Engine Oil On Ground

Pressure Gauge Console Panel Indicates engine oil pressure.
9. Gas/Off! On Ground Flip toggle left to use gasoline, right to use propane.
Propane Switch Console Panel In "CONDOR" position, the engine does not get fuel
(optional) supply.
10. Engine Throttle On Ground Flip toggle to down for low (idle) engine speed, up
Switch Console Panel for mid range (operating) engine speed for
generator use.
11. Boom Fully On Ground Indicates when boom is fully raised and angle
Raised Console Panel sensor is correctly calibrated.
MANUAl9237!HlO1
April 1998
(PLATFORM CONTROLS)
7 12
14
MANUAl9237!HlO1
April 1998
(PLATFORM CONTROLS)
1. Emergency Stop On Platform Used to stop all functions in an emergency. Push

Button Console Panel for emergency stop. Pull or rotate clockwise to
reset, depending on style used.
When the button is reset, the engine distress light

and axle not extended light will flash three times
and the chassis tilt alarm will sound three times. If
any of these indications do not occur at reset, do not
operate machine.
2. Off/On/Start On Platform Three position toggle switch. Up is "OFF". Move

Toggle Console Panel to center position to tum ignition "ON", down to
engage starter. If the engine does not start within
10 seconds, switch must be turned off and then on
again to start.
IMPORTANT: Engine will not start with foot switch

depressed.
3. Glow Plug/ On Platform Flip toggle to center position for low (idle) engine
Chokelldle/ Console Panel speed, up for mid range (operating) engine speed
Operating Speed for generator use.
Toggle (Engine
Throttle) Choke toggle for gas or dual fuel engines. Press
and hold while starting a cold engine.
Glow plug toggle for some Diesels. Press and hold

(if so equipped) to preheat combustion chamber
before starting a cold engine.
4. Emergency On Platform Press and hold to activate battery powered hydraulic

Pump Push Console Panel pump, allowing operation of boom or platform
Button functions should the engine powered hydraulic pump
be disabled.
5. Engine Distress On Platform Red light indicates low engine oil pressure, high
Light Console Panel engine coolant temperature or broken fan belt(if so
equipped). Engine will shut down automatically if
condition does not correct itself in approximately 10
seconds.
MANUAL92375-001
April 1998
(pLATFORM CONTROLS, CONTINUED)
14
MANUAL92375-001
April 1998
6. Boom Extend! On Platform Lever controls the boom extend I Retract function.
Retract Lever Console Panel Pull back to extend boom. Push forward to retract
boom. Boom speed will be proportional to handle
movement.
7. Main Boom Lift On Platfrom Dual function lever.

and Swing Lever Console Panel
Push lever forward to raise main boom. Pull lever
back to lower main boom. Boom speed will be
proportional to handle movement.
Push lever to right to swing superstructure to right

(counterclockwise). Push lever to left to swing left
(clockwise). Superstructure can rotate 3600 continu-
ously in either direction. Swing speed will be propor-
tional to handle movement.
8. Platform Rotate On Platform Press and hold switch to left to rotate platform to
Toggle Console Panel left (counterclockwise). Press and hold switch to
right to rotate platform right (clockwise). One speed
only.
9. Platform Leveling On Platform Press and hold switch forward to tilt platform
Toggle Console Panel forward. Press and hold switch back to tilt platform
backward. One speed only.
10. Jib Boom Lever On Platform Push lever forward to raise jib boom. Pull lever
Console Panel back to lower jib boom. Boom speed will be propor-
tional to handle movement.
11. Drive Lever On Platform Lever Controls forward and reverse travel of
Console Panel machine at a speed proportional to handle move-
ment. ( Engine automatically shifts to high range
speed when driving.)
A WARNING
WITH PLATFORM SWUNG OVER
STEERING WHEELS, USE CAUTION
WHEN SELECTING THE TRAVEL
DIRECTION. TRAVEL DIRECTION
WILL BE OPPOSITE DRIVE LEVER
MOVEMENT.
MANUAl92375-001
April 1998
(PLATFORM CONTROLS, CONTINUED)
7 12
14
MANUAl 92375-001
April 1998
12. Steer Switch On End of Drive Move switch left and hold to tum steer wheels to
Lever left, and right to tum steer wheels to right. Push and
hold in opposite direction to straighten wheels.
A WARNING
WITH PLATFORM SWUNG OVER THE
STEERING WHEELS, USE CAUTION
WHEN SELECTING THE STEERING
DIRECTION. STEERING DIRECTION
WILL BE OPPOSITE STEER SWITCH
MOVEMENT.
13. Function Speed On Platform Press toggle up for "IllGH" function speed, down
Toggle Console Panel for "LOW" function speed for all proportional
functions (boom,jib, swing, drive). High speed travel
is available only while boom is below horizontal and
extended less than 3 feet (0.9 Meters).
14. Hom Button On Platform Press button to sound warning hom.

Console Panel
15. Light Toggle On Platform Flip toggle to tum head lights on and off ( if so
(optional) Console Panel equipped).
16. Sensor Override On Platform Press button to override the position sensor(if so
Button (optional) Console Panel equipped).
17. Axles Not On Platform When lit, the light indicates that the axles are not
Locked Console Panel locked. This is a danger light that boom has
extended or raised and the axle lock cylinders have
not locked the axle.
18. Steer Select On Platform Press switch up for "FRONT" wheel steer, down
Switch(optional) Console Panel for "REAR" wheel steer (with 4 wheel steer option)
19. Foot Switch On Platform Floor Must be depressed to activate main hydraulic pump,
allowing operation ofany hydraulic function( drive,
steer, boom or platform movement) from the
platform. Depress foot switch before selecting
function.(Engine automatically shifts to mid range
for all functions.)
MANUAl92375-001
April 1998
• START-UP PROCEDURES
SHIFT CHECKS
Before the CONDOR T-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.
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 engine oil and fuel levels.
Check engine coolant level (with liquid cooled engines).
Check volt meter on ground controls for battery condition and wire connections.
Check hydraulic fluid level with booms fully retracted end lowered.
Check that all shutoff valves on the hydraulic tank are "Open". When open, valve
handles will be parallel with the length ofthe valve.
A CAUTION
The shutoff valves on the hydraulic tank must be left open at all times,
except during repairs or transport. If one or more of these valves are
closed when the unit is running, extensive pump damage will occur.
Check wheel lug nuts tightness. Check tire pressure (see Machine
Specifications).
Check hoses and cables for worn areas.
Check hose carrier to make sure that it is not bent or sagging.
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.
MANUAl92375-001
April 1998
START-UP PROCEDURES (CONTINUED)
Check that the ANGLE SENSOR is calibrated. Retract boom fully and raise until
it stops. Verify that the "Boom Fully Raised" light comes on, located at the ground
•
control box. Ifthe light is not on, DO NOT operate machine and see Service Manual
for calibration.
Boom Fully Raised

ANGLE SENSOR
00
\ cAUBRAl10N UGHT
0
0 0
0
0 0
0 0 0
0 0 0
Boom Fully Raised Light
On Ground Control Box Under
Cover
Check that the length sensor is calibrated. With boom in the horizontal position, extend
out until it stops. Verify that the alignment marker on the boom tip is in the black
"Operational Zone". If it stops outside ofthe "Operational Zone", DO NOT operate
machine and see Service Manual.
<lJ'l >
L ACCEPTAlILE 1PERATD¥i ~---1
Switch the key to platform control and then pull the emergency switch up at the platform.
Verify that you hear three beeps and all platform lights flash three times.lfnot, a safety
light or buzzer has failed and should be repaired before operating the machine.
MANUAl92375-001
April 1998
.,
MACHINE START-UP
.& DANGER
ALL OPERATORS MUST THOROUGHLY READ AND UNDERSTAND THE
"SAFETY RULES AND PRECAUTIONS" SECTION OF TillS MANUAL PRIOR
TO OPERATING THE MACmNE.
A COMPLETE VISUAL INSPECTION OF THE MACmNE MUST BE

PERFORMED PRIOR TO OPERATIONAL CHECKS.
• Disengage lock pin before swinging the turret.
• Ensure that "EMERGENCY STOP" buttons on ground control panel and platform control
console panel are disengaged. Pull out or twist to reset, depending on style.
• Tum the main power key switch to the "GROUND" position to energize the electrical
system.
• While starting a cold engine or dual fuel engine, press choke button.
For some optional Diesel engines, press glow plug button, and hold it there for 30 to
45 seconds prior to engaging starter motor.
• Press and hold engine start button to start engine.
MANUAl92375-001
April 1998
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 "GROUNDIPLATFORM" key switch.
• While pressing the "OPERATE CONTROLS" button, press and hold the main "BOOM"
toggle to the "UP" position to raise the main boom to the horizontal position or slightly above.
Release the "BOOM" toggle.
• Press and hold the "nB BOOM" toggle on the remote pendant controls to the "UP" position
to raise the jib boom to the end of its travel (10 0 above main boom position). Release the
"nB BOOM" toggle.
Listen for any unusual noises.

Check for any vibration 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 "nB BOOM" toggle on the remote pendant controls to the "DOWN"
position to lower the j ib boom to the end of its travel (90 0 below the main boom position).
Release the "nB BOOM" toggle.
• Press and hold the boom "EXTENDIRETRACT" toggle on the remote pendant controls to
the "EXTEND" position. Extend the boom to the end of its travel.

Check for any vibration while the boom extends.
• Release the "OPERATE CONTROLS" button and "EXTENDIRETRACT" toggle.
• Inspect the boom sections visually for any damage along their entire lengths.
• Push down on each of the three fastened comers of the tilt alarm on the ground controls.
The alarm should sound as each comer is pressed beyond 5 degrees.
MANUAL92375-001
April 1998
• GROUND OPERATION AND CHECKS (Continued)
• While pressing the "OPERATE CONTROLS" button, press and hold "BOOM" toggle
to the "UP" position. Raise the boom to the end of its travel. Then, release the "BOOM" toggle.

Check for any vibration 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 during boom travel.
Report to supervisor and repair any problem.
• Press and hold the "BOOM" toggle to lower the boom slightly.
• Press the "EMERGENCY STOP" button. All machine functions must stop, including the engine.
Pull the button out or twist to reset. Release the "OPERATE CONTROLS" button.
With the engine off,
• Press the "EMERGENCY" button.
• Press and hold the "BOOM" toggle to lower the boom slightly.

Check for any vibration while the boom travels down.
• Once boom movement had been established using the emergency pump, release the
"EMERGENCY" button and "BOOM" toggle. Restart engine.
• Return the booms to their stowed positions by using the appropriate toggles for "RETRACT"
and "DOWN" correspondingly, and the "OPERATE CONTROLS" button.

Check for any vibration while the booms lower and retract.
• Operate the "SWING" toggle in each direction while holding the "OPERATE CONTROLS"
button.

Check for any vibration while the turret swings up.
• Release the "SWING" toggle.

MANUAl9237tHJ01
April 1998
GROUND OPERATION AND CHECKS (Continued)
• Press the "EMERGENCY STOP" button. All functions (including engine) must stop
immediately. Pull the button out or twist to reset. Restart engine.
• Return the machine to the stowed position by pressing appropriate toggle switches
correspondingly, as well as the "OPERATE CONTROLS" button.
• Shut the engine off.
PLATFORM OPERATION AND CHECKS
• Complete Ground Operation Checks before performing Platform Operation Checks.
• Select "PLATFORM CONTROLS" with the "GROUNDIPLATFORM" Key switch.
• Enter the platform. Close gate securely.
• Ensure that the "EMERGENCY STOP" button is released.
• Move "OFF/ON/START" toggle to center position to tum ignition "ON", down to

engage starter, then release it to the "ON" position.
• Flip the "ENGINE THROTTLE" toggle to "OPERATING SPEED".
A WARNING
BE SURE BOOM TRAVEL AREA IS CLEAR OF OBSTRUCTIONS.
DO NOT OPERATE MACHINE IF THESE CHECKS REVEL ANY

DEFECT OR ABNORMALITY.
• Press the "HORN" button briefly to check that the hom works. The hom also acts as a
signal for the tilt alarm as well as its normal warning function.
• Depress the foot switch mounted on the floor of the platform. (Activate foot switch
to operate any of the machine functions.)
• Slowly move the "JIB BOOM" lever forward to the "JIB UP" position. The jib boom will
start to rise. Function speed will be proportional to handle movement. Raise the jib boom to the
fully raised position (approximately 10° above the main boom). Slowly return the lever to the
center position.
MANUAl 92375.001
April 1998
• PLATFORM OPERATION AND CHECKS (Continoed)
• Slowly move the "BOOM/SWING" lever forward to the "BOOM UP" position. The main boom
will start to rise. Function speed will be proportional to handle movement. Raise the boom to the
horizontal position. Slowly return the lever to the center position.
• Slowly move the "EXTENDIRETRACT" lever back to the "EXTEND" position. Extend
boom out a short distance. Extend speed will be proportional to handle movement.

Check for any vibration while the boom telescopes out.
• Slowly return the lever to the center position.
• Slowly move "BOOM/SWING" lever forward to "BOOM UP" position. The main boom
will start to rise. Function speed will be proportional to handle movement.

Check for any vibration while the main boom travels up.
• Slowly return the lever to the center position.
• Return the booms to the travel position by slowly operating the levers in the "RETRACT" and
"BOOM DOWN" directions correspondingly.

Check for any vibration while booms lower and retract.
• Slowly return the levers to their center positions.
Slowly move the "BOOM/SWING" lever right to swing right (counterclockwise) and left to
swing left (clockwise). Swing speed will be proportional to handle movement.

Check for any vibration while the unit rotates.
Slowly return the lever to the center position.
• Operate the platfonn rotate function by moving the "PLATFORM ROTATE" toggle .
Move the toggle in both directions.

Check for any vibration while the platfonn rotates.
MANUAL92375-001
April 1996
PLATFORM OPERATION AND CHECKS (ContinUed).
• Return the platform to the center position with the "PLATFORM ROTATE" toggle.
• Operate the platform level function by moving "PLATFORM LEVEL" toggle. Move
the toggle in both directions.

Check for any vibration while platform tilts forward or back.
• Return the platform to a level position with the "PLATFORM LEVEL" toggle.
• Switch the machine "FUNCTION SPEED" toggle to "LOW".
IMPORTANT: JIB BOOM SHOULD BE RAISED FOR SUFFICIENT GROUND

CLEARANCE.
Ir--A.--W-M-N-IN-G-'
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 "DRIVE" lever forward. The machine should smoothly accelerate in the
forward direction.
Movement alarm sounds whenever the machine is in motion.

Check for any vibration while the unit travels.
• Operate the "STEER" rocker switch and check for proper steering control. Note position
of the platform to the steering wheels. (If so equipped, operate the optional rear steering by
flipping the "STEER SELECT" switch.)
• Return the wheels to the straight ahead position.
• Slowly move the "DRIVE" lever backward. The machine will smoothly accelerate in the
reverse direction.
Movement alarm sounds whenever the machine is in motion.
• Press "EMERGENCY STOP" button. All functions (including engine) must stop immediately.
MANUAL92375-001
Apn11998
e PLATFORM OPERATION AND CHECKS (CONTINUED)
I 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

IMMEDIATELY!
• Reset "EMERGENCY STOP" button by turning or pulling, and restart engine.
• Raise the main boom to above horizontal, and repeat the drive tests. Machine should
travel a maximum of 0.5 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 main boom raised br extended.
NOTE: At "creep speed", a tire makes one complete revolution in

approximately twenty (20) seconds. If one revolution takes much less
than this time, the machine must be adjusted to bring the "creep speed"
back down to 0.5 M.P.H. (0.8 K.P.H.).
• Return the machine to the straight ahead position, with main boom below horizontal
and fully retracted. Positionjib boom for adequate ground clearance for travel.
• Switch the "MAClllNE FUNCTION SPEED" toggle to "HIGH", and repeat the drive tests.
• Move all levers and toggles back to their neutral positions. Release the foot switch.
NOTE: All machine motion should stop upon release of the foot switch.
• Flip "OFF/ON/START' toggle to the "OFF" position to shut offthe engine.
• While pressing the "EMERGENCY PUMP" pushbutton, slightly raise the jib boom.
Then returnjib boom to stowed position.
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 valve levers 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.
MANUAl92375-001
April 1998
BOOM OPERATION
The boom operation includes SOFT-TOUCH CONTROL which automatically slows
the boom motion down in high reach positions for safer operation and also controls the
amount of side reach by automatically retracting when booming down into extreme side
reach positions. See the following Working Range Diagrams for operation zones.
A CAUTION
Booming down at the extreme positions will result in the boom retracting to closely
follow the side reach curve.
Platform Operation
Depress the deadman foot switch and the engine will rev up to the required RPM. Then
move the required function and the following will move.
Ground Operation
Lift the OPERATE FUNCTIONS switch and simultaneously move the required function
switch and after a short delay, the engine will rev up and the function will move.
MANUAl92375-001
April 1998
T60 wORKING RANGE DIAGRAM
-10 10 20 30 40 50
(-305M) GOSM) (6,09M) (914fD (l2.l9r~) (l5.24M)
SO
(2439M)
70
(21.34fD
AUTOMATIC SLOW SPEED
BOOM DOWN ZONE
AUTOMATIC RETRACT TO FDLLOW7
CURVE WHEN BOOMING DOWN
60
(lS,29M)
AUTOMATIC"
SLOW SPEED \
BOOM UP
ZONE I 50
(15 24M)
I 40
(121914)
30
L : / N
; ;\
I
\
(914fD
I
/ i
.:"
\ 20
(6091·1)
1M
II _ 10
GOSl-Il
-10
(-]05,1)
MANUAl92375-001
April 1998
-10
(-3.05M)
T66J 'WORKING RANGE DIAGRAM
10
G051~)
20
(6,09M)
30
(9,14fl)
40
(l2.l9H)
50
(l5,24M)
•
80
(24.391-1)
70
(21.34M)
AUTOMATIC RETRACT
TO FOLLO'W CURVE
7
W'HEN BOOMING DO'WN
60
(lB.29M)
AUTOMATIC
SLOW' SPEED
BOOM UP
ZONE
50
(l524fl)
40
(]219fl)
30
(9WIl
20
(SQ9fn
10
G05fl)
-10
(-3.05fl)
MANUAL92375-001
April 1998
CD
DRIVING AND STEERING
A WARNING
ENSURE THAT THE ROUTE OF TRAVEL IS CLEAR OF PERSONNEL AND
DEBRIS.
Depress the foot switch. Slowly push the "DRIVE" 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 ofthe 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 over the non-steering axle.
The stowed position can be identified by the large "FORWARD" arrows on the undercarriage,
or by the line up ofthe lock pin holes. When driving with the platform over the opposite axle,
remember that 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 slow the
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.
A 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.
MANUAl92375-001
April 1998
GASOLINE ENGINE OPERATION
• To start engine, press "START" button and the "CHOKE" button (at ground station),
OR press and hold the "ENGINE THROTTLE" toggle to "CHOKE" and the
"OFF/ON/START" toggle to "START" (at platform).
• As soon as the engine starts, release both switches.
DUAL FUEL ENGINE OPERATION
GASOLINE OPERATION
• Operate the machine as normal.
GASOLINE TO PROPANE SWITCHING
This option is done from the Ground Controls. The unit may be switched with engine
running or not running.
• Open valve on propane tank.
• Switch selector switch to off position so all unburned fuel will be consumed.
• Switch to "L.P" on selector switch. Start engine as in normal manner.
NOTE: Doing this procedure may shut off ignition circuit if engine has not started
after six seconds, tum key switch off then back to "Ground" or "Platform" and restart.
PROPANE TO GASOLINE SWITCHING
This procedure is just opposite of switching gasoline to propane.
NOTE: While doing either procedure while engine is running their mayor may not
be a hesitation depending on weather conditions.
DIESEL ENGINE OPERATION
FOR DIESEL ENGINES EQUIPPED WITH GLOW PLUGS:
• Press the "GLOW PLUG" button (at platform or ground controls), and hold for 30
to 45 seconds (when the engine is cold) prior to engaging the starter motor.
MANUAl92375-001
April 1998
• SHUT -DOWN PROCEDURES
• When finished with the machine, place the booms in the stowed position.
• Park the unit on a level surface.
• With all toggles/levers to "NEUTRAL" position, allow the engine to slow to idle speed.
• Tum "OFF" the "GROUNDIPLATFORM" key switch. Remove key to prevent

unauthorized operation.
MOVING JOB SITE TO JOB SITE
UNLOADING PROCEDURES
A WARNING
TO AVOID A SERIOUS PERSONAL INJURY OR DEATH, ENSURE
THAT THE MACHINE IS IN "LOW" DRIVE SPEED WHILE UNLOADING
FROM A TRUCK OR TRAILER.
• 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).
• Remove the pin that locks the turret to the undercarriage near the swing bearing.
Stow the lock pin in the location provided nearby.
• Remove all machine tie downs. Remove wheel chocks, if used. Switch the
"GROUNDIPLATFORM" key switch to "PLATFORM".
• Enter the platform, and restart the engine using the platform controls. Select the "OPERATING"
engine speed, 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 offthe 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 "Predelivery Inspection Report" must
be completed and returned in order to activate the Time Condor Limited Warranty.
MANUAL92375-001
April 1998
TRUCK OR TRAILER TRANSPORT
UNASSISTED LOADING OR UNLOADING OF ANY MOBILE PLATFORM IS

NOT RECOMMENDED.
1. Enter the platfonn, secure the safety gate, and start the engine using the platfonn
controls. Select the engine "OPERATING SPEED".
2. Raise the main and jib booms to allow greater ground clearance so that the platfonn
will clear any obstacles as the machine goes up the loading ramp.
3. Carefully drive the unit onto the truck or trailer.
4. Lock the superstructure to the undercarriage by installing the lock pin provided.
5. Ensure that the main boom is fully retracted. Next, the jib boom tip should rest on the
truck or trailer bed. Then, use the platfonn level lever to rest the platfonn base on the
bed of the truck or trailer, but do not apply pressure onto bed.
6. Tie down locations are located on all four comers of the undercarriage and at the
base of the jib boom. Use four (4) 1/2 inch, "Grade 7" chains from each of the tie down
lugs, and run the chains as shown in the diagram below.
Ratchet type load binders are recommended. If using lever type load binders, wire or
strap them shut, or wrap chains around them to prevent opening.
TRANSPORTING THE UNIT
TOWING PROCEDURES
WITHOUT OPTIONAL TOWING PACKAGE:
• If optional towing package is not installed, refer to "UNPOWERED EMERGENCY

MOVEMENT" in this section.
WITH OPTIONAL TOWING PACKAGE:
• Securely attach the T60 to a tow vehicle with the tow bar provided.
• Disengage torque hubs:
A WARNING
MANUAl92375-001
April 1998
• WHENEVER DISENGAGING THE DRIVE TORQUE HUBS OR BEFORE
DISCONNECTING FROM TOWING VEHICLE, ENSURE THAT THE UNIT
CANNOT ROLL.
Type 1: remove the plate in the center of the torque hub, tum the plate so
that the boss faces in, then reinstall the plate.
Type 2: remove the large hex cap in the center ofthe torque hub, push in
and tum screw slot in the center ofthe torque hub to line up with
the "TOW" mark on the hub, then reinstall the cap.
• Pull steer wander control valve, located near the ground controls, to allow steering
wheels to track behind tow vehicle.
The tow vehicle must have sufficient braking capability in order to safely stop itself as
well as the T60. Tow speed shall not exceed 3 MPH (4.8 KPH).
MANUAl92375-001
April 1998
EMERGENCY SYSTEM AND PROCEDURES 0
.. DANGER
IF THE UNIT FAILS TO OPERATE WHEN THE PLATFORM IS RAISED OR
EXTENDED, DO NOT ATTEMPT TO CLIMB DOWN THE BOOM ASSEMBLY.
SERIOUS INJURY MAY RESULT.
EMERGENCY PUMP
The T60 has an emergency pump which can be operated from the operator's platform or
ground controls to safety return the platform to the ground position when the unit has lost
engine/pump power. Operation from the ground controls override platform controls.
• Press and hold the "PUMP" toggle to "EMERGENCY" on the remote pendant controls,
OR
• Press and hold the "EMERGENCY PUMP" button on the platform control console.
Select the proper function (boom retract, boom lower, or swing) as required to safely lower
the platform to ground level.
To prevent the battery from completely discharging and the emergency pump from
overheating, release the emergency pump button to allow a 30 second rest period after
every 30 seconds of operation. Once the unit has been safely positioned, correct the cause
of the failure before returning the unit to service.
UNPOWERED EMERGENCY MOVEMENT
• Every attempt should be made to restore engine/pump power to the unit before using
this procedure.
.. DANGER
TillS PROCEDURE REQUIRES RELEASING THE VEHICLE BRAKES,
WIDCH RESULTS IN NO MEANS TO STOP THE UNIT'S TRAVEL.
TIME CONDOR RECOMMENDS USING TillS 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.).
MANUAL92375-001
April 1998
• UNPOWERED EMERGENCY MOVEMENT (CONTINUED)
1. Secure the unit chains or ropes.
The T60 is equipped with tie down lugs (front and rear of undercarriage) 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. Close brake circuit needle valve located at the center rear of the undercarriage.
4. Disengage torque hubs:
A WARNING
WHENEVER DISENGAGING THE DRIVE TORQUE HUBS OR BEFORE
DISCONNECTION FROM TOWING VEmCLE, ENSURE THAT THE UNIT
CANNOT ROLL.
Type 1: remove the plate in the center of the torque hub, tum the plate so
Type 2: remove the large hex cap in the center of the torque hub, push in and
tum screw slot in the center of the torque hub to line up with
5. Disconnect steer cylinder.
After unchocking the wheels, the unit will be ready to be moved.
After engine/pump power has been restored to the machine, engage the torque hubs, reset
the brake circuit needle valve, and connect steer cylinder. The machine is now ready for
normal operation.
MANUAl92375-001
April 1998
EMERGENCY LOWERING
It is not possible for us to foresee every emergency situation that could arise during
operation of this machine. Information on the following pages describes three typical
emergency situations, and lists appropriate actions that can be taken.
When faced with an emergency, above all please remember:
• Stay calm.
• Think through the situation before operating the machine.
• Get help if necessary.
SITUATION ONE: Platform elevated, operator not incapacitated, but unit will not
respond to platform controls.
PossmLE CONDITION:
• One or more functions not operating correctly.
• Unit movement from unselected lever.
• Unit function will not stop unless power is switched off.
CORRECTIVE ACTION
1. Remove foot from foot switch.
2. Push the red "Emergency Stop" Button.
3. Evaluate the nature of the failure. Return to the ground, using the emergency pump and
lowering procedure (see "Emergency Pump", earlier in this section).
.. DANGER
DO NOT TRY TO CLIMB DOWN THE BOOM.
HAVE AN EXPERIENCED OPERATOR USE THE EMERGENCY PUMP TO

SAFELY LOWER THE PLATFORM.
MANUAL92375-001
April 1998
• 4. If unable to return to the ground using the platfonn controls and the emergency pump,
contact an experienced operator to lower the machine with the emergency pump using
the remote pendant controls (see "Emergency Pump", earlier in this section).
5. Report the incident to your supervisor immediately.
SITUATION TWO: Unit elevated, with operator incapacitated at platform controls.
& DANGER
DO NOT TOUCH UNIT!!!
DETERMINE THE CAUSE OF THE PROBLEM BEFORE YOU TOUCH THE

MACHINE.
CORRECTIVE ACTION
1. Have someone summon first aid or rescue squad.
2. Attempt to talk to operator before taking any rescue measures.
3. Check to see if the operator is in a pinned position, or would be endangered

if platform is moved, before attempting emergency lowering procedure.
4. After establishing that the machine is not in contact with live power lines, lower the
platfonn using the emergency lowering procedure (see "Emergency Pump", earlier
in this section).
5. Render first aid to the operator.
IMPORTANT: Any incident involving personal injury must be immediately

reported to the local Time Condor Corporation.
MANUAL9237s.oo1
April 1998
SITUATION THREE: Platform in contact with live power lines and operator
incapacitated.
... DANGER
DO NOT TOUCH UNIT !!!
ELECTROCUTION HAZARD !!!
CORRECTIVE ACTION
1. Contact authorized personnel to disconnect power supply touching unit.
3. If operator is unconscious, check to see ifhe is in a pinned position, or would be

endangered ifplatform is moved.
4. AFTER POWER IS CUT, use the emergency lowering procedure to bring platform
with operator to a safe location to render first aid (see "Emergency Pump", earlier
in this section.)

MANUAl9237~1
April 1998
MACHINE SPECIFICATIONS
T60 T66J
WorkingHght. 66' 20.12m 72' 21.95m
PlatformHght. 60' 18.29m 66' 20.12m
Stow. Height 7'11"> 2.42m 7'11" 2.42m
Stow. Length ··28'211 8.59m 32'4" 9.86m
Overall Width 7'lfi' 2.42 m 7'11" 2.42 m
Platform Cap. $OOlbs 226.8 kg SQOlbs 226.8 kg
Platform Size 6Qu",3§"J.5xO.9m 6()"x36" 1.5xO.9m
Horiz. Reach 4'7' 14.33 m 47' 14.33 m
Tail Swing .' 3'61/~" 1.08 m 3'6 / 2" 1.08 m
~
1
In. TurnRad. 8''/''

8
2.46m 8'7/'i
8
2.46m
Out.TurnRad. 18'11J4 " 5.52m 18'11/4" 5.52m
Gradeability 30% 30% 30% 30%
Travel Speed 525mph8.45 kmh 5.25 mph 8.45 kmh
Ground Clear. 1()1/2"26.67 em lOlJ2" 26.67 em
Tire Size 12 x16.512 x 16.5 12 x 16.512 x 16.5
Jib Length N/A N/A 6' 1.83 m
Jib Rotation N/A N/A 135 0 135 0
Turret Rotat. 3600 C 3600 C 3600 C 3600 C
Plat. Rot. (hyd.) 1600 1600 1600 1600
Power Souree Gas Gas Gas Gas
Gross Weight 18,6001bs 8437 kg 18,6001bs 8845 kg
Wheel Base 8' 2.44 m 8' 2.44 m
Fuel Tank Cap. 40 gal 151.411 40 gal 151.411
Hyd. Tank Cap. 45 gal 170.341 45 gal 170.341
MANUAl92371HJ01
Apri/1998
ATTENTION
MANUAL OF RESPONSIBILITIES
for
Dealers, Owners, Users, Operators,
Lessors and Lessees
of
ANSIISIA A92.5-2006
Boom-Supported Elevating Work Platforms
WARNING
FAILURE TO COMPLY with your REQUIRED
RESPONSIBILITIES in the use and operation of the Aerial
Platform could result in DEATH OR SERIOUS INJURY.
IMPORTANT
You are required by ANSI/SIA A92.S-2006 to read and understand YOUR

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

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

platfonn and for further INFORMATION OPERATION.
The ANSI/SIA A92.5-2006 ".oU'Y"'L Elevating Work Platfonns became

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

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

the sum of the moments which tend to overturn the unit
3 Definitions exceeds the sum of the moments tending to resist
overturning.
Aerial platform: A mobile device that has an adjustable Insulated platform: A platform designed and
position platform, supported from ground level by a to meet the specific electrical insulation
structure. consistent with the manufacturer's u'....,••" . .'vi.'''
Alternative configuration(s): Arrangements of the Interlock: A control or mechanism
aerial platform or its components which differ from each specified conditions, automatically
other. Alternative configurations mayor may not have the operation of another control or
the same rated workload. Lessee: A person(s) or entity
Anchorage(s): A secure point of attachment to be used platform is provided by
with personal fall protection equipment (PFPE). arrangement. A lessee may
Authorized personnel (authorized person): Personnel user or operator.
apP.roved or assigned to perform a specific type of duty or Lessor: A
dutIes at a specific location or locations at a work site.
Base: The relevant contact points of the aerial platform
that form the stability fulcrum (e.g., wheels, casters,
outriggers, stabilizers).
Boom: A cantilever beam which supports the platform.
Broker: An independent business entity or person that
arranges a lease or transfer of ownership of an aerial
platform, but does not own the aerial platform. If the : A document containing
entity or person is an employee of the buyer, seller, lessor 3) and the requirements
or lessee of the aerial platform, he shall not be vUJllMUCl this Standard for the following entities:
a broker. 5); Owners (Section 6): Users
Operators (Section 8); Lessors (Section 9);
Chassis: The integral part of the aerial platform
(Section 10); and Brokers (Section 11).
provides mobility and support for the
~Hllfal~tlllrer: A person or entity who
Configurations: All positions in which an
platform or any part thereof can be placed makes, builds, or produces an aerial platform.
intended operating limits. Maximum travel height: The maximum platform
Critical component(s): Load height or the most adverse configuration(s) with
respect to stability in which travel is permitted by the
support or stabilize the 1..HO'UlJP111Jl.rl
manufacturer.
Dealer: A person or entity
manufacturer or U,,,llllJUL\ Modification, modifies: To make a change(s) to an
and services aerial aerial platform which affects the operation, stability,
safety factors, rated load, or safety of the aerial
Delivery:
platform in any way.
custody of the or entity to
another Most adverse stability conditions: The permitted
configuration of the aerial platform most likely to cause
instability. Factors to be considered shall include:
1 With zero load to maximum test load.
a minimum
2. Up to and including maximum platform height.
(50.8mm).
3. All positions and configurations of the platform(s).
The mechanisms used to position
4. All wheel and axle positions.
to the aerial platform chassis.
5. Forward and backward configurations of the
Providing information regarding the
elevating assembly.
and safety devices for the aerial
6. All other moveable features which affect the
to a qualified person or operator who controls
stability of the aerial platform.
of an aerial platform.
Multiple rating(s), multiple rated loads: Two or
system: A vertical barrier primarily intended
more different rated work loads based on alternative
against personnel falling to lower levels.
configurations of the aerial platform.
Hazardous location: Any location that contains, or has
Non-ductile materials: Materials having an
the potential to contain an explosive or flammable
elongation ofless than 10% in 2 inches (50.8mm).
atmosphere as defined in ANSIINFP A 505 for Powered
Operation: Performance of functions of an aerial
Industrial Trucks, Including Type Designations, Areas of
platform within the scope of its specifications and in
Use, Maintenance, and Operation.
accordance with the manufacturer's instructions, the
2
user's work rules, and applicable governmental Should: The word "should" indicates that the rule is a
regulations. recommendation, the advisability of which depends on
Operator: A qualified person who controls the the facts in each situation.
movement of an aerial platfonn. Stability/Stable: A condition of an aerial
Outriggers: Devices that increase the stability of the which the sum of the moments which tend
aerial platfonn and that are capable of lifting and leveling the unit is less than the sum of the t11{1,t11pnt...
the aerial platfonn. resist overturning.
Override: To take over aerial platfonn movement Stabilizers: Devices that increase
control functions at the upper control station by those at aerial platfonn but are not capable
the lower control station. the aerial platfonn.
Owner: A person or entity who has possession of an Training: Instruction to
aerial platfonn by virtue of proof of purchase. a qualified person regarding
Passive: Under specified conditions, automatically including knowledge
perfonned and not requiring any specific action to Unintended
accomplish.
Platform: The portion of an aerial platfonn intended for
occupation by personnel with their necessary tools and maximum
materials. aerial platfonn
Platform height: The vertical distance measured from in all operating
the floor of the platfonn to the surface upon which the
aerial platfonn is being supported. ) that has care, control,
Platform reach: The horizontal distance measured from platfonn. This person or
the center line of rotation to the outer most edge of the also be the employer of the operator, a
platfonn. owner, lessor, lessee, or operator.
Powered functions: Those which control motion of •.,,,.....,,,, of Dealers
platfonn or the aerial platfonn and are caused by Principles. Sound principles of
electromechanical, hydraulic, or pneumatic , training, inspection, maintenance, application,
Qualified person: One who, by possession operation consistent with all data available
recognized degree, certificate, or professional regarding the parameters of intended use and expected
by extensive knowledge, training, environment shall be applied in the training of
successfully demonstrated his/her operators, in maintenance, application, safety
resolve problems related to the provisions and operation of the aerial platfonn with due
or the project. consideration of the knowledge that the unit will be
Rated horizontal force: carrying personnel.
horizontal force at the 5.2 Manuals
aerial platfonn as 5.2.1 Machine Manual(s). Dealers shall keep and
Rated work load: maintain a copy(ies) ofthe:
(l) Operating manual
(2) Maintenance manual
(3) Parts manual
(4) Repair manual
The operating manual and maintenance manual shall be
provided with each rental, lease, or sale delivery and
shall be stored in the weather resistant storage
compartment on the aerial platfonn. Manual(s) are
The modification of an aerial platfonn, considered an integral part of the aerial platfonn and
its original manufacturer or another qualified are vital to communicate necessary safety infonnation
that the aerial platfonn will comply with the to owners, users and operators. In addition, repair
in effect on the date the modification is and parts manuals should be provided with each sale
delivery.
Repair: The act of restoring to good condition that 5.2.2 Manual of Responsibilities. The current
which has been broken, damaged or worn due to use, Manual of Responsibilities for dealers, owners, users,
abuse or other reasons. operators, lessors, lessees and brokers of boom-
Shall: The word "shall" is to be understood as supported elevating work platfonns shall be provided
mandatory. and stored in the weather resistant storage
compartment.
3
Reprint from ANSI/SIA A92.5-2006 RESPONSIBILITIES MANUAL
5.3 Predelivery Preparation. Aerial platforms shall of use), the dealer shall assume the responsibilities of
be inspected, serviced and adjusted to manufacturer's users as specified in Section 7 of this standard. All
requirements prior to each delivery by sale, lease, or personnel authorized to operate the aerial PlaltIO,rm
rental. shall have been:
5.4 Maintenance, Inspection and Repair. (1) Trained
5.4.1 Maintenance. When a dealer accomplishes (2) Familiarized with the aerial
preventive maintenance on the aerial platform, it shall be operated
in accordance with the manufacturer's recommendations (3) Made aware of the reS1POncSlO'111
and based on the environment and severity of use. operators as outlined in Section 8
5.4.2 Inspection. When the dealer accomplishes standard
frequent and annual inspections, they shall be in 5.10 Assistance to
accordance with the manufacturer's manuals and unable to answer an owner's
instructions. relating to rated
5.4.3 Repairs. Repairs accomplished to correct repair, inspection,
malfunctions and problems shall be in accordance with the dealer shall
the manufacturer's manuals and instructions.
5.5 Maintenance Safety Precautions. Before
adjustments and repairs are started on an aerial platform,
the following precautions shall be taken as applicable:
(1) Power plant stopped and starting means rendered
inoperative at least four years:
(2) All controls in the "Off' position and all operating of the purchaser of each aerial
systems secured from inadvertent motion by brakes, number and date of delivery
blocks, or other means of the pre-delivery preparation
(3) Boom and platform lowered to the full down to each delivery
position, if possible, or otherwise secured by Records of frequent and annual machine
cribbing to prevent dropping accomplished
(4) Hydraulic oil pressure relieved from Records of repairs accomplished to correct
circuits before loosening or removing malfunctions and problems
components (5) Name of the person(s) trained
(5) Safety props or latches (6) Name of the person(s) providing the training
as prescribed by the U>C'Luu.a" (7) Date of Training
5.6 Replacement Parts. (8) Name ofperson(s) receiving familiarization with
replaced, they shall be the aerial platform upon each delivery unless this
aerial platform parts or individual has been provided with familiarization on
5.7 Training. the same model, or one having characteristics
The dealer shall consistent with the one being delivered, within the
requirements prior 90 days
inspection, 5.11.2 Proof of training. The dealer should
operation of the aerial provide trainees who successfully complete training a
means to evidence they are trained. The dealer shall
Delivery. provide such proof if requested by the trainee. The
sale, rental or any form of use, document evidencing training shall include the
the responsibility with the person following information:
receiving entity for accepting the aerial (1) Name of trainee
(2) Name of entity providing training or retraining
the weather resistant compartment (for (3) Name oftrainer(s)
storage) (4) Clear identification that training covered Boom-
,",V<JLHU,U that the manual(s), as specified by the Supported Elevating Work Platforms
are on the aerial platform (5) Date of training
(3) Review control functions 5.11.3 Record dissemination. Upon request, the
(4) Review safety devices specific to the model aerial dealer shall provide the following information:
platform being delivered (1) To the owner of the aerial platform, a copy of
5.9 Dealer as User. Whenever a dealer directs frequent or annual inspections performed
personnel to operate an aerial platform (loading, (2) To the owner of the aerial platform, a copy of
unloading, inspecting, sales demonstrations, or any form repairs accomplished
4
(3) To a user, proof of training for an operator, is part of the aerial platform. The manual(s) is
including name of trainer and date of training considered an integral part of the aerial platform and is
(4) To a user, the name of the person(s) receiving vital to communicate necessary safety information
familiarization upon delivery of the aerial platform owners, users and operators. In addition, repair
5.12 Modifications. Modification, alteration or parts manual(s) should be provided with
remanufacture of an aerial platform shall be made only delivery.
with prior written permission of the manufacturer. 6.3.2 Manual of Responsibilities.
5.13 Manufacturer's safety bulletins. The dealer Manual of Responsibilities for
shall comply with safety-related bulletins as received operators, lessors, lessees and
from the manufacturer. supported elevating work
5.14 Responsibilities upon sale. When the aerial and stored in the weather
platform is sold, the dealer: compartment.
(1) Shall, upon delivery, ensure the operating and 6.4 Maintenance,
maintenance manuals are conveyed to the owner 6.4.1
(2) Shall, upon delivery, provide a copy of the current
Manual of Responsibilities
(3) Should, within 60 days of sale, provide repair and
parts manuals
(4) Shall, within 60 days of the sale, notify the
manufacturer or its successor (if existing) of the sale,
providing the full name and address of the purchaser
(5) Should, if the aerial platform is used, accomplish an
annual machine inspection
prior to delivery and provide a copy to the purchaser
within 60 days of the sale
(6) Shall, upon delivery, familiarize the person and problems identified in the inspection
designated by the receiving entity with the corrected before the aerial platform is returned
being acquired.
6 Responsibilities of Owners 6.4.3 Repairs. When the aerial platform is damaged
6.1 Basic Principles. Sound or in need of repair, all malfunctions and problems
training, inspection, maintenance, identified shall be corrected before the aerial platform
operation consistent with all is returned to service.
parameters of intended use and 6.5 Pre-delivery Preparation. Aerial platforms
shall be applied in the shall be inspected, serviced, and adjusted in accordance
of owners WIth due with the manufacturer's specifications prior to each
the aerial platform delivery by sale, lease, or rental.
6.2 n~:'I'UIII:!iIUIIJl~ 6.6 Frequent Inspection. The owner of an aerial
platform shall ensure that a frequent inspection is
performed in accordance with the manufacturer's
instructions, on an aerial platform:
(1) That was purchased used. This inspection shall
be accomplished unless it is determined that the
sixty (60) of acquisition of the frequent and annual inspections are current
. the manufacturer with the full (2) That has been in service for three months or 150
of the buyer along with the model and hours, whichever comes first
aerial platform acquired (3) That has been out of service for a period longer
the aerial platform is used, ensure the than 3 months
inspection and annual inspections are current The inspection shall be made by a person
become familiar with and conform to the qualified as a mechanic on the specific type
of owners as set forth in the Manual of aerial platform or one having similar design
Responsibilities for Boom-Supported Elevating Work characteristics. The inspection shall be in
Platforms accordance with items specified by the
6.3 Manuals manufacturer for a frequent inspection and shall
6.3.1 Machine Manual(s). Owners shall provide a include, but not limited to the following:
copy(ies) of the operating and maintenance manual(s) (1) All functions and their controls for speed(s),
with each rental, lease, or sales delivery by ensuring they smoothness, and limits of motion
are properly stored in the weatherproof compartment that
5
(2) Lower controls including the provisions for specified in Section 7 of this standard and shall ensure
overriding of upper controls the person has been:
(3) All chain and cable mechanisms for adjustment and (1) Trained
worn or damaged parts (2) Familiarized with the aerial platform to
(4) All emergency and safety devices operated
(5) Lubrication of all moving parts, inspection of filter (3) Made aware of the responsibilities
element(s), hydraulic oil, engine oil, and coolant as as outlined in Section 8 of this "t"t,r1",rrl
specified by the manufacturer 6.11.2 Assistance to user.
(6) Visual inspection of structural components and when an owner sells, leases, rents
other critical components such as fasteners, pins, shafts, platform for any form
and locking devices that time shall offer to do
(7) Placards, warnings and control markings
(8) Items specified by the manufacturer
(9) Emergency lowering means
6.7 Annual Inspection. The owner of an aerial
platform shall ensure that an annual inspection is
performed on the aerial platform no later than thirteen
(13) months from the date of the prior annual inspection. H;;o.I"'.0111. compartment (for
The inspection shall be made by a person(s) qualified as a
mechanic on the specific type of aerial platform or one as specified by the
having similar design characteristics. The inspection shall aerial platform
be in accordance with items specified by the manufacturer functions with the operator or
for an annual inspection. The owner shall not place the UvOIll",I.,au;;'u by the user
aerial platform into service until all malfunctions and safety devices specific to the model
problems have been corrected. being delivered
6.8 Maintenance safety precautions. Before Operation. When an owner operates an aerial
adjustments and repairs are started on an . the owner shall have the responsibilities of
the following precautions shall be taken as as specified in Section 7 of this standard and his
(1) Power plant stopped and starting means operating personnel shall have responsibilities of
inoperative operators as specified in Section 8 of this standard.
(2) All controls in the "Off' 6.14 Assistance to users and operators.
systems secured from in"£l,,,·rtpnt If an owner is unable to answer a user's or operator's
blocks, or other means question(s) relating to rated capacity, intended use,
(3) Elevating assembly maintenance, repair, inspection, or operation of the
down position, if jJV",,.."\ aerial platform, the owner shall obtain the proper
blocking or ,-,,,,Jun.,,," information from the dealer or manufacturer and
(4) Hydraulic provide that information to the user or operator.
circuits 6.15 Record Retention and Dissemination.
6.15.1 Record Retention. The owner shall date and
(5) retain the following records for at least 4 years:
(1) Name and address of the purchaser of each aerial
by the manufacturer platform by serial number and date of delivery
When parts or components are (2) Written records of the frequent and annual
be identical or equivalent to original inspections performed. The record shall include
or components. deficiencies found, corrective action accomplished and
training. The owners shall train identification of the person(s) performing the
un1ten:anc:e personnel in inspection and inspection and repairs
of the aerial platform in accordance with the (3) Written records of repairs accomplished on the
s recommendations and Sections 6.2, 6.3, aerial platform. The records shall include corrective
,6.6,6.7,6.8,6.9 and 6.11 of this standard and action accomplished and identification of the person(s)
with the manufacturer's recommendations. performing the repairs
6.11 Training (4) Pre-delivery preparation performed prior to each
6.11.1 Operator training. Whenever an owner directs delivery
or authorizes an employee to operate an aerial platform, (5) Name of the person(s) trained
(loading, unloading, inspecting or any form of use) the (6) Name ofperson(s) providing training
owner shall assume the responsibilities of the user as (7) Name ofperson(s) receiving familiarization upon
each delivery unless the individual has been provided
6
with familiarization on the same model, or one having 7.2.1 Machine manuals. Users shall keep and
characteristics consistent with the one being delivered, maintain a copy(ies) of the operating and maintenance
within the prior 90 days manual(s) in the weather resistant storage f''''Yln'"rhm
(8)Name ofperson(s) providing familiarization upon provided by the manufacturer. The manual(s)
delivery considered an integral part of the aerial
6.15.2 Proof of Training. Owners providing training vital to communicate necessary safety .
should provide successful trainees a means to evidence users and operators.
their training and shall provide such proof if requested by 7.2.2 Manual of Ke!ipOnSiitlili1tie§.
the trainee. The document evidencing training shall Manual of Responsibilities for
include the following information: operators, lessors, lessees and
(1) Name of entity providing training or retraining supported elevating work
(2) Name oftrainer(s) and stored in the weather
(3) Clear identification that training covered Boom- compartment.
Supported Elevating Work Platforms 7.3 Inspection
(4) Date of training inspect and . required to
(3) Name of trainee of inspection
6.15.3 Record dissemination. Upon request, an by the
owner accomplishing training and/or familiarization ~uu ..v"" and be compatible
shall provide the following: the severity of the
(1) To a user, proof of training for an operator, platforms that are not in
including name of trainer and date of training shall be immediately
(2) To a user, the name of the person(s) receiving until repaired. Repairs shall be
familiarization upon delivery of the aerial platform ........uu,,'y person and the repairs shall be in
6.16 Modifications. The owner shall not modify or with the manufacturer's
concur in modification or alteration to the aerial
without the modifications being approved and Frequent Inspection. Users of an aerial
writing by the manufacturer. shall ensure that frequent inspections are
6.17 Manufacturer's Safety Bulletins. <711',,,,,,,,,,, as outlined in Section 6.6 of this standard.
The owner shall comply with safety related 7.3.2 Annual Inspection. Users of an aerial
received from the manufacturer or platform shall ensure that annual inspections are
6.18 Responsibilities upon conducted as outlined in Section 6.7 of this_standard.
aerial platform, the seller: 7.3.3 Pre-start inspection. Before use each day or
(1) Shall, upon delivery, at the beginning of each shift, the aerial platform shall
maintenance manuals are be given a visual inspection and functional test
(2) Shall, upon including, but not limited to, the following:
Manual Reimonsilli.liltii (1) Operating and emergency controls
(3) Should (2) Safety devices
(3) Air, hydraulic and fuel system leaks
(4) Cables and wiring harness
(5) Loose or missing parts
(6) Tires and wheels
(7) Placards, warnings, control markings, and
information in this standard operating manual( s)
by good job management, safety (8) Outriggers, stabilizers, extendable axles and
I-'I.JJllv"'UVll of sound principles of safety, other structures
maintenance, application and (9) Guardrail system
V"''''''''"' with all data available regarding the (l0) Items specified by the manufacturer
of intended use and expected environment. 7.3.4 Maintenance Safety Precautions.
user has direct control over the application and Before adjustments and repairs are started on an aerial
of aerial platforms, conformance with good platform, the following precautions shall be taken as
practices in this area is the responsibility ofthe applicable:
user and the operating personnel, including the operator. (1) Power plant stopped and starting means rendered
Decisions on the use and operation ofthe aerial platform inoperative
must always be made with due consideration for the fact (2) All controls in the "Off' position and all
that the aerial platform will be carrying personnel whose operating systems secured from inadvertent motion by
safety is dependent on those decisions. brakes, blocks, or other means
7.2 Manuals
7
(3) Boom and platfonn lowered to the full down (6) Hazardous locations and atmospheres (reference
position, if possible, or otherwise secured by blocking or ANSIINFPA 505-1996)
cribbing to prevent dropping (7) Inadequate surface and support to withstand
(4) Hydraulic oil pressure relieved from all hydraulic load forces imposed by the aerial platfonn in
circuits before loosening or removing hydraulic operating configurations
components (8) Wind and weather conditions
(5) Safety props or latches installed where applicable (9) Presence of unauthorized "'M',U"'"
as prescribed by the manufacturer (10) Other possible unsafe ,..",""rtn"
(6) Precautions specified by the manufacturer 7.9 Determination of
7.4 Replacement Parts. When parts or components are be the responsibility of the
replaced, they shall be identical or equivalent to original classification of the intended
aerial platfonn parts or components. Aerial platfonns operated in
7.5 Maintenance Training. The user shall ensure be approved in
only qualified personnel inspect and maintain the aerial required, by
platfonn in accordance with the manufacturer's 7.10
recommendations and Section 7.3, 7.4 and 7.6 of this
standard and with the manufacturer's recommendations.
7.6 Operator Training and Retraining. .,.,n,nffi,r their perfonnance and
Whenever a user directs or authorizes an individual to the use, application, and
operate an aerial platfonn, the user shall ensure that the ".u.UJ ..... is in confonnance with
person has been: Section 8 of this standard,
(1) Trained before being assigned to operate the aerial hazards, provide means to
platfonn lUemlIleo hazards, and explain the
(2) Familiarized with the aerial platfonn to be ope:rat<~ of not following proper
(3) Made aware of responsibilities of operators as ,UIU.I;""1"'''. Instructions and guidelines
outlined in Section 8 of this standard proper operation shall include, but not
(4) Retrained, if necessary, based on the be limited to the following issues and
observation and evaluation of the operator.
7.6.1 Trainee Records. A record of the (1) Fall Protection. Principal fall protection is
aerial platfonn instruction shall be provided by the guardrail system. The user shall direct
for at least four (4) years. and monitor the operator to ensure that all components
7.7 Familiarization Before U of the guardrail system are in place. The user shall
only properly trained personnel direct and monitor occupants of the work platfonn to
platfonn. The user shall ensure that they wear a personal fall arrest system to
operator is familiar with protect against the potential effects of ejection or a fall
to be operated, and restraint system to prevent free fall.
(1) Knows (a) Election of Systems: The user may elect to
for manual(s) use either a restraint or an arrest system
(2) Knows maUnt:emmc:e manuals 1. Fall Restraint Systems - An anchorage, belt or
supplied by the stored in the weather harness and a lanyard which prevent free fall. These
resistant r.{)1'Y1n.~nl'Y1, «U'.U11o<11 with the operating systems are arranged to keep occupants in the platfonn
in the event of dynamic forces which might cause
ejection.
(1.1) Occupants shall use a restraint system to
understands all safety devices keep the occupant(s) within the platfonn.
aerial platfonn being used (1.2) Restraint systems may include either belts or
Inspection. Before the aerial platfonn harnesses and do not include arresting or deceleration
during use, the user shall check the area in devices.
aerial platfonn is to be used for possible 2. Fall Arrest System - An anchorage, full
such as, but not limited to: body harness and a lanyard used to arrest an employee
(1) Drop-offs or holes, including those concealed by in a fall from an aerial platfonn. Such systems allow a
water, ice, mud, etc. fall over the guardrail system. The force applied to the
(2) Slope(s) body shall be limited to 1800 lbs. (8,000N).
(3) Bumps and floor obstructions (2.1) A fall arrest system shall allow workers to
(4) Debris move around the platfonn but provide a minimum of
(5) Overhead obstructions and electrical conductors lanyard slack.
8
(2.2) A fall arrest system for aerial lifts shall include supervisor any problem(s) or malfunction(s) that
a lanyard, and full body harness. A deceleration device if become evident during operation. The user shall
used will not allow a fall further than that required to ensure all problems and malfunctions that affect
arrest the fall without exceeding 1800 lbs. (8,000N) of safety of operations are repaired prior to
force on the worker. Fall arrest systems, beyond the (12) Reporting potentially hazardous
anchorage, are not part of the aerial work platform and The user shall direct the operator to .
are to be specified and supplied by the user of the aerial to a supervisor any potentially HaL.ru.UIV'
work platform. that become evident during opl~ra1tlO];
(2) Slope and grade. The aerial platform shall not be (13) Hazardous location
operated in any manner on grades, side slopes or ramps aerial platforms not approved
exceeding those for which the aerial platform is rated by in a hazardous location shall
the manufacturer. (14) Entanglement. Care
(3) Deployment of stability enhancing means. rope, electric cords,
Outriggers, stabilizers, extendable axles, oscillating axles entangled in the
or other stability enhancing means shall be deployed and (15) LallaCI1l:
locked into place as required by the manufacturer. rated number exceeded when
(4) Guardrail system. Guardrails shall be installed at any height.
and positioned, and access gates or openings shall be direct the operator
properly closed per the manufacturer's instructions. the aerial platform is
(5) Distribution ofload. The load and its distribution pml1n1mpnT before lowering the
on the platform and any platform extension(s) shall be in
accordance with the engine (if applicable) shall be
manufacturer's rated capacity for that specific tanks are being filled. Fueling
configuration. in a well-ventilated area free of flame,
(6) Maintaining overhead clearance. The nn'F'T"t..... hazards that may cause fire or
shall be instructed to ensure that adequate
maintained from overhead obstructions and Battery charging. Batteries shall be charged in
electrical conductors and parts. ",...,uu.",u area free of flame, sparks, or other
(7) Electrocution hazard. All applicable hazards that may cause fire or explosion.
related work practices intended to electric (19) Improper platform stabilization. The aerial
covered by the Code of Federal (CFR) platform shall not be positioned against another object
1910.333 shall be defined and the operator to steady the platform or improve stability.
by a qualified person. In shall (20) Misuse as a crane. The aerial platform shall
direct the operator not be used as a crane.
qualifications to mannt:alf (21) Unusual operating support conditions. The
(MAD) from enelrgi~~d aerial platform shall not be operated from a position on
CFRI91O.333c. trucks, trailers, railway cars, floating vessels, scaffolds,
(8) The user or similar equipment unless the application is approved
shall direct personnel on the in writing by the manufacturer or a qualified person.
platform wear equipment (PPE) as (22) Travel speeds. The user shall direct the
required. operator to limit travel speed according to conditions,
"PT,,,.,,nnpl shall maintain a firm including the condition of the support surface,
while working thereon. congestion, visibility, slope, location of personnel, and
on the mid-rail or top-rail of the other factors leading to hazards which may cause
.uo£,hil"it".r! The use of planks, ladders, collision(s) or result in potential injury(ies) to
on the platform for achieving personnel.
or reach is prohibited. (23) Driving requirements. Before and during
rrE~Calllti(m for other moving equipment. When driving while the platform is elevated, the user shall
equipment and vehicles are present, special direct the operator to:
shall be taken to comply with local (a) Maintain a clear view of the support
ordinances or safety standards established for the surface and route of travel
workplace. Warnings such as, but not limited to, flags, (b) Ensure personnel in the worksite area
roped off areas, flashing lights, and barricades shall be that may be affected are aware of the
used as appropriate. movement, communicating and
(11) Reporting problems or malfunctions. The user maneuvering the aerial platform as
shall direct the operator to immediately report to a required to protect against personal
9
injury (35) Adequate support requirements. The user
(c) Maintain a safe distance from obstacles, shall ensure the support surface is adequate for the
debris, drop-offs, holes, depressions, aerial platform and the load carried.
ramps, and other hazards to ensure safe (36) Leveling the aerial platform.
travel leveling devices supplied by the manuf'actlure.l
(d) Maintain a safe distance from overhead utilized to level the aerial platform when
obstructions and energized electrical conductors. (37) Protecting against l1n,o .. tlhnr'i ..
(24) Stunt driving. Stunt driving and horseplay are user shall direct the operator not to
prohibited. provide the aerial platform for any
(25) Securing the aerial platform. The user shall use unless so authorized.
direct the operator to implement means provided to 7.11 User as Operator. If
protect against use by an unauthorized person(s). of an aerial platform, the user
(26) Altering safety devices. Interlocks or other safety responsibilities of
devices shall not be altered or disabled. this standard as
(27) Snagged platform. If the platform or elevating
assembly becomes caught, snagged, or otherwise
prevented from normal motion by adjacent structures or ;eniOnnel to cease
other obstacles such that control reversal does not free the Incase of any
platform, all personnel shall be removed from the aerial platform, or any
platform before attempts are made to free the platform condition('S) that may be
using lower controls. further information as to
(28) Vacating (or entering) an elevated aerial owner, dealer, or manufacturer
platform. If permitted by the manufacturer, personnel operation of the aerial platform.
shall only vacate or enter a raised aerial platform by Retention and Dissemination.
following the guidelines and instructions provided by Retention. The user shall retain the
manufacturer. records for at least 4 years:
(29) Modifications. Modification or Names of the operator(s) trained and retrained
aerial platform or the fabrication and attlcbllnt Names of operator(s) provided familiarization
frameworks, or the mounting of attachments (3) The owner (or the entity designated by the
tools or materials onto the platform owner) is responsible to ensure frequent and annual
system shall only be accomplished inspections are conducted and written records are
permission of the manufacturer. maintained. The records shall include the date of the
(30) Assistance to the nn'~r,.tl inspection, any deficiencies found, the corrective action
encounters any suspected recommended and identification of the person(s)
platform, or any hazard performing the inspection.
relating to capacity, '.' (4) When employees of the user accomplish repairs
aerial platform, on the aerial platform, the user shall maintain written
aerial plaltto,rm records. The record shall include the date of repair, a
user. description of the work accomplished and identification
Any problem(s) or of the person(s) performing the repair.
of operations shall be 7.13.2 Record Dissemination
aerial platform. (1) When the user directs personnel to accomplish
...."t",riii>h, (larger than the platform). frequent or armual inspections, not later than 60 days
that only properly secured tools and after the inspections, the appropriate records shall be
evenly distributed and can be safely provided to the owner of the aerial platform
) working from the platform, are (2) When the user directs personnel to accomplish
repairs on the aerial platform, not later than 60 days
horizontal force. The user shall direct the after the repairs are accomplished, the appropriate
records shall be provided to the owner
7.13.3 Proof of Training. Users providing training
(34) Bridge cranes. When an aerial platform is to should provide successful trainees a means to evidence
operate within the area of travel of a bridge crane or their training and shall provide such proof if requested
similar equipment, steps shall be taken to prevent a by the trainee. The document evidencing training shall
collision with the aerial platform. include the following information:
(1) Name of entity providing training or retraining
(2) Name oftrainer(s)
10
(3) Clear identification that training covered Boom- 8.4 Problems or malfunctions. Any problems or
Supported Elevating Work Platforms malfunctions that affect the safety of operations shall
(4) Date of training be repaired prior to the use of the aerial platform.
(5) Name of trainee 8.5 Training, Retraining, and Familiarizati~
7.14 Modifications. Modification, alteration or 8.5.1 General Training. Only n"~'''{'''on''l
remanufacture of an aerial platform shall be made only received general instructions regarding
with prior written permission of the manufacturer. application and operation of aerial
7.15 Manufacturer's Safety Bulletins. The user shall recognition and avoidance of
comply with safety related bulletins as received from the their operation, shall operate an
manufacturer, dealer, or owner. items covered shall include,
8 Responsibilities of Operators limited to, the following'
8.1 Basic Principles. The information in this standard (l) The purpose and use of
shall be supplemented by good judgment, safety control, (2) That operating
and caution in evaluating each situation. Since the aerial platform and
operator is in direct control ofthe aerial platform,
conformance with good safety practices in this area is the
responsibility of the operator. The operator shall make
decisions on the use and operation of the aerial platform
with due consideration for the fact that his or her own
safety as well as the safety of others is dependent on those
decisions.
8.2 Manuals
8.2.1 Machine Manuals. The operator shall -ensure and regulations
the operating and maintenance manuals are stored in lOflzatlOn to operate
weather resistant storage compartment on the aerial warnings and instructions
platform. The manual(s) is considered an integral operation of the aerial platform Under
the aerial platform and is vital to communicate of a qualified person, the trainee shall
safety information to the operator. The the aerial platform for a sufficient period of
familiar with the manuals and reference them time to demonstrate proficiency in the actual operation
8.2.2 Manual of Responsibilities. of the aerial platform.
be familiar with the requirements 8.5.2 Retraining. The operator shall be retrained,
forth in Section 8 ofthe HH<uue.... when so directed by the user, based on the user's
observation and evaluation of the operator.
8.5.3 Familiarization. When an operator is
directed to operate an aerial platform he/she is not
familiar with, the operator shall receive instructions
regarding the following items:
day or at the (1) The location of the weather resistant
shall be given
........ v u u compartment (for manual(s) storage)
test including, but not (2) The purpose and function of all controls
(3) Safety devices and operating character-
istics specific to the aerial platform
8.6 Before Operation. Before operation, the
operator shall:
htpl'tnlP devices (1) Read and understand the manufacturer's
and fuel system(s) leaks operating instruction(s) and user's safety rules, or have
and wiring harness them explained
or missing parts (2) Understand all labels, warnings, and instructions
and wheels displayed on the aerial platform or have them explained
Placards, warnings, control markings and operating (3) Ensure all occupants of the aerial platform wear
manual(s) appropriate personal protective equipment (PPE) for
(9) Outriggers, stabilizers, extendable axles and other the conditions, including the environment in which the
structures aerial platform will be operated
(l0) Guardrail system 8.7 Workplace Inspection. Before the aerial
(11) Items specified by the manufacturer platform is used and during use, the operator shall
check the area in which the aerial platform is to be used
for possible hazards such as, but not limited to:
11
(1) Drop-offs or holes, including those concealed by (3) Deployment ofstability enhancing means.
water, ice, mud, etc. Outriggers, stabilizers, extendable axles or other
(2) Slope(s) stability enhancing means shall be deployed and
(3) Bumps and floor obstructions into place as required by the manufacturer.
(4) Debris (4) Guardrail system. Guardrails shall
(5) Overhead obstructions and electrical conductors installed and positioned, and access gates
(6) Hazardous locations and atmospheres (reference openings shall be properly closed per
ANSIINFPA 505-1987) manufacturer's instructions.
(7) Inadequate surface and support to withstand all load (5) Distribution of load. The
forces imposed by the aerial platform in all operating distribution on the platform
configurations extension( s) shall be in
(8) Wind and weather conditions manufacturer's rated capacity
(9) Presence of unauthorized persons configuration.
(10) Other possible unsafe conditions (6) Maintaining The operator
8.8 Prior to each operation. Before each operation shall be ~~.~'n+QrI clearance is
of the platform, the operator shall ensure: and energized
(1) Outriggers, stabilizers, extendable axles, or other
stability enhancing means, are used as required by the operator shall
manufacturer he or she is qualified,
(2) Guardrails are installed ilIJIJU"~"H" safety related work
and access gates or openings are closed per electric shock covered by
manufacturer's instructions '''-''');;,U>Cl'>VU'' (CFR) 1910.333. The
(3) The load and its distribution on the platform and level competence shall be established
any platform extension(s) are in accordance with the qualified to do so. Operators shall
manufacturer's rated capacity for that specific appropriate minimum approach distance
configuration energized power lines and parts covered
(4) All personnel on the aerial platform 1910.333 (c)
appropriate safety gear for the work and Personal Protective Equipment. The operator
envisioned. shall ensure all personnel on the platform wear
8.9 Understanding of Hazardous personal protective equipment as required.
It shall be the responsibility of the (9) Personnel footing. Personnel shall maintain a
the hazard classification of the . firm footing on the platform floor while working
operation according to thereon. Climbing by occupants on the mid-rail or top-
8.10 Operator rail of the aerial platform is prohibited. The use of
The operator shall direct planks, ladders, or any other devices on the platform
platform to be in vV>~>'Cl for achieving additional height or reach is prohibited.
in this standard. (10) Precaution for other moving equipment.
performance ensure the use, Wben other moving equipment and vehicles are
application, platform is in present, special precautions shall be taken to comply
conformance set forth in Section 8 of with local ordinances or safety standards established
this standard, potential hazards, for the workplace. Warnings such as, but not limited to,
identified hazards, and flags, roped off areas, flashing lights, and barricades
corl~eICluf:nclt:s of not following shall be used as appropriate.
Instructions and guidelines (11) Reporting problems or malfunctions. The
VIJ'''Cl'<VU shall include, but not operator shall immediately report to a supervisor any
to the following issues and problem(s) or malfunction(s) that become evident
during operation. The operator shall ensure all
protection. Wbile the guardrail system of the problems and malfunctions that affect the safety of
provides primary fall protection all operations are repaired prior to continued use.
of the work platform shall wear either fall (12) Reporting potentially hazardous locations.
restraint or fall arrest equipment as directed by their The operator shall immediately report to a supervisor
employer. any potentially hazardous location(s) that become
(2) Slope and grade. The aerial platform evident during operation.
shall not be operated in any manner on grades, side (13) Hazardous location operation. Operation of
slopes, or ramps exceeding those for which the aerial aerial platforms not approved and marked for operation
platform is rated by the manufacturer. in a hazardous location shall be prohibited.
12
(14) Entanglement. Care shall be taken platform, all personnel shall be removed from the
to prevent rope, electric cords, and hoses, etc., from platform before attempts are made to free the platform
becoming entangled in the aerial platform. using lower controls.
(15) Capacity limitations. Rated capacities shall not (28) Vacating (or entering) an elevated
be exceeded when loads are transferred to the platform at platform. If permitted by the u.<L...... ,.."
any height. shall only vacate or enter a raised aerial
(16) Work area. The operator shall ensure the area following the guidelines and .U"'UU,,UVJ
surrounding the aerial platform is clear of personnel and the manufacturer.
equipment before lowering the platform. (29) Modifications. "''''UU'''''''.'vu
(17) Fueling. The engine (if applicable) shall be shut aerial platform or the "'~'U""'U'
down while fuel tanks are being filled. Fueling shall be frameworks, or the mounting
done in a well-ventilated area free of flame, sparks, or holding tools or materials onto
other hazards that may cause fire or explosion. guardrail system
(18) Battery charging. Batteries shall be charged in a prior written
well-ventilated area free of flame, sparks or other hazards (30) Ass:.sta~e
that may cause fire or explosion.
(19) Improper platform stabilization. The aerial
platform shall not be positioned against another object to or safe operation of
steady the platform or improve stability. shall cease operation
(20) Misuse as a crane. The aerial platform shall not further information
be used as a crane.
(21) Unusual operating support conditions. malfunction(s). Any
The aerial platform shall not be operated from a position that affect the safety of
Ula,LlUll"u,UU;:)
on trucks, trailers, railway cars, floating be repaired prior to the use of the aerial
vessels, scaffolds, or similar equipment unless the
application is approved in writing by the maillu:tac~tliillO[ r""r..vino materials (larger than
a qualified person. The operator shall ensure that only
(22) Travel speeds. The operator shall secured tools and materials which are evenly
speed according to conditions, including the distributed and can be safely handled by a person( s)
the support surface, congestion, . slope, working from the platform, shall be moved.
of personnel, and other factors (33) Rated horizontal force. The operator shall not
may cause collision(s) or result exceed the manufacturer's rated horizontal force.
personnel. (34) Bridge cranes or contact with any electrical
(23) Driving ...."llIir'..... conductors. When an aerial platform is to operate
driving while the within the area of travel of a bridge crane or similar
(a) Maintain a equipment, steps shall be taken to prevent a collision
route of travel with the aerial platform.
(b) Ensure (35) Adequate support requirements. The
maybe operator shall insure the support surface is adequate for
the aerial platform and the load carried.
personal injury (36) Leveling the aerial platform. Outriggers and
from obstacles, leveling devices supplied by the manufacturer shall be
aeJ)re~;Sl(]lnS, ramps, and other utilized to level the aerial platform when provided.
(37) Protecting against unauthorized use. The
distance from overhead obstacles operator shall not use, rent, lease, or provide the aerial
Stunt driving and platform for any form of beneficial use unless so
authorized.
the aerial platform. The
shall implement means provided to protect 8.11 Record of training. When provided or when
use by an unauthorized person(s). obtained upon the operator's request, proof of training
(26) Altering safety devices. Interlocks or other safety by the training entity should be retained by the
devices shall not be altered or disabled. operator. Records shall contain the following
(27) Snagged platform. If the platform or elevating information:
assembly becomes caught, snagged, or otherwise (1) Name of entity providing training or retraining
prevented from normal motion by adjacent structures or (2) Name oftrainer(s)
other obstacles such that control reversal does not free the
13
(3) Clear identification that training covered Boom-
Supported Elevating Work Platforms
(4) Date of training
(5) Name of trainee
9 Responsibilities of Lessors
9.1 Basic principles. Sound principles of safety,
training inspections, maintenance, application, and
operation consistent with all data available regarding the
parameters of intended use and expected environment
shall be applied in the performance of responsibilities of
lessors with due consideration of the knowledge that the
aerial platform will be carrying personnel.
9.2 Lessor as a Dealer. When a lessor uses the aerial
platform as a dealer, the lessor shall have the
responsibilities of dealers as specified in Section 5 of this
standard.
9.3 Lessor as an Owner. When a lessor uses the
aerial platform as an owner, the lessor shall have the
responsibilities of owners as specified in Section 6 of this
standard.
9.4 Lessor as a User. When a lessor uses the aerial
platform as a user, the lessor shall have the
responsibilities of users as specified in Section 7 of this
standard.
9.5 Lessor as an Operator. When a lessor uses
aerial platform as an operator, the lessor shall
responsibilities of operators as specified in
this standard.
10 Responsibilities of Lessees
10.1 Basic Principles. Sound
training, inspections, malintenllllc:e
operation consistent with all
parameters of intended use
shall be applied in the
lessees with due ",v,"""u.."
aerial platform will
10.2 Lessee as
as specified in Section 6 of this
a User. When a lessee uses the

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

aerial platform as an operator, the lessee shall
have the responsibilities of operators as specified in
Section 8 of this standard.
14
Figure 1 - Typical Examples of Equipment Covered
15
SERVICE MANUAL
MODELS T60 & T66J

(~~~)
o 0
SIDPPINGADDRESS MAILING ADDRESS

CONDOR® CONDOR®
(254)420-5200 (254)420-5200
MANUAL92375-002
April 1998
i
INTRODUCTION
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.
Condor Division reserves the right to modify, improve, add, and/or delete certain design features of its
products without any obligation to incorporate new features into products previously sold. Our
manuals are continually updated to reflect these changes.
DO NOT ALTER OR MODIFY THIS UNIT WITHOUT PRIOR WRITTEN

APPROVAL FROM THE MANAGEMENT OF TIME CONDOR Corporation
Many of the parts used in the manufacture of the CONDOR® have specific properties, and the
manufacturer recommends that replacement parts be purchased through Condor Division 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 Condor Division's
Operation, Parts & Maintenance Manual for information on service and maintenance of the
CONDOR®.
MANUAl92375-002
April 1998
ii
CONDOR® SERVICE INFORMATION
1. Ifyou need assistance or have any service or maintenance questions, TIME CONDOR
Corporation service and parts personnel are always available by phone or fax. The telephone
numbers are:
(254) 420-5200 Telephone

(817) 420-5298 Voice Mail
(800) 443-5803 FAX
2. There are numerous written Maintenance Procedures available for this machine. These procedures
are available through the TIME CONDOR Corporation Service Department to anyone who
requests them.
3. Service and maintenance are not a substitute for trained, qualified service technicians. TIME
CONDOR Corporation conducts service schools on a continuing basis. Call any ofour service or
sales persons for a schedule. Remember, training ofmechanics is the responsibility of their
employer, but TIME CONDOR Corporation. Service Schools help you provide this training.
4. TIME CONDOR Corporation Service School Training Manuals are available forpurc hasethrough
the parts department. The part numbers for these manuals are: #92333 for self-propelled models;
and #92334 for truck-mounted models.
8300 IMPERIAL DRIVE, P.o. Box 21447, WACO, 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 Corp. is free from defects in material and workmanship arising under normal use and service in the case
of major weldments, (chassis, turret, and booms), for a period of five (5) years after the original shipment of the
aerial work platform from the plant of TIME CONDOR Corp.; and in the case of all other parts, for a period of one
(1) year after the aerial work platform is placed in service or two (2) years after the original shipment of the aerial
work platform from the plant of TIME CONDOR Corp., whichever comes first.
The obligation and liability under this Warranty is expressly limited to repairing or, at TIME CONDOR Corp.'s
option, replacing free of charge at its factory in Waco, Texas or at an authorized repair facility designated by
TIME CONDOR Corp., the defective part. In no event shall TIME CONDOR Corp. or its suppliers be liable to the
purchaser or any other person for transportation charges or for any incidental, collateral, special, or consequen-
tial damages, including without limitation damages for loss of profits, loss of customers, loss of goodwill or work
stoppage, claims by any party other than the purchaser, or any other similar damage or loss even if TIME
CONDOR Corp., 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 the 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, improper use or application of the equipment, substitu-
tion upon it of parts not approved by TIME CONDOR Corp. or alteration or repair of the equipment by any
person not authorized by TIME CONDOR Corp. shall, at TIME CONDOR's option, void this Warranty. TIME
CONDOR Corp. shall have no liability or responsibility for damages reSUlting from accident or the malfunction of
equipment and components not supplied by TIME CONDOR Corp.
No agent, employee, distributor, dealer, or other representative of TIME CONDOR Corp. is authorized to modify
this Warranty in any way. Accordingly, additional statements or presentations by any such representative,
whether oral or written, do not constitute warranties by TIME CONDOR Corp. and should not be relied upon as
limited warranties of TIME CONDOR Corp., and no attempt, effort, or promise to repair equipment by TIME
CONDOR Corp. or any such representative at any time shall modify or extend this Warranty in any way. If the
purchaser has used its own order form, no additional or different warranty terms contained in the purchaser's
form will be honored by TIME CONDOR Corp. This Warranty covers only new and unused aerial work platforms
manufactured by TIME CONDOR Corp. 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
of merchantibility and fitness for a particular purpose. Any applicable implied warranty shall be limited in
duration to the warranty period.
TIME CONDOR Corp.

8300 Imperial Drive
P.O. Box2 1447 Phone: (254)420-5200 Printed in the USA
Waco, Texas 76702-1447 Fax: (800)443-5803 06/98
Effective August 27, 1996
WARRANTY PROGRAM
Warranty is a function of a manufacturing company to back up the product it manufactures. It is a guarantee

against defects in design and workmanship of components utilized in the product, and is offered for a certain
period oftime following purchase by a customer.
TIME CONDOR Corporation's warranty states, in general, the TIME CONDOR Corporation will replace
free of charge, any components found to be defective within the time frame of the warranty period. There
are exceptions to some components which are not the responsibility of TIME CONDOR Corporation. These
will be outlined in other paragraphs.
The warranty policy and description are depicted on the attached printed policy. For your reference, the
following is offered:
A. WARRANTY PERIOD
1. The Self-Propelled Boom and Scissor Warranty is one (1) year from placing the unit in
service or two (2) years following shipment from TIME CONDOR Corporation, whichever
comes first. In the case of major weldments (chassis, turret, and booms), the warranty period
is five (5) years following shipment from TIME CONDOR.
2. The truck mounted unit warranty is one (1) year from shipment of the unit from
TIME CONDOR's plant.
3. For parts sold thru the Parts Department, the warranty peroid is six (6) months from utilizing
the component or placing it in service, or twelve (12) months following shipment from
TIME CONDOR, whichever comes first, unless the part is furnished to correct a defective
part on the original CONDOR® shipment still under warranty . No labor is paid under parts
warranty.
4. Replacement parts provided under the terms of the warranty are for the warranty peroid
applicable to the unit in which they were installed as if such parts were original components
of the aerial work platform.
5. In addition to covering the parts replaced under CONDOR® warranty, TIME CONDOR will
pay a dealer warranty labor rate, which is based on a percentage of your standard shop labor
rate.
NOTE: The term "IN SERVICE" means that the warranty starts at the time the CONDOR® is first
used for any purpose. An example: The dealer may have purchased a CONDOR® to have
in stock, but may not use it. After three months, the CONDOR® is sold or the dealer decides
to put the CONDOR® into its rental fleet. In this situation, the warranty period begins the
day the dealer puts the CONDOR® into the fleet or when the CONDOR® is delivered t<;l
the end user.
The submittal of a warranty claim against a stock CONDOR® constitutes it as being "in
service", initiating the warranty period.
B. PRE-DELIVERY INSPECTION SHEET (p.D.I.)
1. Each Self-Propelled Boom or Scissor CONDOR® shipped from TIME CONDOR's facility
will have a Pre-Delivery Inspection (P.D.I.) sheet enclosed in the Safety Manual holder tube.
2. It will be the responsibility of the original recipient ofthe CONDOR® from

TIME CONDOR, whether it will be the dealer or the end user, to complete this form and return
itto TIME CONDOR's facility within 45 days from the date ofreceiptto set up the Warranty
Account.
3. Failure to complete the P.D.!. sheet and return it to TIME CONDOR within the time frame
given will result in voiding the Warranty on the CONDOR®.
NOTE: The form must be filled out completely, giving the name ofthe dealer, address, model
number, serial number, person inspecting the CONDOR® signature, and date ofinspection.
(The date of inspection does not constitute the "In Service" date.)
C. ITEMS NOT COVERED
Some components are used on the machine which are not warranted by TIME CONDOR
Corporation. However, these are warranted by the component manufacturer. Some ofthese are:
1. Engine: Manufacturers used include Wisconsin, Ford, Deutz, Isuzu, Kubota, Onan, Cummins,
John Deere, and others. To apply for warranty on the engine, contact should be made with
the engine manufacturer's dealer in your area. TIME CONDOR Corporation can advise you
if you need assistance locating a dealer.
2. Tires and Batteries: These are normal wear items and are considered normal maintenance
items. However, if they are found to be defective, contact can be made with the
manufacturer's local dealer. NOTE: For international dealers where tires or batteries are
not obtainable from a local in-country supplier, locally supplied tires or batteres can be used.
Components must meet or exceed originally-supplied items. Copies ofinvoices for said items
MUST accompany any Warranty Claims to receive parts credit.
3. Hydraulic Filters and Fluid: These are considered general maintenance and service items, and
are not covered by warranty.
4. Other components: Products or parts manufactured by others are covered only by such
warranties as are extended to TIME CONDOR Corporation by its suppliers.
5. Freight and Charges: The warranty does not include any freight, transportation, other charges,
or the cost ofinstallation or any liability for direct, indirect, or consequential damages or delay
r~sulting from the defect.
6. Travel Time I Mileage: Travel time and the mileage to and from dealer facilities to
CONDOR® location are not covered or reimbursable.
7. Troubleshooting: Troubleshooting is not covered or reimbursable. However,

TIME CONDOR Corporation warranty will cover reasonable labor charges for the removal
and replacement of defective components.
D. PROCESSING OF CLAIM
During the Warranty Period, should a component failure be encountered within the guidelines ofthe
TIME CONDOR Warranty Policy, the following procedure is to be followed:
1. Upon identifying the defective component, the replacement can be obtained by:
a. Issuing an order to our Parts Departmentthrough normal channels, which entails your
company being invoiced.
b. You may have prevoiusly purchased the part from TIME CONDOR for your stock
and will utilize it for this replacement.
The above two methods will enable you to indicate on the claim the TIME CONDOR invoice
number to substantiate the parts purchase and the amount to be credited.
c. Although not recommended, you may purchase the part locally. When this is done a
copy ofthe purchase order or receipt MUST accompany the claim. TIME CONDOR
has the option to ship a replacement part at no charge ifthe local cost would be greater
in lieu of issing credit for locally purchased parts. '
d. When parts are purchased from TIME CONDOR, part numbers with invoice
numbers MUST be referenced in the appropriate section of the claim form.
2. Complete the Warranty Claim as noted in the "Warranty Claim Procedure" section. Provide
as much information as possible to enable TIME CONDOR to thoroughly evaluate the claim
and process it in the shortest amount of time possible.
NOTE: CLAIMS NOT RECEIVED BY TIME CONDOR WITHIN 45 DAYS OF

FAILURE WILL BE DENIED
3. Provided no return parts are required and all the information has been verified, the claim will
be processed and credit will be issued against your account.
E. RETURN AUTHORIZATION
1. If a component is found to be defective within the normal guidelines of the Warranty, a

Warranty Claim Form must be completed.
2. It will be necessary for you to call the TIME CONDOR Service Department and request a
Return Authorization (R/A) number. You will be asked for a Dealer Claim Number. As noted
in Section 2, Item A, ofthe Warranty Claim Procedure, this is a number assigned by the dealer
for the purpose of tracking the claim, as there may be more than one claim for the same
CONDOR®. The R/A number issued must be logged in the appropriate section ofthe claim
form, and the gold copy (R/A) ofthe form MUST be returned with the parts being returned.
NOTE: DO NOT SHIP ANY RETURN PARTS WITHOUT
A RETURN AUTHORIZATION (RIA) NUMBER
Doing so may result in parts getting lost in the system and may delay processing the claim, or
may cause denial due to the time element ofthe claim.
3. All RIA parts must be received at TIME CONDOR Corporation within 45 days from the date
the RIA number was issued. Failure to do so will cause the claim to be denied.
4. All parts claimed under Warrranty will be required to be shipped back to TIME CONDOR
Corporation FREIGHT PREPAID. No freight collect shipments will be accepted.
NOTE: Due to shipping charges and impart duties imposed on INTERNATIONAL DEALERS, these
dealers will not be required to automatically return all parts.
TIME CONDOR Corporation requires that all parts claimed on a Warranty Form be retained
by the international dealer for a period of no less than 180 days. After this period, if no
instructions have been received form TIME CONDOR Corporation, the parts may be
scrapped.
Should TIME CONDOR Corporation request any part be reurned, it will be shipped to our
factory in Waco, Texas, frieght prepaid.
WARRANTY CLAIM PROCEDURE
INTRODUCTION
This procedure is offered to assist our Dealers in properly completing our Warranty Claim
Forms. The more information supplied, the better TIME CONDOR Corporation can evaluate
the problem and expedite processing the claim.
The form should be TYPED or completed LEGIBLY in ink. Several copies are utilized.
Ensure that sufficient pressure is applied to make all copies legible.
PROCEDURE
NOTE: THE NUMBERS NOTED BELOW CORRESPOND TO THE BLOCK

NUMBERS ON THE CLAIM FORM
1. Where to mail: P.O. Box for mailing claim, street address for RIA parts returns.
2. Claim information:
a. Dealer's Claim Number: This assigned number is necessary for Dealer and TIME
CONDOR Corporation tracking purposes, since there may be more than one claim
for the same unit.
b. TIME CONDOR Corporation Warranty Number: Do not write in this section. It is

for Condor Div. use only.
c. Return Authorization Number: All parts replaced under Warranty MUST be returned
to TIME CONDOR Corporation freight prepaid. Call the TIME CONDOR
Corporation Service Department for Return Authorization Number. Parts returned
without proper authorization and gold packing slip will not be accepted.
d. All dates pertinent to the claim and/or RIA are to be entered in the proper locations.
3. Dealer information: Supply the name of the company, address and name of the person
submitting the claim. This person will be the contact if a discrepancy occurs, and will be
referred to on all correspondence.
4. This section is provided to identify the unit: The date ofdelivery (date unit was received at your
facility); In Service date (date sold to end user or date put into operation); Model and Serial
numbers; type of Warranty, (A) Aerial Lift Warranty on a specific unit or (B) Parts
Replacement, Warranty on a new part ordered and found to be defective.
5. Owner Information: Supply end user company name and address. If it is the same as the dealer's,
write "Same".
6. This area is for part number(s) and description(s). It is VERY important that the TIME CONDOR
Corporation invoice number(s) for which the part(s) were purchased be provided along with the
amounts in order to properly process the claim. NOTE: All dollar amounts are to be in U.S. currency.
7. Labor Description: A detailed description of the failure along with the work performed is required in
order to fully evaluate the hours of your claim and the amount TIME CONDOR Corporation will
approve.
8. TIME CONDOR Corporation remarks: This area is completed by TIME CONDOR Corporation A
brief explanation and steps taken in the determination of approval or denial is provided here.
Upon completion ofthe form, remove the YELLOW copy for your records. Remove the GOLD copy (packing
slip) and send it, along with the parts being returned under warranty. The GOLD copy MUST have the RJA
number in the proper location and must be packed in with the parts sent back to Condor Div ..
Mail the remaining copies totheTIME CONDOR Corporation P.O. Boxblock#lforTIMECONDORCorporation

evaluation.
NOTE: CLAIMS NOT RECEIVED WITHIN 45 DAYS OF FAILURE WILL BE
DENIED.
TABLE OF CONTENTS
INTRODUCTION ........................................................................................................................................ i
SERVICE INFORMAnON ........................................................................................................................ i
WARRANTY ............................................................................................................................................. iii
•
Introduction ................................................................................................................................................... 4
Machine Specifications ...................... ,.......................................................................................................... 6
Machine Component Locator ....................................................................................................................... 7
Lubrication Chart .......................................................................................................................................... 8
Lubrication Diagram ..................................................................................................................................... 9
Section 1: Transportation and Emergency Procedures
Transporting the Unit .................................................................................................................................. 13

Truck or Trailer Transport .......................................................................................................................... 13
Unloading Procedures ................................................................................................................................. 14
Emergency System and Procedures ........................................................................................................... 15
Emergency Electrical Pump ........................................................................................................................ 15
Unpowered Emergency Movement ............................................................................................................ 15
Emergency Lowering .................................................................................................................................. 17
Section 2: Hydraulic System
Hydraulic Fluid
Handling Precautions ..................................................................................................................... 22
FluidRecommendations ................................................................................................................. 22
Fluid Contamination Checks .. , ........................................................................................................ 23
System Flushing Procedure ............................................................................................................ 23
Hydraulic System Components ................................................................................................................... 24
Main Hydraulic Pump .................................................................................................................... 24
Main Pump Replacement ................................................................................................................ 24
Emergency Pump ........................................................................................................................... 25
Emergency Pump Adjustment ................................................................................................. 25
Maintenance ............................................................................................................................ 25
Hydraulic Circuit Line Check .................................................................................................. 25
Drive Motor ................................................................................................................................... 26
HydraulicFluidReservoir ............................................................................................................... 26
Hydraulic Reservoir Maintenance ........................................................................................... 26
Hydraulic Fluid Filter ...................................................................................................................... 26
ReturnFilter ............................................................................................................................ 26
High Pressure Filter ................................................................................................................ 26
Main Hydraulic Control Valve ....................................................................................................... 27
Boom Lift System .......................................................................................................................... 28
Boom Lift Valve Segment ....................................................................................................... 28
Flow Control Valve ................................................................................................................. 28
Flow Control Valve Adjustment .............................................................................................. 28
LiftCylinder ............................................................................................................................ 28
Boom Telescope (Extend) System ..................................................................................................... 28
Boom Extend Valve Segment ........................................................................................................ 28
Pressure Relief Valve .................................................................................................................... 28
Telescope (Extend) Cylinder ......................................................................................................... 29
Jib Boom System ........................................................................................................... ,..................... 29
Jib Boom Valve Segment ............................................................................................................... 29
Jib Cylinder .................................................................................................................................... 29
Platform Rotate System ...................................................................................................................... 29
Rotary Actuator ............................................................................................................................. 29
Rotary Actuator Maintenance ....................................................................................................... 29
MANUAL92375-002
Man:hl998
• TABLE OF CONTENTS (Continued)
Section 2: Hydraulic System (Continued)
Platform Levelling System .................................................................................................................. 29

Master Levelling Cylinder .............................................................................................................. 30
Slave Levelling Cylinder ................................................................................................................. 30
Relief Valves ................................................................................................................................. 30
Steer System .............................................................................................................................. '" ...... 30
Selector Valve Segment ................................................................................................................. 30
Steer Pressure Relief Valve .......................................................................................................... 30
Steer Cylinder ................................................................................................................................ 30
Steer System Maintenance ............................................................................................................ 31
Hydraulic Swivel ............................................................................................................................ 31
Section 3: Drive System
Drive System Components ......................................................................................................................... 35

Drive Motor ................................................................................................................................... 35
Drive Valve Manifold - Two Wheel Drive .................................................................................... 35
Hi Speed Drive Enable Valve .................................................................................... '" .......... 36
Flow Divider/ Combiner Valve ................................................................................................ 36
Brake Valve Circuit ................................................................................................................. 36
Drive Valve Manifold - Four Wheel Drive .................................................................................... 37
Hi Speed Drive Enable Valve ................................................................................................. 38
Brake Valve Circuit ................................................................................................................. 38
Selector Spool Valve Circuit ................................................................................................... 38
Toggle Switch on the Pendant Control .......................................................................................... 39
Platform Control Handle (Joystick) ............................................................................................... 39
Section 4: Electrical System
GeneralOperations ............................................................................................................................... 42
Control System Adjustment ................................................................................................................... 44
Error Codes ........................................................................................................................................... 46
Electrical System ................................................................................................................................... 47
Battery ............................... ,................................................................................................................. 47
Battery Maintenance (IN Use) ...................................................................................................... 47
Battery Preventive Maintenance ................................................................................................... 47
Battery Replacement ..................................................................................................................... 48
Movement Alarm ................................................................................................................................. 48
TiltAlarm .............................................................................................................................................. 49
Circuit Breaker ...................................................................................................................................... 49
Limit Switch .......................................................................................................................................... 49
Emergency Pump .................................................................................................................................. 49
Emergency Stop Button ........................................................................................................................ 49
Ground Control Cabinet Switch Removal ............................................................................................. 50
Platform Console Switch Removal ........................................................................................................ 50
Platform Control Board ......................................................................................................•.................. 50
Electronics Control Module ................................................................................................................... 50
Angle Sensor Calibration ....................................................................................................................... 51
Length Sensor Calibration ..................................................................................................................... 52
MANUAl9237!HJ02
Marc:h1998
Section 5: Mechanical Components
TABLE OF CONTENTS (Continued)
Mechanical Components ............................................................................................................................. 57

Tires ................................................................................................................................................. 57
•
Changing Tires ............................................................................................................................... 57
Wheels and Lug Nuts ............................................................................................................................ 57
Drive Hub Assembly ............................................................................................................................. 57
Steer Cylinder Pins ................................................................................................................................ 59
Steer Cylinder ........................................................................................................................................ 59
Steer Cylinder Seal Replacement .................................................................................................. 59
Drive Motor Replacement ............................................................................................................. 60
Turret ............................................................................................................................................. 60
Platform ......................................................................................................................................... 60
Hoses and Cables .................................................................................................................................. 60
Miscellaneous Equipment ...................................................................................................................... 60
Boom .................................................................................................. ,.............................................. 60
Boom Pivot Pin and Bushing Replacement ................................................................................... 60
Wear Pads ..................................................................................................................................... 61
Base Boom Top Wear Pad Replacement ............................................................................... 61
Moving Anchor Wear Pad Replacement ................................................................................ 62
Mid Boom Top Front Wear Pad Replacement ....................................................................... 62
Mid Boom Rear Wear Pad Replacement ............................................................................... 62
Tip Boom Top Wear Pad Replacement .................................................................................. 63
Boom Lift Cylinder ................................................................................................................................ 63
Lift Cylinder Pivot Pin Replacement ............................................................................................ 63
Lift Cylinder Seal Replacement (On Machine) ............................................................................. 63
Bench Replacement Of Lift Cylinder Seals ................................................................................... 64
Counterbalance Valve Inspection .................................................................................................. 66
Jib Boom Removal ................................................................................................................................ 66
Jib Boom Installation ............................................................................................................................. 66
Boom Telescope Cylinder ..................................................................................................................... 67
TelescopeCylinderRemoval ......................................................................................................... 68
Telescope Cylinder Seal Replacement .......................................................................................... 68
Telescope Cylinder Installation ...................................................................................................... 69
Counterbalance Valve Inspection .................................................................................................. 69
Platform Level Cylinders .......................................................................................... ,........................... 69
Platform Level Cylinder Pin Replacement ..................................................................................... 69
Level Cylinder Seal Replacement .................................................................................................. 69
Platform Leveling Procedure ......................................................................................................... 69
Section 6: Maintenance
Maintenance .......................................................................................................................................... 73
General Maintenance Tips .................................................................................................................... 73
First Three Months of Operation ........................................................................................................... 73
Routine Servicing .................................................................................................................................. 74
Shift Operational Checklist .................................................................................................................... 78
Weekly Operational Checklist ................................................................................ '" ............................ 81
Monthly Operational Checklist .............................................................................................................. 83
Semi-Annual Operational Checklist ...................................................................................................... 85
Bolt Torque Chart
MANUAl92375-002
March 1998
• INTRODUCTION
This Service Manual is designed to provide you with the instructions needed to properly maintain the
Time Condor Corporation. T60 Aerial Platform with full hydraulic controls. 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 T60, 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:
.. DANGER
"DANGER" INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF
NOT AVOIDED, WILL RESULT IN DEAm OR SERIOUS INJURY. TmS 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-damage-only accidents.
MANUAL 92375-002
March 1998
Service personnel and machine operators must understand and comply with all warnings and
instructional decals on the body ofthe machine, and at the ground controls and platform
control console.
•
.. DANGER
MODIFICATIONS OF TillS MACHINE FROM THE ORIGINAL DESIGN
AND SPECIFICATION WImOUT 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.
- MANUAl92375-002
March 1998
• MACHINE SPECIFICATIONS
Working Height ..................................................................................................................................... 66 Ft.
Platform Height ..................................................................................................................................... 60 Ft.
Horizontal Reach (Boom Angle 0°) ..................................................................................................... 47Ft.
Platform Capacity (Unrestricted) ..................................................................................................... 500 Lbs.
Platform Size ............................................................................................................................ 36 In. x 60 In.
Stowed Length .............................................................................................................................. 28 Ft. 2 In.

Stowed Height ............................................................................................................................... 7 Ft. 11 In.
Machine Width .............................................................................................................................. 7 Ft. 11 In.
Wheelbase ............................................................................................................................................. 8 Ft.

Ground Clearance ................................................................................................................................ 10.5 In
GrossWeight(Approximately) .................................................................................................... 18,600Lbs.
Maximum Travel Speed:
Boom Stowed ........................................................................................................................... 5.25 MPH
Boom Extended or Elevated ....................................................................................................... 0.5 MPH
TumingRadius
Inside ..................................................................................................................................... 8 Ft. 7 In.
Outside ................................................................................................................................ 18 Ft. .25 In.
Gradeability (On Hard Surface) .............................................................................................................. 30%
Platform Rotation ..... ....... ................ ...... ......... .... .................... ............................... ................... ............... 160°
Superstructure Rotation ................................................................................................ 360° Non-continuous
Tire Size ........................................................................................................................... 15 x 16.5-10 Ply
Tire Pressure (not applicable to foam filled tires) ................................................................................ 80 PSI
Hydraulic Pressure (Maximum) ....................................................................................................... 3000 PSI
Hydraulic Tank Capacity .................................................................................................................... 45 Gal.
Fuel Capacity:
Gas or Diesel ................................................................................................................................. 40 Gal.
Propane ......................................................................................................................................... 30 Lbs.
ElectricalSystem .................................................................................................... One 12 Volt DC Battery
MANUAl92375-002
March 1998
PRIMARY MACHINE COMPONENTS
•
PLATFORM
CONIROLS
PLATFORM
llBBOOM
SLAVELEVELING
CYLINDER
MASTER MAIN BOOM

lEVFl.1NG ASSEMBLY
CYLINDER
-f------ LIFf
CYLINDER
1URREf
:I
c:::=J
GROUND
CONIROLS CHASSIS
LEFT HAND SIDE
MANUAl9237!HlO2
March 1998
LUBRICATION CHART
SPECIFICATION FREQUENCY OF
NO. ITEM AND QUANTITY LUBRICATION
1. Hydraulic Reservoir Shell Tellus T-32 to "Full" Check level & condition each shift.
mark with all cylinders Analye 6 months or 500 hours. *+
retracted. Change yearly or 1000 hours. *+
2. Hydraulic Filters Filter elements. Change 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: Extension Cable Pulley Lithium N.L.G.I. #2 EP. Monthly or every 100 hours. *+
Purge old grease.
7. Wheel Bearings Lithium N.L.G.I. #2 EP. Change every six (6) months or 500
Clean and repair. hours.*+
8. Drive Wheel SAE 90, halffull. 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.
MANUAl9237!HlO2
March 1998
LUBRICATION DIAGRAM
'0
[: .
~--!I,===-=LI__ ,_I'
7
8
- MANUAl92375-002
March 1998
SECTION 1:
TRANSPORTATION
AND
EMERGENCY PROCEDURES
MANUAl92375-002
Man::hl998
TABLE OF CONTENTS,SECTION 1
Transporting the Unit .................................................................................................................................. 13

Truck or Trailer Transport .......................................................................................................................... 13
Unloading Procedures ................................................................................................................................. 14
Emergency System and Procedures ........................................................................................................... 15
Emergency Electrical Pump ........................................................................................................................ 15
Unpowered Emergency Movement ............................................................................................................ 15
Emergency Lowering ....... ,.......................................................................................................................... 17
MANUAL92375-002
March 1998
FACTORY RECOMMENDED
TRANSPORTATION DIAGRAM
LOCATE TURRET AT 50 ANGLE AND USE

TURRET ROTATION LOCK PIN
MANUAL92375-002
March 1998
TRANSPORTING THE UNIT
TRUCK OR TRAILER TRANSPORT
A WARNING
ALWAYS ATTACH THE UNIT TO A WINCH WHEN LOADING OR ,
UNLOADING FROM A TRUCK OR TRAILER. CONNECT WINCH
CABLE TO THE TIE DOWN LUGS ON THE CHASSIS.
UNASSISTED LOADING OR UNLOADING OF ANY MOBILE

PLATFORM IS NOT RECOMMENDED.
1. Enter the platform, secure the safety gate, and start the engine using the platform controls.
Select the engine "OPERATING SPEED".
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. Using a winch, carefully drive the unit onto the truck or trailer.
4. Lock the turret to the chassis by installing the lock pin provided.
A CAUTION
To avoid damaging the unit, the platform MUST NOT be tied to the trailer
bed in any way and should only REST on the bed.
5. The negative battery cables should be disconnected for long distance transport.
It is recommended that the fuel and hydraulic tank valves be closed as well.
6. Tie down locations are located on all four comers of the undercarriage and on the
platform skirt weldment. Use four (4) 112 inch, "Grade 7" chains from each of the tie
down lugs, and run the chains as shown in the diagram. (also located on decals
on both sides of chassis).
Ratchet type load binders are recommended. If using lever type load binders, wire
or strap them shut, or wrap chains around them to prevent opening.
MANUAl 92375-002
March 1998
UNLOADING PROCEDURES
A WARNING
TO AVOID A SERIOUS PERSONAL INJURY OR DEATH,
ENSURE THAT THE MACHINE IS IN "LOW" DRIVE SPEED
WHILE UNLOADING FROM A TRUCK OR TRAILER.
• Inspect the outside of the unit for damage (including the underside). Inspect all hoses,
boom sections and cables for chafing road damage. Confirm that all wheel lug nuts
and swing bearing bolts are tight (refer to specifications).
• Remove the pin that locks the turret to the chassis near the swing bearing.
Stow the lock pin in the location provided nearby.
• Unlock and open both side compartment doors. Inspect all fuel, electrical and hydraulic
connections for damage and security.
• Connect battery cables to batteries if required. Check electrolyte level.
• Check engine oil level, and add as required per engine manufacturer's recommendations.
• Check fluid level at the sight gauge on the hydraulic tank, and add fluid as required
(see Lubrication Chart). Check that shutoff valves on the hydraulic tank are open.
• Close side compartment doors.
• Attach the unit to a winch for the unloading procedure.
A WARNING
ALWAYS ATTACH THE UNIT TO A WINCH WHEN LOADING OR
UNLOADING FROM A TRUCK OR TRAILER. CONNECT WINCH
CABLE TO THE TIE DOWN LUGS ON THE CHASSIS. UNASSISTED
LOADING OR UNLOADING OF ANY MOBILE PLATFORM IS NOT
RECOMMENDED.
READ AND UNDERSTAND ALL SAFETY, CONTROL AND OPERATING

INFORMATION FOUND ON THE MACHINE AND IN THIS MANUAL
BEFORE OPERATING THE UNIT.
• Remove all machine tie downs (see Transporting Unit). Remove wheel chocks, ifused.
Switch the "GROUND !PLATFORM" key switch to "PLATFORM".
MANUAl92375-002
March 1998
• Enter the platform, and restart the engine using the platform controls. Select the
" OPERATING" engine speed, 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 with the assistance of a winch.
NOTE: The brakes are automatically released for driving, and will automatically apply
when the unit stops.
• Before placing the unit into service, all operators must read and understand the
contents of the Operator's Manual.
EMERGENCY SYSTEM AND PROCEDURES
& DANGER
IF THE UNIT FAILS TO OPERATE WHEN THE PLATFORM IS RAISED OR
EXTENDED, DO NOT ATTEMPT TO CLIMB DOWN THE BOOM ASSEMBLY.
SERIOUS INJURY MAY RESULT.
EMERGENCY PUMP
The T60 has an emergency pump which can be operated from the operator's platform or
ground controls to safety return the platform to the ground position when the unit has lost
engine/pump power. Operation from the ground controls override platform controls.
• Press and hold the "PUMP" toggle to "EMERGENCY" on the ground control box,
OR
• Press and hold the "EMERGENCY PUMP" button on the platform control console.
Select the proper function (boom retract, boom lower, or swing) as required to safely lower
the platform to ground level.
To prevent the battery from completely discharging and the emergency pump from
overheating, release the emergency pump button to allow a 30 second rest period after
every 30 seconds of operation. Once the unit has been safely positioned, correct the cause
of the failure before returning the unit to service.
UNPOWERED EMERGENCY MOVEMENT
• Every attempt should be made to restore engine/pump power to the unit before using
this procedure.
MANUAL9237&002
March 1998
THIS PROCEDURE REQUIRES RELEASING THE VEmCLE BRAKES,
WIllCH RESULTS IN NO MEANS TO STOP THE UNIT'S TRAVEL.
TIME CONDOR RECOMMENDS USING TillS 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.).
~ DANGER
UNPOWERED EMERGENCY MOVEMENT (CONTINUED)
1. Secure the unit chains orropes.
The T60 is equipped with tie down lugs (front and rear ofchassis) that can be used
fortowingtheunit. The chains or ropes must be ofsufficient 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. Close brake circuit needle valve located at the center rear ofthe chassis.
4. Disengage torque hubs:
A WARNING
WHENEVER DISENGAGING THE DRIVE TORQUE HUBS OR BEFORE
DISCONNECTION FROM TOWING VEHICLE,ENSURE THAT THE UNIT
CANNOT ROLL.
Type 1: remove the plate in the center ofthe torque hub, turn the plate so
MANUAl92375-002
March1998
Type 2: remove the large hex cap in the center ofthe torque hub, push in and
turn screw slot in the center of the torque hub to line up with
5. Disconnect steer cylinder.
Afterunchocking the wheels, the unit will be ready to be moved.
After engine/pump power has been restored to the machine, engage the torque hubs, reset
the brake circuit needle valve, and connect steer cylinder. The machine is now ready for
nonna! operation.
EMERGENCY LOWERiNG
It is not possible for us to foresee every emergency situation that could arise during
operation ofthis machine. Information on the following pages describes three typical
emergency situations, and lists appropriate actions that can be taken.
When faced with an emergency, above all please remember:
• Stay calm.
• Thinkthrough the situation before operating the machine.
• Gethelpifnecessary.
SITUATION ONE: Platform elevated, operator not incapacitated, but unit will not
respond to platform controls.
posSmLECONDITION:
• One or more functions not operating correctly.
• Unit movement from unselected lever.
• Unit function will not stop unless power is switched off.
CORRECTIVE ACTION
1. Remove foot from foot switch.
MANUAl92375-002
March 1998
2. Push the red "Emergency Stop" Button.
3. Evaluate the nature ofthe failure. Return to the ground, using the emergency pump and
lowering procedure (see "Emergency Pump", earlier in this section).
~ DANGER
DO NOT TRY TO CLIMB DOWN THE BOOM.
HAVE AN EXPEIDENCED OPERATOR USE THE EMERGENCY PUMP TO

SAFELY LOWER THE PLATFORM.
4. Ifunable to return to the ground using the platform controls and the emergency pump,
contact an experienced operator to lower the machine with the emergency pump using
the ground controls (see "Emergency Pump", earlier in this section).
SITUATION TWO: Unit elevated, with operator incapacitated at platform controls.
~ DANGER
DO NOT TOUCH UNIT I!!
DETERMINE THE CAUSE OF THE PROBLEM BEFORE YOU TOUCH THE

MACHINE.
CORRECTIVE ACTION
2. Attempt to talk to operator before taking any rescue measures.
3. Check to see if the operator is in a pinned position, or would be endangered

ifplatform is moved, before attempting emergency lowering procedure.
4. After establishing that the machine is not in contact with live power lines,lowerthe
platform using the emergency lowering procedure (see "Emergency Pump", earlier
in this section).
5. Render first aid to the operator.

MANUAl 92375-002
March 1998
SITUATION THREE: Platform in contact with live power lines and operator
incapacitated.
.. DANGER
DONOTTOUCHUNIT!!!
ELECTROCUTION HAZARD II!
CORRECTIVE ACTION
1. Contact authorized personnel to disconnect power supply touching unit.
3. Ifoperator is unconscious, check to see ifhe is in a pinned position, or would be

endangered ifplatform is moved.
4. AFTER POWER IS CUT, use the emergency lowering procedure to bring platform
with operator to a safe location to render first aid (see "Emergency Pump", earlier
in this section.)
IMPORTANT: Any incidentinvolving personalinjury must be immediately

MANUAL92375-002
March 1998
SECTION 2:
HYDRAULIC SYSTEM
MANUAl 92375-002
March 1998
TABLE OF CONTENTS, SECTION 2:
Hydraulic Fluid ............................................................................................................................................ 22

Handling Precautions ............................................................................................................................. 22
FluidRecommendations ........................................................................................................................ 22
Fluid Contamination Checks .................................................................................................................. 23
System Flushing Procedure ................................................................................................................... 23
Hydraulic System Components .................................................................................................................... 24
Main Hydraulic Pump ........................................................................................................................... 24
Main Pump Replacement ............................................................................................................... 24
Emergency Pump .................................................................................................................................. 25
Emergency Pump Adjustment ....................................................................................................... 25
Maintenance .................................................................................................................................. 25
Hydraulic Circuit Line Check .................................................................................................. 25
Drive Motor ........................................................................................................................................... 26
Hydraulic Fluid Reservoir ...................................................................................................................... 26
Hydraulic Reservoir Maintenance ................................................................................................. 26
HydraulicFluidFilter ............................................................................................................................. 26
RetumFilter ................................................................................................................................... 26
High Pressure Filter ....................................................................................................................... 26
Main Hydraulic Control Valve .............................................................................................................. 27
Boom Lift System ................................................................ , ................................................................ 28
Boom Lift Valve Segment ............................................................................................................. 28
Flow Control Valve ........................................................................................................................ 28
Flow Control Valve Adjustment ..................................................................................................... 28
LiftCylinder ................................................................................................................................... 28
Boom Telescope (Extend) System ........................................................................................................ 28
Boom Extend Valve Segment ........................................................................................................ 28
Pressure Relief Valve .................................................................................................................... 28
Telescope (Extend) Cylinder ......................................................................................................... 29
Jib Boom System ................................................................................................................................... 29
Jib Boom Valve Segment ............................................................................................................... 29
Jib Cylinder .................................................................................................................................... 29
Platform Rotate System ........................................................................................................................ 29
Rotary Actuator ............................................................................................................................ 29
Rotary Actuator Maintenance ................................................................................................. 29
Platform Levelling System .................................................................................................................... 29
Master Levelling Cylinder .............................................................................................................. 30
SlaveLevellingCylinder ................................................................................................................ 30
Relief Valves ................................................................................................................................. 30
Steer System ......................................................................................................................................... 30
Selector Valve Segment ................................................................................................................ 30
Steer Pressure Relief Valve .......................................................................................................... 30
Steer Cylinder ................................................................................................................................ 30
Steer System Maintenance ............................................................................................................ 31
Hydraulic Swivel ........................... ,................................................................................................ 31
MANUAl9237~
March 1998
HYDRAULIC FLUID
HANDLING PRECAUTIONS
AWARNING
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 THE EYES, it must

be WASHED OUTTHOROUGHLYusing abunciantquantities 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.
AWARNING
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 MAYNOT 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 AFEWHOURS.
FLUID RECOMMENDATIONS
We strongly recommend the use of SHELL TELLUS T-32 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.
MANUAl92375-002
March1998
FLUID 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.
If system flushing and replacement of fluid is recommended, refer to the flushing procedure.
SYSTEM FLUSHING PROCEDURE
With·BOTH MAIN BOOM AND JIB BOOM DOWN AND FULLY RETRACTED
(in stowed position), drain hydraulic fluid from hydraulic tank into a clean, empty container.
This can be done with an oil filter cart so the fluid may be reused if analysis is good.
When the hydraulic tank is empty, remove suction hoses and return line hose. Remove all hoses
between pump and high pressure filter. Flush the hoses. Remove hydraulic fluid filter, and flush
the filter body and attaching hoses. Discard old filter element and replace.
With hoses removed from the hydraulic tank, flush out the tank. When this is complete, all the
hoses removed in the previous steps should be properly reinstalled EXCEPT the system return
line to tank. This hose should be lengthened to drain into the reservoir fluid container.
Fill hydraulic tank with filtered, fresh hydraulic fluid (refer to Lubrication Chart).
MANUAl92375-002
March 1998
• Make sure the suction lines are open to allow fluid to flow to the hydraulic pump. Loosen hose
fittings at pump to allow pump to flood with hydraulic fluid, then tighten pump fittings.
Tum the main power key switch to the "GROUND" position. Press engine start button
to start engine. After a brief warm-up period, select the "HIGH" engine RPM setting.
Briefly cycle all boom functions to flush the hydraulic components of the hydraulic fluid.
Use care when doing this as hydraulic fluid is now being returned to container provided.
This will remove old fluid from the hydraulic system as the boom is cycled to its maximum
limits.
A CAUTION
Monitor the hydraulic reservoir fluid level when cycling the unit
functions, adding fluid as necessary to replace that being discharged
to container at system return line. This fluid may be returned to the
reservoir through a filter cart, if good.
-
Three cycles of all hydraulic cylinder functions should remove old hydraulic fluid.
When the above procedures have been completed, reconnect system return hose to tank.
Fill hydraulic tank to full mark on sight gauge. Operate all functions to their full extreme positions
to ensure proper operation. Check for leaks and correct as necessary. Unit is now ready to be
placed back in operation.
HYDRAULIC SYSTEM COMPONENTS
Following is a description of the major components of the hydraulic system.
Main Hydraulic Pump
The SAUER-SUNDSTRAND SERIES40-M46 hydrostatic pump is a 46cc variable pump.

The pump's displacement can be controlled by three different methods; manually, electrically,
or hydraulically. The pump comes with Electric Displacement Control (EDC), the pump
displacement and output flow, in either direction, is approximately proportional to an electrical
input signal.
Main Pump Replacement
1. With all ball valves closed, ensure hydraulic tank is filled with oil.
2. The replacement pump should be installed with the same orientation as the existing
pump.
IMPORTANT: When installing the replacement pump, the pump shaft coupling teeth must
properly mate with the engine nylon element. Adjust the coupling on the pump shaft for
maximum engagement.
MANUAl92375-002
March 1998
3. Open all ball valves from hydraulic tank.
4. Fill the pump case with hydraulic fluid by loosening the vent/fill plug in the pump case,
opening the inlet line and allowing gravity to prefill the inlet line pump case.
5. Disable engine ignition and crank engine for a maximum of30 seconds to ensure that
pump is primed. (For gasoline engine, pull coil wire: for Diesel engine, disconnect fuel
solenoid).
6. Tighten vent/fill plug in the pump case.
7. Check all inlet connections to be sure they are air-tight. An air leak in the inlet line can cause
the pump case to drain down and cause the pump to loosen prime during succeeding
start-ups.
8. The pressure compensator is factory set and can be adjusted (if necessary) for start-up.
Clockwise rotation increases the compensator setting and counterclockwise rotation
decreases this setting. Pump compensator should be set with the system deadheaded.
9. Differential pressure adjustment and horsepower control adjustment are factory set.
Readjustment is NOT recommended. Consult Time Condor Corporation, if necessary.
EMERGENCY PUMP
The emergency pump is driven by a 12 volt DC electric motor. This pump delivers
hydraulic fluid, under pressure, to the manifold assembly. The electric motor is
rated for noncontinuous duty and will fail prematurely ifactivated continuously
for extended time periods.
NOTE: This pump should only be used in emergency situations.
EMERGENCY PUMP ADJUSTMENT
The emergency pump pressure setting screw is located on the side of the adapter plate. To
adjust the relief pressure on the pump, remove the acorn nut, loosen the jam nut and tum
the adjusting screw in to increase pressure. To decrease pressure, tum the adjusting screw
out.
MAINTENANCE
Hydraulic Circuit Line Check
Insert hydraulic lines and connections for signs of looseness or obstruction.
Tighten loose fittings and correct any crimped hoses:
• From pump through pressure filter to valve stack.
• Lines between valve stack and reservoir.
• All hoses to the cylinders.
• Tie-down of hoses.
MANUAl92375-002
March 1998
• NOTE: Entrapped air in the hydraulic lines is common upon start-up and may result in
temporary irregular motion. However, if after a reasonable operating period this condition
persists, hydraulic lines should be bled to remove entrapped air and carefully inspected
for leaks, starting with the pump suction line.
DRIVE MOTORS
For two wheel drive systems, there are two drive motors on the rear wheels, and for four wheel
drive systems there are four drive motors (front and rear wheels). The drive motor connects to
the torque hub which has an integral brake. The SAUER-SUNDSTRAND SERIES 40-M35
fixed displacement motor is used as the T60's drive motor.
HYDRAULIC FLUID RESERVOm
The hydraulic fluid reservoir consists of the tank, a sight gauge, a filler cap with filter, a strainer, a
vent, a sump with drain plug, one valve for suction line, five valves for return lines and a valve for
the emergency pump suction line.
HYDRAULIC RESERVOm MAINTENANCE
Check tank for signs of leakage. Inspect tank securing bolts for tightness. Clean cap filter by
flushing with clean water and dry thoroughly.
HYDRAULIC FILTER
There are two hydraulic filters: a return filter and a high pressure filter. They are both located
near the hydraulic tank.
MANUAl9237~
March 1998
MAIN HYDRAULIC CONTROL VALVE
The main control valve is located on the same side as the ground controls on the hydraulic tray
•
assembly. The location ofthe different hydraulic functions' solenoids, relief valves (if applicable), .
and flow controllers are located on the isometric drawing below. The individual hydraulic functions
that the main hydraulic control valve regulates are described in more detail in the following pages .
and the isometric drawing below shows the location ofthe individual solenoids, reliefvalves
(if applicable), and flow controllers.
800M RETRACT FLOW CONTROLLER
BOOM EXTEND RELIEF VALVE -----""-
PLATFORM ROTATE eew
BOOM EXTEND
STEER LEFT (eN/OFF)

TURRET SWING RELIEF VALVE
f:::;~"""""'------ STEER RIGHT (ON/OFF)
~ _ _ _ _- - UN LOADER
THIS SOLENOID IS FOR THE OSCILLATING
AXLE LOCK OPTION. DO NOT INSTALL IF THIS - - - - - - P L A T F O R M LEVEL uP (ON/OFF)
OPTION IS NOT USED
LOCK VALVE #1
'f(f:~l-t------ PLATFORM LEVEL DO;.N (ON/OFF)
~):X~~~ PLATFORM ROTATE CW
(ffJ,rr~~~-- 800M EXTEND/RETRACT

PROPORTIONAL
SYSTEM RElIEF VALVE
BOO'! DOWN
TURRET SWING RIGHT ecw
TURRET SNlNG LEFT CW
JIB UP (DO NOT INSTALL ON 140 AND T60)
JI8 DOWN (DO NOT INSTALL ON T40 AND T60)
- MANUAL9237~
March 1998
BOOM LIFT SYSTEM
The boom lift system consists of a hydraulic valve segment on the ground valve bank, a flow
control valve, a lift cylinder with a counterbalance valve, a lift toggle switch on the remote control
pendant and a cohtrollever 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 raises or lower the boom.
FLOW CONTROL VALVE
The flow control valve, located at the boom up outlet on the boom lift valve segment,
controls boom down speed. The flow control valve allows full hydraulic fluid flow for the
boom up function. For the boom down function, the flow control valve meters the hydraulic
fluid flow, thus allowing a smooth descent.
Flow Control Valve Adjustment
If boom bounces while descending, adjust the valve clockwise until boom descends smoothly.
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
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 remote control pendant and a control lever 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 V ALVE
The pressure relief valve limits the pressure on the base end ofthe cylinder to 1500 PSI (103
Bar, 105.5 Kglcm2) to prevent the cylinder rod from buckling. The pressure relief valve is
factory set and needs no adjustment.
MANUAl92375-002
March 1998
TELESCOPE CYLINDER
The telescope cylinders control the extending and retracting of the boom.
JIB BOOM SYSTEM
The jib boom system consists of a hydraulic valve segment on the ground valve bank, a cylinder
with a counterbalance valve, and a control lever on the platform console and a toggle switch on
the remote control pendant.
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 of the 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 ofthe 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 only be 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.
ROTARY ACTUATOR MAINTENANCE
Change the hydraulic fluid once every year (see Lubrication Chart).
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, fluid circuit through the platform level control valve.
The platform levelling system in only controlled from the platform console.
Refer to "Boom Component Locators" in the introduction of this manual for platform leveling
system component locations.
MANUAl92375-002
March 1998
MASTER LEVELLING CYLINDER
The master levelling cylinder is a double acting cylinder located between the upper frame ofthe
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.
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.
RELIEF VALVES
The relief valves are factory set at 3000 PSI (207 Bar/211 Kg/cm2) and prevent high pressure
spikes in the levelling circuit that could result in component damage. High pressure spikes can
occur when the platform is manually controlled for levelling, which cause the slave level cylinder
to bottom out before the master level cylinder stops moving as the boom is lowered.
STEER SYSTEM
The two wheel steering system consists of a selector valve assembly, a steer valve segment,
hydraulic swivel, a steer cylinder, a steer toggle switch on the remote control pendant and a
steer rocker switch on the drive lever at the platform console. Refer to "Component Locators"
in the introduction of this manual.
The four wheel steering system also includes a diverter valve located on the undercarriage,
that is activated by a toggle switch at the platform controls. This valve is used to select front
or rear steer.
STEER VALVE SEGMENT
When the steer control lever on the platform console or the steer control toggle switch on the
remote control pendant 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 PRESSURE RELIEF VALVE
The steer pressure relief valves limits the pressure on the base end of the cylinder to 1900 PSI
(131 Bar, 131.5 Kg/cm2) to prevent the cylinder rod from buckling. The pressure relief is
factory set and needs no adjustment.
STEER CYLINDER
The cylinder is double acting and is directly connected to the steering linkage assembly. This
cylinder powers all steering movements.
MANUAl92375-002
March 1998
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).
HYDRAULIC SWIVEL
The hydraulic swivel allows passage of hydraulic fluid from the steer valve segment in the
turret to the steer cylinder in the undercarriage and back. The swivel allows for 3600 of
continuous turret rotation in either direction. 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).
MANUAl92375-002
Marc:h1998
This page intentionally left blank
MANUAl9237~
March 1998
SECTION 3:
DRIVE SYSTEM
MANUAl 92375-002
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TABLE OF CONTENTS, SECTION 3
Drive System Components ......................................................................................................................... 35

Drive Motor ........................................................................................................................................ 35
Drive Valve Manifold - Two Wheel Drive ......................................................................................... 35
Flow Divider/ Combiner Valve .......... ,..................................................................................... 36
Brake Valve Circuit ................................................................................................................ 36
Drive Valve Manifold - Four Wheel Drive ......................................................................................... 37
Brake Valve Circuit ................................................................................................................ 38
Selector Spool Valve Circuit ................................................................................................... 38
Toggle Switch on the Pendant Control ............................................................................................... 39
Platform Control Handle (Joystick) .................................................................................................... 39
MANUAL92375-002
March 1998
DRIVE SYSTEM COMPONENTS
The standard T60 is propelled by two hydraulic drive motors. The optional 4 wheel drive T60 is
propelled by four hydraulic drive motors. The drive circuit consists ofthe hydraulic drive motors,
the drive valve segment, the drive manifold, a toggle switch on the ground control and a platform
drive control lever (joystick).
DRIVE MOTOR
For two wheel drive systems, there are two drive motors on the rear wheels, and for four
wheel drive systems there are four drive motors (front and rear wheels). The drive motor
connects to the torque hub, which ifit has an internal brake, or to a separate brake ifneeded.
DRIVE VALVEMANIFOLD-TWOWHEEL DRIVE
REAR FLOW DIVIDER (P-66) BRAKE SOLENOID
o G1
\
L HIGH SPEED SOLENOID
MANUAL92375-002
March 1998
• DRIVEVALVEMANIFOLD-TWOWHEELDRIVE
NOTE: Refer to "Machine Specifications" to determine maximum system pressure

for your T60.
m SPEED DRIVE ENABLE VALVE
The hi speed drive enable valves are 2 positions, 2 way solenoid valves that bypass the
flow divider valve and are used to control the fluid flow for travel speed. The valves require
no adjustment and seal kits are available (see Illustrated Parts Catalog).
FLOW DIVIDER/COMBINER VALVE
In the forward direction, this valve divides flow, and in the reverse direction it combines the
flow. The single flow divider directs the flow so that 50% goes to the left and 50% goes to
the right. The valve requires no adjustment and a seal kit is available (see Illustrated Parts
Catalog).
There is a non-serviceable, fixed orifice that allows hydraulic fluid to transfer from one drive
motor to the other. When making turns, the outside tire turns faster and requires more hydraulic
fluid flow. Since the flow divider gives each motor equal flow, this orifice will allow the transfer
of hydraulic fluid from the inside wheel to the outside wheel and prevent tire scrubbing on hard
surfaces.
BRAKE VALVE CIRCUIT
The brake valve circuit consists of a shuttle valve, a pressure reducing valve and a flow
control valve. The shuttle valve diverts maximum pressure from either the forward or
reverse supply ports and sends it to the pressure reducing valve which reduces it to 500
PSI maximum. The flow control valve delays the application of the spring applied hydraulically
released brake when releasing the drive handle. This delay allows for a smooth stop by
restricting the return flow of oil. The valves require no adjustment and seal kits are available
(see Illustrated Parts Catalog).
MANUAl92375.Q02
March 1998
DRIVE VALVE MANIFOLD - FOUR WHEEL DRIVE
•
HIGH SPEED SOLENOID BRAKE SOLENOID
REAR FLOW DIVIDER (P-44)
FRONT TO REAR
FLOW DIVIDER (P-66) FRONT FLOW DIVIDER (P-44)
MANUAl92375-002
March 1998
DRIVE VALVE MANIFOLD - FOUR WHEEL DRIVE
NOTE: Refer to "Machine Specifications" to determine maximum system pressure for your T60.
HI SPEED DRIVE ENABLE VALVE
The hi speed drive enable valves are 2 positions, 2 way solenoid valves that bypass the
flow divider valve and are used to control the fluid flow for travel speed. The valves require
no adjustment and seal kits are available (see Illustrated Parts Catalog).
FLOW DIVIDER/COMBINER VALVE
In the forward direction, these valves divide flow, and in the reverse direction they combines the
flow. The single flow divider directs the flow so that 50% goes to the left and 50% goes to the right
The remaining two flow dividers direst the flow for each side so that 50% goes to the front and 50%
goes to the rear. These two valves guarantee flow to all wheels (4 wheel positraction) and are only
active while the function speed switch at the platform console is in low. The valves require no
adjustment and seal kits are available (see Illustrated Parts Catalog).
There is a non-serviceable, fixed orifice that allows hydraulic fluid to transfer from one drive motor to
the other. When making turns, the outside tire turns faster and requires more hydraulic fluid flow. Since
the flow divider gives each motor equal flow, this orifice will allow the transfer of hydraulic fluid from.
the inside wheel to the outside wheel and prevent tire scrubbing on hard surfaces.
BRAKE VALVE CIRCUIT
The brake valve circuit consists of a shuttle valve, a pressure reducing valve and a flow
control valve. The shuttle valve diverts maximum pressure from either the forward or
reverse supply ports and sends it to the pressure reducing valve which reduces it to 500
PSI maximum. The flow control valve delays the application of the spring applied hydraulically
released brake when releasing the drive handle. This delay allows for a smooth stop by
restricting the return flow of oil. The valves require no adjustment and seal kits are available
(see Illustrated Parts Catalog).
SELECTOR SPOOL VALVE CIRCUIT
The hi speed selector valve is a 2 position, 4 way solenoid valve that pilots the two selector spools open
when energized in high speed. This results in a series - parallel flow operation. When the hi speed
selector valve is not energized, the system diverts 25% of the flow to each wheel motor. The selector
spool flow valves divert flow from the flow dividers and reduce heat generation.
MANUAL92375-002
March 1998
TOGGLE SWITCH ON THE PENDANT CONTROL
To operate the drive function from the ground, use the "Drive" toggle switch on the pendant control.
See "Section 4: Electrical System" for switch replacement.
PLATFORM CONTROL HANDLE (JOYSTICK)
To operate the drive function from the platform, use the platform control handle. See "Section 4:
Electrical System" for control handle adjustment or replacement.
MANUAl92375-002
March1998
•
SECTION 4:
ELECTRICAL SYSTEM
MANUAl92375-002
March 1998
TABLE OF CONTENTS, SECTION 4
GeneralOperations ............................................................................................................................... 42
Control System Adjustment ................................................................................................................... 44
Error Codes ........................................................................................................................................... 46
Electrical System .................................................................................................................................. 47
Battery ................................................................................................................................................. 47
Battery Maintenance (In Use) ....................................................................................................... 47
Battery Preventive Maintenance ................................................................................................... 47
Battery Replacement ..................................................................................................................... 48
MovementAlarm .................................................................................................................................. 48
Tilt Alarm .............................................................................................................................................. 49
Circuit Breaker ........................................................................................................................................... 49
Limit Switch ................................................................................................................................................ 49
Emergency Pump ........................................................................................................................................ 49
Emergency Stop Button .............................................................................................................................. 49
Ground Control Cabinet Switch Removal ................................................................................................... 50
Platform Console Switch Removal .............................................................................................................,50
Platform Control Board ............................................................................................................................... 50
Electronics Control Module ................................................•........................................................................ 50
AngleSensorCalibration ............................................................................................................................ 51
Length Sensor Calibration ........................................................................................................................... 52
MANUAl9237lHJ02
March 1998
• GENERAL OPERATION
The control system in the T-Series machines consists of the following parts. (See Diagram On Page 43)
Platform Joysticks and Switches

Platform Control Board
Ground Control Switches
Ground Control Board
Hydraulic Valve
Hydraulic Actuators
All platform switches and proportional joystick wires are connected directly to the platform control board.
Communication of these inputs is transmitted to the ground contro board via two wires in the 8 conductor
shielded boom cable using RS232 protocol. This data is transmitted at a very high speed where no delay
in operation is noticed. The ground control board receives the signal and outputs the correct signal
to drive the hydraulic valve. Hydraulic actuation then takes place. The ground board is a solid state
switching board that takes the place of many failure prone mechanical relays.
The ground control board consists of24 on/off outputs and 12 proportional outputs. All switches and
lights are controlled by the on/off outputs. All joysticks are controlled by the proportional outputs.
MANUAl92375-002
March 1998
CONTROL SYSTEM DIAGRAM
JOYSTICK
PLATFORM
CONTROL
PLATFORM CONTROL BOX BOARD
8 CONDUCTOR SHEILDED
CABLE THROUGH BOOM.
GROUND CONTROL BOARD
HYDRAULIC VALVE
ACTUA TOR
MANUAl 92375-002
March 1998
CONTROL SYSTEM ADJUSTMENT
All adjustment are made by turning the 14 tum potentiometers located on the ground control board.
No adjustments are made on the platform control board. Function speeds are adjusted using the following
three potentiometers:
MAX Potentiometer
This adjusts the current (or speed) of the function when the joystick is at full on. Initial current settings
for each function are listed in Table 1. The function speed (time to move through the complete motion of
function in seconds) is also listed. The procedure should be to initially set the current, then go back and
do any final tweaking to get the correct speed. Valve tolerances vary from one to another so function
speed should always be the final setting. Adjusting the MIN potentiometer will effect the MAX setting.
You will have to go back and forth to get the final setting for both.
MIN Potentiometer
This adjusts the current (or speed) of the function when joystick is moved just slightly. This is sometimes
referred to as the threshold. In order to achieve the smoothest full joystick range of proportional control,
it is desired to have the machine initially start to move when the joystick is just moved slightly, and at full
speed when the joystick is full on. With the ammeter connecter (see diagram 1), move the joystick until
the first reading is displayed. The required current for the specific function is listed in Table 1.
If the current needs to be increased, tum the pot in (clockwise). If it needs to be reduced tum it out
(counterclockwise). If the machine lurches when the joystick is initially moved, the setting is to high and
should be reduced. The final adjustment should be based on how the functions feel. If you have to move
the joystick a long way before the function starts moving, the setting is too low. Adjusting the MAX
potentiometer will also effect the MIN setting, so you have to go back and forth. Remember, if you
increase the MAX, it will increase the MIN slightly and vice versa. The MIN adjustment also directly
effects the speed when the platform function speed switch is set to low. This is sometimes a more
important adjustment based on feel.
RAMP Potentiometer
The ramp adjustment determines how quickly the function will start and stop when the joystick is moved
suddenly. Caution should be used because when ramping off, you do not have the control to quickly stop
the function unless you remove your foot from the deadman switch. Initial settings are listed in Table 1.
MANUAl92375-002
March 1998
GRUUND CUNTRUL BUARD
4 DIGIT ERROR S~ING RIGHT RAMP ADJUSTMENT
CODE DISPLAY
S~ING RIGHT MIN ADJUSTMENT
12 PROPORTlONAL LED'S
24 ON/OFF LED'S S~ING RIGHT MAX ADJUSTMENT
o o
~
0
..MP
".,
..cTlVE ENGINE EMERG. CHOKE LIGHTS
RAMP
II MIN "'IN B 0
• • • • • B
START PUMP GLoIJ PLUG • MAX
• GOOD MAX •
DATA S'JING BOOM.
LEFT RETRACT
ON/OFF
UNLoADER ENGINE SLoIJ FAST
• • • •
VALVE ON THROTTLE THROTTLE
MOVEMENT HORN HIGH STEER

a-RAMP-B RMP
• • • • • MAX
RAMP a
ALARM DRIVE RIGHT
fit MIN -"'1111- MlhI .,
B
•
0 - MAX _ 0
MAX
BOOM BOOM. JIB JIB.
DolJN UP DOIJN UP
STEER PLATFRoM PLATFORM PLATFORM
• • • •
LEFT RIGHT LEFT UP
PLATFORM AXLE AXLE AXLE
• • • • §RAMP RAMP
R
Do'JN LIGHT VALVE I VALVE 2
§-RAM~§
o "'IN
~
_MIN_
. MIN 0
• • •
1___ 0 MAX MAX e
-MAl(- ._.
STl[R SI£ER ANGLl BRAKE DRIVE BOOM
DRIVE. BOOM . .
• • •
VALVE I VALVE 2 INDlCATDR VALVE REVERSE FoR'JARD EXTEND RETRACT
PROPDRTIONAl PROPORTIONAL
PolJER
•
(+5V ON)
0 0
f\
0 U
MANUAL92375-002
March 1998
• ERROR CODES
E[HAN AR rililAGNOSTIC SYSTEM
EJ
ERROR CODE DISPLAY
THE FOLLOWING CHART ASSISTS THE USER IN TROUBLE-
_ OK - SHOOTING THE ELECTRICAL SYSTEM. PLEASE REFER TO
SERVICE MANUAL FOR ADDITIONAL INFORMATION.
ERROR CODE DESCRIPTION PROBABLE CAUSE

ECOl DATA LINES DA T A LINE PROBLEM OR PROBLEM AT PLATFORM BOX-
EC02 DRIVE BAD CONNECTION AT DRIVE JOYSTICK
EC03 BOOM UP/DOWN BAD CONNECTION AT BOOM UP/DOWN JOYSTICK
EC04 SWING BAD CONNECTION AT SWING JOYSTICK
ECOS BOOM EXT.jRET. BAD CONNECTION AT EXTENDED/RETRACT JOYSTICK
EC06 JIB BAD CONNECTION AT JIB JOYSTICK
EC07 STARTER SHORT OR OPEN CONNECTION TO STARTER RELAY
ECOB EMERGENCY PUMP SHORT OR OPEN CONNECTION TO EMERGENCY PUMP
EC09 CHOKE/GLOW PUMP SHORT OR OPEN CONNECTION TO CHOCK/GLW PLUG RELAY
EC10 PUMP STROKER SHORT OR OPEN CONNECTION TO DUMP VALVE
ECll HORN SHORT OR OPEN CONNECTION TO HORN RELAY
EC12 HIGH SPEED DRIVE SHORT OR OPEN CONNECTION TO SERIES/PARALLEL VALVE
EC13 PLATFORM ROTATE RIGHT SHORT OR OPEN CONNECTION TO PLATFORM ROT. RT VALVE
EC14 PLATFORM ROTATAE LEFT SHORT OR OPEN CONNECTION TO PLTFRM ROTATE LF VALVE
EC1S PLATFORM LEVEL UP SHORT OR OPEN CONNECTION TO PLTFRM LEVEL UP VALVE
EC16 PLA TFORM LEVEL DOWN SHORT OR OPEN CONNECTION TO PLTFRM LEVEL DOWN VALVE
EC17 AXLE LIGHT SHORT OR OPEN CONNECTION TO AXLE LIGHT
EC18 AXLE LOCK VALVE 1 SHORT OR OPEN CONNECTION TO AXLE LOCK VALVE 1
EC19 AXLE LOCK VALVE 2 SHORT OR OPEN CONNECTION TO AXLE LOCK VALVE 2
EC20 STEER VALVE 1 SHORT OR OPEN CONNECTION TO STEER VALVE 1
EC2l STEER VALVE 2 SHORT OR OPEN CONNECTION TO STEER VALVE 2
EC22 BRAKE SHORT OR OPEN CONNECTION TO BRAKE VALVE
EC23 AXLE PROXIMITY SWITCH AXLE NOT IN LEVEL POSITION
EC24 ENGINE DISTRESS OIL PRESSURE OR WATER TEMP SWITCH OR ,\IRING I
EC2S BOOM EXTENSION BAD LENGTH SENSOR
EC26 BOOM ANGLE BAD ANGLE SENSOR I
CDIDQ!
The error codes identify where to look for bad connections or failed components.
MANUAL92375-002
March 1998
ELEC11UCALSYSTEM
The following section is a description of maintenance for the major components of the electrical system.
BATTERY
One 12 volt batteries supply the electrical power required to operate the machine.
BATTERY MAINTENANCE (IN USE)
Check battery and surrounding area for signs of damage or corrosion.
Check battery terminals for:
• Corrosion. Regular clean connections and apply a non-metallic grease or protective

spray to retard corrosion.
• Loose Connections. Be sure all cable connections are tight, and that good contact is
made to terminals.
• Broken or Frayed Cables. Be sure all cable connections are good, and that no loose
or broken wires are exposed. Replace as needed.
Check battery electrolyte level. Replenish the electrolyte, if necessary. Remove vent caps before filling,
and USE ONLY DISTILLED WATER. Fill all cells to the proper level. Do not overfill. Fill to level
indicator ( or 112 inch over the top of the separators ifthere is no level indicator). Fill after charging to
prevent overflow of acid due to expansion. Do not use a hose to add water to batteries.
Allowing the electrolyte level to drop below the top of the separators will lead to shortened battery
life. Excessive water usage can indicate that a battery has been overcharged, has been subjected to
excessively high temperatures, or is nearing the end of its service life.
Keep battery clean. Wash the top ofthe battery, making sure all vents are in place. Do not allow
cleaning water or other foreign matter to enter the cells. Use a solution of bicarbonate of soda and
water to wash the battery if there is an accumulation of acid.
BATTERY PREVENTIVE MAINTENANCE
Once a month, after the battery has been charged, spot check the specific gravity of two or more cells.
A fully charged battery should indicate 1.28 specific gravity. If low readings are noted, check the
following:
• Check terminals for corrosion, loose connections and broken or frayed cables.
• Check all cells with a hydrometer for variation in specific gravity. A variation of 0.03 points or
more between cells is cause for concern.
Recheck specific gravity of all cells after recharging.
MANUAl92375-002
March 1998
• BATTERY REPLACEMENT
To remove the battery, follow these procedures:
AWARNING
BEFORE REMOVING BATTERY FROM THE UNIT, TURN
OFF THE IGNITION SWITCH. THERE SHOULD BE NO POWER
TO THE MACHINE.
AWARNING
Always disconnect the negative battery cables first.
Remove bolts holding battery to turret.
Lift the battery from the turret. Put the battery to the side and dispose of properly.
AWARNING
Always connect the positive battery cable first.
To install the battery, lift and position it on turret. Secure battery in position with wing nuts and battery
hold downs. Connect battery cables.
MOVEMENT ALARM
The optional movement alarm is activated as soon as the platform console drive controller or drive
toggle switch on the ground control is moved offthe center ''Neutral'' position.
AWARNING
THE MOVEMENT ALARM IS PROVIDED FOR YOUR PROTECTION,
AND PROTECTION OF PERSONS WORKING IN IMMEDIATE AREA.
DISABLING THIS IMPORTANT SAFETY DEVICE MAY RESULT IN
DEATH OR SERIOUS INJURY.
MANUAL92375-002
March 1998
TILT ALARM
The tilt alarm gives an audible warning when the machine is 4-112° or more out of level. 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.
TILT 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 ofthe three fastened comers ofthe
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 4-112°. The yellow LED indicates the sensor is tilted beyond 4-
112° and the 3 second delay has expired (tilt alarm should sound at the platform). On these units, there is
an in-line 2 amp fuse. Check the fuse first, if the alarm sounds continuously when the sensor is level.
Then, check the flange nuts.
TILT 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.
cmCUIT BREAKER
There is one 20 amp circuit breaker mounted on the face ofthe 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 ofthe 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 PUMP
There is an emergency pump mounted near the ground control box. It is activated when the Emergency
Pump push button on the platform control console or on the remote control pendant is pressed. When
either push button is pressed and held, the emergency pump is energized, allowing all hydraulic functions
to operate should the main motor powered hydraulic pump is disabled. When either of the emergency
pump push-buttons is energized, main pump, high speed, and low speed throttle solenoids are turned off
automatically.
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.
MANUAl9237~2
March 1998
f
• GROUNDCONTROLBOXS~TCHREMOVAL
To replace a ground control switch or button, disengage the ground control cover retaining screws to
gain access for switch or button removal. Remove the appropriate button mounting screws and wires.
PLATFORMCONTROLCONSOLES~TCHREMOVAL
To replace a platform switch,joystick or light, remove the six platform console screws and swing the
console up on its hinges, to gain access for removal. Remove the appropriate switch,joystick, or light
mounting screws and wires.
PLATFORM CONTROL BOARD
The platform control board contains the microprocessor or related electronics for the control of
platform lights and sending data to the electronics control module.
To replace the platform control board remove the six platform console screws and swing the console
up on its hinges to gain access for removal. Unlatch the individual connectors by pressing on top of
the connector locks and remove connectors. Remove four bolts holding the board in place.
ELECTRONIC CONTROL MODULE
The electronics control module, located in the ground control box, contains the microprocessor and
related electronics for the control of all ofthe machine functions. It is a non-serviceable unit. Ifthe
module is suspected of being faulty, remove the four bolts that secure it in place inside the ground
control box. Also, unplug the two connectors. Return the module to TIME CONDOR Corporation.
When installing the electronics control module, secure it in place with the four bolts, and plug in the
two cable connectors. The connectors are keyed so they cannot be interchanged.
Refer to the troubleshooting section for electronics console module fault code identifications and
diagnostic procedures.
MANUAl92375-002
March 1998
•
PROCEDURE FOR CALIBRATING ANGLE SENSOR
The following procedure is to be followed to calibrate the angle sensor.
l. With the boom in the fully lowered position, insert the slot screw (part #71531) into the end of the boom pin.
After the slot screw is flush with the jam nut, rotate the screw until its' slot is vertical and tighten the jam nut.
2 After the jam nut is tight, raise the boom to its fully raised position. Then, install the angle sensor, along with
the angle sensor blade (part #71728), onto the angle sensor plate (part #71529) using two # 10-32 x 1.75" long
screws. Leave the screws loose enough so that the angle sensor can be rotated.
3. Finally, rotate the angle sensor until the angle sensor calibration light comes on the lower control box.
Tighten down the screws and install the boom angle sensor cover (part #71499).
~
ANGLE SENSOR _ / 00
CAUBRA nON LIGHT
0
0 0
0
0 0
0 o 0
0 0 0
~
0 0"
LOWERCONTROLBOX
MANUAL92375-002
March 1998
PROCEDURE FOR CALIBRATING THE LENGTH SENSOR
The following procedure is to be followed to calibrate the length sensor.
1. Place the machine on a flat level surface. Next, raise the boom until it is horizontal with the ground.
Then, extend the boom until it stops. The boom extend decal located on the tip boom (shown below) displays the
acceptable operating zone along with a calibration line on the center of the decal. In general operation, the boom
may extend slightly more or slightly less. As long as it always stop within the acceptable range it is O.K. But,
when doing any adjustments it should be set to the calibration line. The initial adjustment must be such that the
end of the midboom must lie inline with the calibration line.
2. If the midboom does not line up with the calibration line, the length sensor will need to be calibrated
3. Location ofthe length sensor is in the box mounted to the outerboom located just above the boom's pivot
pin on the inside of the outer boom. To get to the length sensor adjustment, take the cover off the end of the
outer boom and set aside. Then, take off the box's cover and set aside.
COVER MTG
SCREWS
LENGTH BASE BOOM

SENSOR COVER REMOVED
MANUAl92375-002
March 1998
GEAR 8 GEAR A
LEVER ARM
PULLED AWAy
VIEW" A" VIEW "8"
4. In order to calibrate the length sensor if the boom is extending past the acceptable operating zone, the lever arm
needs to be pulled away from Gear B (See View B). Rotate Gear A counter clockwise at 1 tooth increments to
calibrate the sensor. If the boom is not extending far enough, rotate gear A clockwise. Rotate the lever arm back
until Gear A meshes with Gear B. Retract the boom slightly and extend until it stops. Repeat this step until
alignment is achieved.
MANUAL92375-002
March 1998
CD
MANUAl92375-002
March 1998
SECTION 5:
MECHANICAL COMPONENTS
MANUAl 92375-002
March 1998
Table of Contents, Section 5
Mechanical Components ................................................................................................................. 57

Tires .................................................................................................................................... 57
Changing Tires .................................................................................................................... 57
WheelsandLugNuts ................................................................................................................ 57
Drive Hub Assembly ................................................................................................................. 57
Steer Cylinder Pins .................................................................................................................... 59
Steer Cylinder ........................................................................................................................... 59
Steer Cylinder Seal replacement .......................................................................................... 59
Drive Motor Replacement ......................................................................................................... 60
Turret .................................................................................................................................... 60
Platform .................................................................................................................................... 60
Hoses and Cables ..................................................................................................................... 60
Miscellaneous Equipment ........................................................................................................... 60
Boom .................................................................................................................................... 60
Boom Pivot Pin and Bushing Replacement ........................................................................... 60
Wear Pads ......................................................................................................................... 61
Base Boom Top Wear Pad Replacement ...................................................................... 61
MovingAnchorWearPadReplacement ....................................................................... 62
Mid Boom Top Front Wear Pad Replacement .............................................................. 62
MidBoomRearWearPadReplacement ...................................................................... 62
Tip Boom Top Front Wear Pad Replacement ............................................................... 63
Boom Lift Cylinder .................................................................................................................... 63
Lift Cylinder Pivot Pin Replacement .................................................................................... 63
LiftCylinderSealReplacement(OnMachine) ..................................................................... 63
BenchReplacementOfLiftCylinderSeals .......................................................................... 64
Counterbalance Valve Inspection ........................................................................................ 66
libBoomRemoval .................................................................................................................... 66
lib Boom Installation ................................................................................................................. 66
BoomTelescope ....................................................................................................................... 67
Telescope Cylinder Removal ............................................................................................... 67
Telescope Cylinder Seal Replacement ................................................................................. 67
Telescope Cylinder Installation ............................................................................................ 68
Counterbalance Valve Inspection ........................................................................................ 68
Platform Levelling Cylinders ....................................................................................................... 69
Platform levelling Cylinder Pin Replacement ......................................................................... 69
Levelling Cylinder Seal Replacement ................................................................................... 69
PlatformLevellingProcedure .............................................................................................. 69
MANUAl92375-002
March 1998
MEC~CALCO~ONENTS
Following is a description ofthe major mechanical components.

•
TIRES
Tires used are pneumatic or the optional foam filled. Inspect tires for cuts, sidewall damage or
abnormal wear. Any tire faults MUST BE CORRECTED before further machine operation.
CHANGING TIRES
A WARNING
CALCIUM FILLED AND/OR FOAM FILLED TIRES ARE EXTREMELY
HEAVY. CARE MUST BE TAKEN TO AVOID PERSONAL INJURY.
When a tire change is necessary, follow these steps:
A CAUTION
ALWAYS BLOCK THE WHEELS before you raise the machine.
• Loosen and remove lug nuts, and pull off the wheel assembly and tire.
• Replace the tire and reinstall.
• Fasten lug nuts and tighten to proper torque (see Machine Specifications).
• Lower the machine and remove the blocks.
WHEELS AND LUG NUTS
Check the security of the wheel lug nuts (see Machine Specification for proper torque) and
examine the wheel rims for damage.
DRIVE HUB ASSEMBLY
Drive hub assembly consists of a hydraulic motor, and a torque hub.
• To remove drive hub assembly:
1. Block the steer wheels and raise the machine at the drive end.
MANUAL92375-002
March 1996
AWARNING
2. Remove tire and wheel assembly:
a. Loosen and remove the lug nuts.
b. Pull off the tire and wheel assembly.
A CAUTION
Plug all open hydraulic fittings to prevent contamination by dirt or other foreign
objects.
3. Disconnect hoses to the drive hub assembly.
4. Loosen and remove eight capscrews and flat washers on the drive hub assembly.
5. Slide off hydraulic motor and torque hub as one unit.
• Install drive hub assembly:
I. Align the drive hub assembly (hydraulic motor and torque hub) with the axle tube
assembly.
2. Install and torque the eight capscrews with flat washers.
3. Connect hydraulic hoses to the drive hub assembly.
AWARNING
4. Install tire and wheel assembly:
a. Position tire and wheel assembly.
b. Install and torque lug nuts.

5. Lower the machine and remove the steer wheel blocks.
MANUAl92375-002
March 1998
STEER CYLINDER PINS
Check all pins for wear. Ifpin rotates, check for a missing retaining ring. If wear is detected,
the pin must be replaced.
CYLINDER PIN REPLACEMENT
1. Remove retaining rings (rod end) or hair pin clips (base end).
2. Remove the pin.
3. Grease and install new pin retaining rings or hair pin clips.
STEER CYLINDER
The steer cylinder is of the double acting type. Check the cylinder for hydraulic fluid leaks.
STEER CYLINDER SEAL REPLACEMENT
1. Disconnect the hydraulic hoses.
2. Remove the steer cylinder pin.
3. Remove the cylinder.
4. Clean the end ofthe cylinder.
5. Loosen the end cap and withdraw it over the piston rod.
A CAUTION
Take care not to damage the rod surface and guard against dirt
entering the system.
6. Remove the rod and piston assembly.
7. Replace the seals and "0" -rings.
8. Install the rod and piston assembly.
9. Install and tighten the end cap.
10. Install cylinder.
11. Connect the hydraulic hoses.
MANUAL92375-002
March 1998
DRIVE MOTOR REPLACEMENT
Disconnect hoses and remove bolts that secure drive motor to drive assembly. Then slide motor out.
To install drive motor, secure it to the drive assembly with bolts. Connect hoses to drive motor.
TURRET
The turret consists of two compartments; one is the engine compartment and the other is the
hydraulic compartment.
Steam clean the turret once a year, and inspect all welds and brackets. Check for cylinder
pins that tum in their mounting, which will indicate sheared pin lock bolts.
PLATFORM
Steam clean the platform and inspect all welds and brackets. Check all the hydraulic and electrical
components.
HOSES AND CABLES
Inspect all hoses and electrical cables for security and damage. Check for leaks at fittings. ANY
DAMAGED HOSES OR CABLES SHOULD BE REPLACED. Cables and hoses should be
examined for rubbing and chafing, especially in the swing bearing area and the hose track area.
MISCELLANEOUS EQUIPMENT
Check all miscellaneous equipment mounted on the machine for secure attachment. Check
for evidence of oil or hydraulic fluid leakage.
BOOM
Clean the boom once a year and inspect along the boom structure, especially all welds and brackets.
BOOM PIVOT PIN AND BUSHING REPLACEMENT
IMPORTANT: It is NECESSARY TO MAINTAIN THE CORRECT

ALIGNMENT between the boom and pylon weldment during this
operation. Any relative movement will make fitting of the pin more
difficult.
AWARNING
THE BOOM WILL FALL IF NOT SUPPORTED WHEN THE PIVOT PIN IS REMOVED.
MANUAl 92375-002
March 1998
1. SUPPORT THE BOOM securely (on a boom stand or similar rigid platform).
2. Remove the retaining rings, capscrew and locknut, and drive out the boom pivot pin,
taking care not to damage the inner bore, bushings, sleeve bearings or thrust bearings.
3. Check bushings, sleeve bearings and thrust bearings and replace if necessary.
4. Install new pivot pin.
5. Install capscrew, locknut and retaining rings.
6. Apply grease to pin through the grease fitting.
WEAR PADS
Wear to boom sections is prevented by the installation of wear pads at several points along
the boom length. The wear pads should be checked for wear approximately every six months.
Fully retract the boom, and check the gap between the wear pad and the boom section.
Wear pads are located at the top front of the tip boom and at the top front of the mid boom,
and at the top, bottom and side rear of the mid boom, and at the top, bottom and side rear
ofthe base boom. There is also a moving anchor wear pad mounted on a weldment located
on the side of the base boom.
A CAUTION
If a pad wears to approximately 3/8" (9.5) thick, it should be replaced or shimmed.
Generally, only the bottom pad at the upper end and the top pad at the lower end of
the boom will show wear.
Base Boom Wear Pad Replacement
1. Fully retract and lower the boom.
2. Remove the capscrews, lockwashers and jam nuts holding the top and side wear pads.
3. Slide out the top and side wear pads.
4. Use a crane to hold the mid and tip boom section off the bottom wear pad.
5. Remove the capscrews, lockwashers and jam nuts holding the boom wear pad.
6. Remove the bottom wear pad.
7. Install new bottom wear pad with capscrews, lockwashers and nuts.
8. Rest the mid and tip boom section on the new bottom wear pad.
9. Install new base boom top and side wear pads.
10. Install capscrews, lockwashers andjam nuts.

MANUAL92375-002
March 1998
Moving Anchor Wear Pad Replacement
1. Fully retract and lower the boom.
2. Remove the capscrews, flat washers and locknuts holding moving anchor wear pad.
3. Remove wear pad.
4. Install f!.ew wear pad.
5. Install capscrews, flat washers and locknuts.
Mid Boom Top Front Wear Pad Replacement
1. Fully retract the boom and support the boom in the horizontal position.
2. Remove the telescope cylinder pin retaining rings and flat washers.
3. Remove telescope cylinder pin and lower the end of the telescope cylinder.
4. Access can now be gained to the mid boom top front wear pad retaining bolts,
lockwashers and nuts.
5. Remove bolts, washers and nuts; wear pad will easily fall out.
6. Install new wear pad with bolts, lockwashers and nuts.
7. Raise cylinder and install cylinder pin, retaining rings and flat washers.
Mid Boom Rear Wear Pads Replacement
I. Fully retract and lower the boom.
2. Remove the capscrews, lockwashers and jam nuts holding the top and side wear pads.
3. Slide out the top and side wear pads.
4. Use a crane to hold the tip boom section offthe bottom wear pad.
5. Remove the capscrews, lockwashers and jam nuts holding the bottom wear pad.
6. Remove the bottom wear pad.
7. Install new bottom wear pad with capscrews, lockwashers and nuts.
8. Rest the tip boom section on the new bottom wear pad.
9. Install new base boom top and side wear pads.
10. Install capscrews, lockwashers and jam nuts.
MANUAl92375-002
March 1998
Tip Boom Top Front Wear Pad Replacement
1. Fully extend the boom and support the boom in the horizontal position.
2. Remove bolts, washers and nuts; wear pad will easily fall out.
3. Install new wear pad with bolts, lockwashers and nuts.
BOOM LIFT CYLINDER
The boom lift cylinder is ofthe double acting type. During operation, the cylinder should not leak,
but a slight dampness at the rod seal is acceptable. The pins should be checked for wear. Check
the pin capscrew for tightness. The cylinder and holding valve should be inspected for fluid leakage,
damage and security.
LIFT CYLINDER PIVOT PIN REPLACEMENT
A CAUTION
Support the boom any time maintenance is required on the boom or boom cylinders.
1. Support the boom securely (on a boom stand or similar rigid platform).
2. Operate the boom lift control to release hydraulic pressure and remove any load on the
lift cylinder.
3. Remove the retaining rings.
4. Remove the capscrews and nuts.
A CAUTION
The cylinder will fall if not supported when the pivot pin is removed.
5. SUPPORT THE LIFT CYLINDER and remove the pin.
6. Install new pin, capscrews, nuts and retaining rings.
7. Apply grease to pin through grease fitting.
LIFT CYLINDER SEAL REPLACEMENT (ON MACHINE)
I A CAUTION I
MANUAl92375-002
March 1998
1. Support the boom securely in the horizontal position (on a boom stand or similar
rigid platform).
2. Operate the boom lift control to release hydraulic pressure and remove any load in the lift
cylinder circuit.
3. Clean the cylinder, and loosen the cylinder end cap by several turns.
A. CAUTION
The cylinder barrel will fall if not supported when the pivot pin is removed.
4. Remove the rod end pivot pin, and support the cylinder barrel.
5. Loosen the end cap completely, and withdraw it carefully over the piston rod.
A. CAUTION
Take care no to damage the rod surface and guard against dirt entering the system.
7. Replace the "O"-rings, seals and backup rings.
8. Reassemble the lift cylinder, again AVOIDING DIRT AND ROD DAMAGE.
9. Tighten the end cap.
10. Install rod end pin.
BENCH REPLACEMENT OF LIFT CYLINDER SEALS
The lift cylinder can also be removed from the machine for seal replacement.
1. Operate boom lift to horizontal position.
A. CAUTION
MANUAL92375-002
March 1998
2. SUPPORT THE BOOM (on a boom stand or similar rigid platform) at the horizontal position.
3. Disconnect the hydraulic hoses from the cylinder.
A CAUTION
The cylinder will fall if not supported when rod end pin is removed.
4. Support the cylinder with a crane.
5. Remove the rod end cylinder pin.
6. With the cylinder supported, remove the base end cylinder pin.
7. Move the cylinder to a bench for examination.
8. Extend the cylinder, and examine the protruding rod for score marks and damage.
9. Clean the holding valve and examine for signs ofleakage.
10. Clean the end of the cylinder.
11. Loosen the end cap, and withdraw it carefully over the piston rod.
A CAUTION
Take care not to damage the rod surface and guard against dirt entering the system.
NOTE: It is recommended that the backup rings be placed when seals are changed.
13. Replace the seals and backup rings and reassemble the cylinder, AVOIDING DIRT AND ROD.
DAMAGE.
14. Tighten the end cap.
15. Install the base end of the cylinder on the machine.
16. Connect all the hydraulic hoses.
17. Extend the lift cylinder and install the rod end to the boom.
18. Remove cylinder support.
MANUAL92375-002
March 1998
19. Remove boom support.
20. BLEED THE SYSTEM after reinstalling the cylinder.
COUNTERBALANCE VALVE INSPECTION
1. Place rated load in platform, raise the boom to the horizontal position, extend the boom
to full side reach and stop the engine.
2. Ifthe cylinder subsequently begins to move, the counterbalance valve is faulty and the
cartridge should be replaced.
A DANGER
BOOM MUST BE SUPPORTED WHEN CHANGING THE COUNTERBALANCE
VALVE. CYLINDER WILL RETRACT WHEN CARTRIDGE IS REMOVED.
NOTE: The counterbalance valve is preset at the factory and is not field adjustable.
JIB BOOM REMOVAL
A. CAUTION
Plug all open hydraulic fittings to prevent contamination by dirt or other foreign objects.
1. Raise jib boom and support the platform.
2. Disconnect all electrical cables and hydraulic hoses at the platform and from the jib boom.
Note the connection of cables and hoses for ease of proper assembly.
3. Remove articulation cylinder pin.
4. Remove parallel arm pin to free jib boom weldment.
5. Remove upper jib boom pin to freejib boom weldment.
JIB BOOM INSTALLATION
To installjib boom and platform.
1. Attachjib boom weldmentto tip boom withjib boom pin.
2. Attach parallel arm weldment to tip boom with parallel arm pin.
3. Attach jib boom articulation cylinder to jib boom weldment with articulation cylinder pin.
4. Connect all electrical cables and hydraulic hoses at the platform and to the jib boom.
MANUAl92375-002
March 1998
BOOM TELESCOPE CYLINDER
The function of the telescope cylinder is to extend and retract the boom segment to allow positioning
ofthe work platform. The double acting cylinder must be removed from the machine before a
thorough inspection can be accomplished.
TELESCOPE CYLINDER REMOVAL
1. Elevate the boom to the horizontal position.
A. CAUTION
2. Extend the boom until the telescope cylinder rod end mounting pins on the mid boom are
exposed.
3. SUPPORT THE EXTENDED TIP BOOM (on a boom stand or similar rigid platform).
4. Remove retaining clips and the two pins at the rod end of the telescope cylinder to the tip
boom.
5. Close the hydraulic valves and disconnect the hydraulic hoses from the telescope cylinder.
Plug hose ends.
6. Remove the remaining rings, flat washers and pins from the boom base end of the cylinder.
7. Remove the two boom cap plates that secure the telescope cylinder to the mid boom.
8. Using a crane, withdraw the cylinder from the back end of the boom.
TELESCOPE CYLINDER SEAL REPLACEMENT
1. Remove the end cap from the cylinder.
A. CAUTION
Take care not to damage the rod surface and guard against dirt entering the system.
MANUAl92375-002
March 1998
2. Pull the cap and rod straight out of the cylinder barrel.
3. Remove the nut from the end of the rod.
4. Slip off the piston.
5. Examine the rod and seals for signs of damage or wear.
6. Remove the old seals and backup rings. Refer to Illustrated Parts Catalog.
7. Install new seals and backup rings. Refer to Illustrated Parts Catalog.
TELESCOPE CYLINDER INSTALLATION
A CAUTION
1. SUPPORT THE EXTENDED TIP BOOM (on a boom stand or similar rigid platform)
IN THE HORIZONTAL POSITION.
2. Connect the hydraulic hoses to the telescope cylinder and open hydraulic lines.
3. Cycle the telescope cylinder several times to BLEED THE SYSTEM.
4. Measure the distance from base boom pin holes to tip boom pin holes, and extend the telescope ....
cylinder that direction.
5. Using a crane, slide the telescope cylinder into the boom and align the rod end mounting
holes with the holes in the tip boom.
6. Install the two pins and retaining rings holding the rod end ofthe telescope cylinder to the tip
boom.
7. Install the pin, flatwashers and retaining rings in the base end of the cylinder.
8. Install the two boom cap plates that secure the telescope cylinder to the mid boom.
COUNTERBALANCE VALVE INSPECTION
I. Place rated load in the platform, hoist the boom to full elevation and extend the telescope
cylinder, then stop the engine.
2. If the telescope cylinder subsequently begins to move, the counterbalance valve is faulty and
the cartridge should be replaced.
NOTE: The counterbalance valve is preset at the factory and is not adjustable.
MANUAL92375-002
March 1998
PLATFORM LEVELLING CYLINDERS
The platform levelling system automatically keeps the platform level, using a master/ slave cylinder
arrangement. Whenever the boom is raised or lowered, the master cylinder is forced to move.
The fluid displacement from the mastercylinder is in turn sent up the boom to the slave cylinder.
This forces the slave cylinder to move the same distance as the master cylinder, which keeps
the platform parallel to the ground in any boom position.
The platform levelling cylinders (master and slave) are of the double acting type. The pivot pins
should be checked for wear. Check the pivot pin locking bolts for tightness. The cylinders should
be inspected for fluid leakage, damage and security. The seals should be replaced whenever the
cylinder is serviced.
LEVELLING CYLINDER PIN REPLACEMENT
SUPPORT THE PLATFORM to remove the load on both master and slave cylinders. Remove
the retaining ring, the pin locking bolts and nuts, and remove the pin.
Install new pin, locking bolts and nuts (lubricate bolts before installation) and retaining ring.
Apply grease to pin.
LEVELLING CYLINDER SEAL REPLACEMENT
Lower the main boom. SUPPORT THE PLATFORM to remove the load on both master and slave
cylinders. Remove the lock collar and pin. Slave cylinder seals can be replaced on the machine.
Master cylinder must be removed for seal replacement.
Clean the end of the cylinder. Unscrew the end cap and pull the cap and rod straight out to the
cylinder barrel. TAKE CARE NOT TO DAMAGE THE ROD SURFACE, AND GUARD
AGAINST DIRT ENTERING THE SYSTEM. Remove the split pin and nut from the end
of the rod. Slip offthe collar. Examine the rod and seals for signs of damage or wear.
Remove the old seals and install a new seal kit.
PLATFORM LEVELLING PROCEDURE
After a platform levelling cylinder has been repaired or replaced, or if the platform does not remain
level with the raising and lowering of the boom, the platform levelling circuit may need to be bled.
With the platform near ground, operate the platform level control to move the platform fully
backward and forward. Perform procedure five (5) times in order to expel any air from the system.
A CAUTION
CARE MUST BE TAKEN WHEN OPERATING LEVEL CONTROL. AIR IN
CYLINDERS CAN CAUSE UNCONTROLLED PLATFORM MOTION.
MANUAL9237!HXl2
March 1998
•
MANUAl92375-002
March 1998
SECTION 6:
MAINTENANCE
MANUAL 92375-002
March 1998
• Table of Contents, Section 6
Maintenance Schedule ................................................................................................................................ 73
General Maintenance Tips .......................................................................................................................... 73
First Three Months Of Operation ............................................................................................................... 73
RoutingServicing ................................ ,....................................................................................................... 74
Shift Operational Checklist ......................................................................................................................... 78
Weekly Operational Checklist ..................................................................................................................... 81
Monthly Operational Checklist .................................................................................................................... 83
Semi-Annual Operational Checklist ............................................................................................................ 86
MANUAl92375-002
March 1998
MAINTENANCE
The T60 is designed to require a minimum amount ofmaintenance. However, it is essential that the
specified services be perfonned at the indicated intervals, and that the instructions contained in this
manual are followed to ensure safety and reliability.
A DANGER
DEATH OR SERIOUS INJURY MAY RESULT IF MACIDNE IS OPERATED IN
AN UNSAFE CONDITION. DO NOT OPERATE ANY MACmNE IF IN UNSAFE
OPERATING CONDITION.
GENERALMAINTENANCETWS
• 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 (see Lubrication Chart in this manual). Improper
lubricants or incompatible lubricants may be as harmful as no lubrication.
• Watch for makeshift "fixes", which canjeopardize safety as well as lead to more costly repairs.
• Any work platfonn found not to be in safe operating condition should be removed from
service until repaired. All repairs should be made by authorized personnel in confonnance
with the manufacturer's operating, maintenance, and repair manuals.
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 ofoperation, 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.
MANUAl92375-002
March 1998
ROUTINE SERVICING
NOTE: The following recommendations are based on advice of our component suppliers,
and the requirements ofvarious safety regulations. They should be followed with discretion
based on factors such as amount and type ofmachine usage, environmental conditions, and
local safety regulations.
IMPORTANT: Make certain that the unit is inspected per the operational checklists at the
end ofthis section.
SIllFI'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 sight
gauge, located on the side oftank. Refer to Lubrication Chart for correct grade of hydraulic fluid.
Ensure that the filler cap is secure to prevent entry ofwater or other impurities into the tank.
Tire Condition
Check that the tires are not damaged.
Platform Rails and Safety Gate
Check security ofplatform and safety gate.
Steering
Check the steer cylinder for fluid leakage. Inspect steering linkage for signs ofwear.
Batteries
Check the electrolyte level in battery cells. Replenish with distilled water, if necessary.
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 ofthe drive assembly, including drive motor and steering. Test the operation
ofall machine boom functions.
MANUAL92375-002
March 1998
Checklist
•
PerfolID 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, and check optional oil bath
swing bearing case.
Checklist
PerfolID 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 ofleakage, particularly at
flexible hoses, connections and hydraulic components. Check hydraulic fluid color. Ifthe
hydraulic fluid does not appear clear amber, but has a cloudy appearance, it is usually an
indication that water is present. A dark drown color, accompanied by a strong "burnt" smell,
indicates that the fluid has overheated. Ifeither condition occurs, a complete hydraulic fluid and
filter change will be necessary.
The cause ofhydraulic fluid deterioration should be investigated and rectified. Have fluid analyzed
by a qualified laboratory.
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.
MANUAl92375-002
Man::h1998
Platform Mounting
Check that platfonn weldments and platfonn frame members are in good condition.
Checklist
Perfonn all items on the Monthly Checklist found later in this section.
SEMI-ANNUAL SERVICE
Boom Cylinders
Fully retract, then extend the boom lift cylinder. At each extreme position, check that there
is no movement between cylinder rod and bearing housing, or between cylinder cap and tube.
Fully retract, then extend the boom telescope cylinder. At each extreme position, check that
there is no movement ofthe cylinder pin.
Hydraulic Filter
Change the high pressure and return filter elements.
In severe use applications, more frequent filter changes wills be necessary.
Checklist
Perfonn all items on the Semi-Annual Checklist found later in this section.
ANNUAL SERVICE
NOTE: Machine Annual Inspection Report Fonns 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
Ifthe 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.
MANUAl92375-002
March 1998
Hydraulic Fluid Tank
•
Carefully check the condition ofthe fluid inside the tank to ensure that it flows easily and is
of clear, amber color. In cases ofgross contamination, it will be necessary to completely
drain and refill the entire hydraulic system.
Place a suitable waste oil container under the drain tap, or attach a suitable hose from the
drain tap to the container. Open the drain tap, and completely drain the fluid from the tank.
Clean or replace the suction hose, and close the drain tap. Refill the tank to the correct level.
Structural Examination
A thorough examination ofthe machine should be carried out for signs ofcorrosion,
misalignment, material fractures, and other damage. Particular attention should be given
to the condition ofwelded joints.
FOUR YEARINTERVAL 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.
MANUAL92375-002
March199B
• SIllFT 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.
DA1E: INSPECTED BY:

-------------------- -------------------
MODELNUMBER: _ _ _ _ __ 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.
KEEPYOURCONDORMACIDNECLEAN!!!
AWARNING
TIDS CHECKLIST MUST BE USED AT DAILYINTERVALS 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, tom or loose hoses, hydraulic fluid leaks, tom or disconnected
wires, flat or damaged tires etc. The compartment doors on both
sides can be opened to inspect components inside.
2. Check for machine damage, broken welds, improper or makeshift

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

excessive wear, chafing or twisting.
4. Check engine oil and fuel levels.
5. Check engine coolant level (liquid cooled engine only).
MANUAL92375-002
March 1998
INITIAL
SHIFT OPERATIONAL CHECKLIST (Continued)
DESCRIPTION
•
6. Check battery electrolyte level. Check battery tenninals 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 ofhydraulic fluid in the reservoir. Fluid should be a clear
amber color.
8. Check that all shutoffvalves on hydraulic tank are open

(parallel to flow).
9. Check tires proper inflation pressure (see Machine Specifications).
10. Check ifwheel lug nuts are tight.
11. Check hose carrier to verifY that it is not bent or sagging.
12. Inspect safety equipment as required by OSHA, government and

local rules.
13. Inspect the work platform and boom structure for signs of damage
and broken welds. Check platform gate latch for damage.
14. Check pivot pins for security.
15. Check that no attempt had been made to override the drive interlock
system by a previous operator.
16. Check that all warning and instructional decals are legible and
secure.
17. Start engine. Check hydraulic pressure (see Machine Specifications).
18. Check that the tilt alarm is working properly.
19. When all pre-inspection checks have been completed, test the
ground controls for proper operation.
MANUAl92375-002
March 1998
SHIFf OPERATIONAL CHECKLIST (Continued)
INITIAL DESCRIPTION
20. Check emergency pumps for operation and pressure (see Machine
Specifications).
21. With the main boom raised, check for the smooth operation of drive,
creep speed.
22. Follow instructions for servicing engine daily. Refer to the Engine
Maintenance Manual supplied with your machine.
ADDITIONAL MAINTENANCE REQUIREMENTS FOR HARSH ENVIRONMENTS
NOTE: Do not lubricate wear pads or boom cables in dusty or sandblast environments.
There are boots and guards available to extend the unit's life in these applications.
Consult TIME CONDOR Service Department.
INITIAL DESCRIPTION
• Inspect cylinder bots, 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.
• Follow instructions for servicing engine when used severely. Refer to

the Engine Maintenance Manual supplied with your machine.
MANUAL92375-002
March 1998
WEEKLY OPERATIONAL CHECKLIST
DATE:--------------------- INSPECTED BY:
MODEL NUMBER: - - - - - - - SERIAL NUMBER:
GENERAL INFORMATION
1. Keep inspection records up- to-date.

Keep your Condor machine clean!!
AWARNING
Tms CHECKLIST MUST BE USED AT WEEKLY INTERVALS OR EVERY
25 HOURS, WmCHEVER 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 (120 LB-FT).
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 (see Lubrication Chart).
Check lubricant in optional oil bath swing bearing case, if so

equipped, for proper level, and check for dirt or mental
contamination (see Lubrication Chart).
MANUAl92375-002
March 1998
WEEKLY OPERATIONAL CHECKLIST (CONTINUED)
NOTE: Do not lubricate wear pads or boom cables in dusty or sandblast environments. There
are boots and guards available to extend unit's life in these applications. Consult Time Condor
Parts Department.
INITIAL DESCRIPTION
• Lubricate all grease fittings (see Lubrication Chart).
• Check oil level in swing drive motor assembly (see

Lubrication Chart).
• Check oil level in power hubs (see Lubrication Chart).
• Follow instructions for servicing engine when used

severely. Refer to the Engine Maintenance Manual
supplied with your machine.
MANUAl92375-002
March 1998
MONTHLY OPERATIONAL CHECKLIST
DATE:-------------------- INSPECTED BY:
MODEL NUMBER: -------------- SERIAL NUMBER:
GENERAL INFORMATION
1. Keep inspection records up- to-date.

AWARNING
Tms CHECKLIST MUST BE USED AT MONTHLY INTERVALS OR EVERY
100 HOURS, WmCHEVER 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 (see Lubrication Chart).
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 protective rubber cover around hoses at moving

anchor, tip boom, boom hose passages, and at swing bearing.
6. Check boom hose carrier for sag and damage. If damaged,

have them repaired.
7. Check torque of swing bearing bolts (170LB-FT).
MANUAL 92375-002
March 1998
MONTHLY OPERATIONAL CHECKLIST (CONTINUED)
INITIAL DESCRIPTION
8. Check torque of rear axle mounting bolts (200 LB-FT).
9. 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 (55LB-FT).
10. Check oil level in swing drive gear box (see Lubrication Chart).
11. Check oil level in power hubs (see Lubrication Chart).
12. Check that tires are not leaning in or out.
13. Check that wheel spindles tum freely, with no end play.
14. Check drive wheel power hub mounting bolttorque (11 OLB-FT).
15. Check that neither the main boom nor jib boom drift with a full load,
when there is no hydraulic pressure (engine off) and the controls are in
the "BOOM DOWN" position.
16. Inspect boom cables.
17. Check to make sure boom sections are not dented or bent.
18. Check that all adjustable flow valves are locked. Check settings if
any are not locked.
19. Check fuel shutoff rack for proper operation. Loosen lever arm and
lubricate with WD-40 or equivalent.
20. Follow instructions for servicing engine monthly. Refer to the Engine
Maintenance Manual Supplied with your equivalent.
EVERY 90 DAYS
INITIAL DESCRIPTION
• Replace high pressure filter element.
• Follow instructions for servicing engine when used severely. Refer

to the Engine Maintenance Manual supplied with your machine.
MANUAL92375-002
March 1998
120 LB-FT
110 LB-FT
~ ~200 LB-FT
200 LB-FT
200 LB-FT
~f----I ~
U
~~ 200 LB-FT
MANUAL 92375-002
March 1998
CD SEMI-ANNUAL OPERATIONAL CHECKLIST
DATE:-------------------- INSPECTED BY:
MODEL NUMBER: ----_________ SERIAL NUMBER:
GENERAL INFORMATION
1. Keep inspection records up- to-date:

AWARNING
Tms CHECKLIST MUST BE USED AT SIX MONTH INTERVALS OR
EVERY 500 HOURS, WmCHEVER 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
l. 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.
MANUAl92375-002
March 1998
SEMI-ANNUAL OPERATIONAL CHECKLIST (CONTINUED)
INITIAL DESCRIPTION
6. Replace high pressure and return filter elements.
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.
9. Follow instructions for servicing engine semi-annually. Refer to the

Engine Maintenance Manual supplied with your machine.
EVERY YEAR
10. Drain and replace fluid from hydraulic reservoir. Drain and replace
fluid from drive wheel power hubs. If badly contaminated, it may be
necessary to disassemble and inspect components.
EVERY TWO YEARS
11. Drain and replace fluid from swing drive motor assembly. Ifbadly
contaminated, it may be necessary to disassemble and inspect
components.
ADDITIONAL MAINTENANCE REQUIREMENTS FOR HARSH ENVIRINMENTS
EVERY SIX MONTHS
• Drain and replace fluid swing drive motor assembly and drive wheel
power hubs.
• Follow instructions for servicing engine when used severely. Refer

to the Engine Maintenance Manual supplied with your machine.
MANUAl92375-002
Man::h1998
APPENDIX A
BASIC STRESS
MAJOR AREA SAEGRADE8
NOMINAL DIA SQ. IN
TIIREADS INCH
NOTES:
1. THIS CHART SHOWS RECOMMENDED BOLT TORQUES.
2. TORQUE = R X D X T
R = .150 FOR LUB CONDITIONS
R = .200 FOR DRY CONDITIONS
TO ASSURE CONSISTENCY IN TORQUE, LUBRICATE FASTENERS WITH ENGINE OIL
(MAY BE USED OIL)
D = NOMINAL DIAMETER IN INCHES
T = DESIRED CLAMP LOAD IN POUNDS = 75% PROOFLOAD X STRESS AREA
APPENDIXB
BOLT TORQUE CHART
FOR METRIC HEX HEAD CAP SCREWS
- RECOMMENDED ASSEMBLY TORQUES IN FOOT-POUNDS

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

FOR ANY THREAD PITCH IN THAT DIAMETER.
DRY
TIlREADS TIlREADS TIlREADS TIlREADS
M4 27.5* 17* IS* 3S.5* 24* 32.5*
M5 56.5* 33.5* 37* 7S* 47* 65*
M6 95* 57.5* 61* 132* 79* 109*
MS 19 12 13 27 16 22
MIO 39 23 25 53 32 44
M12 67 40 73 44 92 55 76
M14 107 64 116 69 146 S9 122
M16 167 100 lSI lOS 230 13S 190
M20 325 195 352 211 449 269 370
M24 562 337 609 386 775 465 640
M30 1117 670 1210 726 1540 924 1271

Power Wheel Service Manual
Model 6 Double Reduction
Wheel Drives With Integral
Parking Brake Option .
PHONE: (219) 925-3200
FAX: (219) 925-4725
I
I
9
10 11
/ /
12
I
13
I
000(0
11 16
/~@
14 . \
-"'-"/"'" 0 @e; f) oo~ !
15
L )00
19
, 30
OPTIONAL
ITEM DESCRIPTION * NO. USED ITEM DESCRIPTION * NO. USED
NO. IN ASS'Y. NO. IN ASS'Y.
1 Socket or Torx Head Screw 4 20 Disengage Spring 1
2 Piston Assembly 1 21 Ring Gear 1
3 Disc Pack 1 22 Secondary Carrier Assembly 1
4 Coupling 1 23 Primary Carrier Assembly 1
5 Retaining Ring 1 24 Primary Sun Gear 1
6 Input Shaft 1 25 Thrust Washer 1
7 Sleeve Bearing 1 26 Thrust Washer 1
8 Spindle 1 27 Disengage Plunger 1
9 Oil Seal 14-00-044-010 1 28 "0" Ring 1

Cast Iron Cover 614101
10 Bearing Cone 04-01-101-35 1 Aluminum Cover 10-00-141-113
11 Bearing Cup 04-01-102-12 2 29 Large Cover 1
12 Wheel Bolt 9 30 Hex Head Bolt 8
13 Hub 1 31 'Magnetic Plug 14-00-052-002 1
14 Hex Head Bolt (Grade 8) 6-12 32 Disengage Cover 14-02-039-005 1
15 Rat Washer 6-12 33 Hex Head Bolt 2
16 Bearing Cone 04-01-101-17 1 34 Quick Disconnect Gasket 1
17 . Retaining Ring Kit 14-02-410-003 1 35 Quick Disconnect Assembly 1
18 Retaining Ring 2 36 Hex Head Bolt 2
19 Washer 2
* Contact Auburn Gear with part number and order code of drive to obtain the apropriate parts list.
Refer to parts list for the specific part numbers and quantities.
Model 6 Power Wheel Service Kits
Part No. Description Included Items
14-02-410-003 Retaining Ring Kit 17 (7 Retaining Rings)

641008 ** Bearing and Seal Kit 9,10,11,16,17 and 28
641017 ** Seal Kit 9,17, and 28
** Indicates kit also includes a tube of sealant, part number 604101.

IDENTIFICATION
IMPORTANT: All Power Wheel units and kits are shipped with a name plate that includes the Auburn Gear part number and order code as shown.
, Power Wheel E>"""

ORDER CODE: 6WBI3156C
Example: PART NO.: 6000236
SERIAL NO.: 143434 L~

AUburnGe~
" AUBURN,IN U.S.A. ~
In addition to the nameplate, Power Wheel drives are stamped \\::: ....., identification number which appears on the cover or hub flange as shown.
Example: 6000236-A-4-9
When ordering parts, the information included on the nameplate or the stamped identification number is necessary to accurately identify the drive and obtain
the correct replacement parts. Once this information has been obtained, contact Aubum Gear for the appropriate parts list.
DISASSEMBLY OF POWER WHEEL

STEP 1 remains with large cover (29). Remove disengage plunger (27) and '0' ring
If brake portion of drive is to be serviced: SAE A and SAE B MOUNT (28) from cover on end of input shaft (6). The thrust washer (26) will usually
BRAKES-Remove motor from planetary drive. SAE B MOUNT BRAKES- remain in position on thrust face of large cover (29).
Temporarily install two 112 -13xl.25 screws into hydraulic motor mounting STEP 8
holes and torque to 50 lb. ft. (67 Nm). These must be used to hold spring Remove sun gear (24) and thrust washer (25), used in aluminum cover units
back-up plate in position when parking brake assembly is removed from the only, from end of input shaft (6).
drive. If the brake portion of drive does not require service go to step 5. SJEP9
STEP 2 Remove primary carrier assembly (23).
SAE A MOUNT BRAKES-Remove the four socket head cap screws (1) STEP 10
retaining the brake to the drive, leaving the two screws in line with the motor Remove the secondary carrier assembly (22). It may be necessary to
mounting holes in place. These two screws hold the spring back-up plate in remove the ring gear (21) first, if difficulty is encountered in removing the
position when the parking brake assembly is removed from the drive. SAE carrier.
B MOUNT BRAKES -Remove the four T-50 Torx head screws (1) holding STEP 11
the parking brake assembly in position. (Some models may be equipped Remove the inputshaft (6) from spindle (8). Remove the retaining rings (18),
with socket head cap screws). It may be necessary to IighUy strike the piston washers (19), and spring (20) from input shalt (6) only if replacement is
assembly (2) with a rubber mallet to loosen from spindle or Cover. required.
STEP 3 STEP 12
Remove disc pack (3) from drive only if necessary. Be careful to maintain Remove the 6 or 12 bolts (14) and washers (15) from hub (13) and ring gear
discs in order. (21) and remove ring gear (21 ).It may be necessary to strike ring gear (21)
STEP 4 with a rubber mallet to loosen from hub (13).
If brake piston assembly (2) has been removed slide the coupling (4) and STEP 13
retaining ring (5) from splines on input shaft (6). Remove sleeve bearing (7) Remove the retaining ring (17) from in front of the bearing cone (16) and lilt
if replacement is required. hub (13) from spindle (8). If bearings are not a loose fit, it may be necessary
STEP 5 to press spindle (8) from hub (13). NOTE: Use a retaining ring expander tool
Position the assembly upright on face of spindle (8). to remove retaining ring (17).
STEP 6 STEP 14
Remove the disengage cover (32) if necessary. Remove the oil seal (9) and bearing cones (10 & 16) from hub (13). Inspect
STEP 7 bearing cups (11) in position and remove only if replacement is required.
Remove bolts (30) and large cover (29). Disengage plunger (27) usually
ASSEMBLY OF POWER WHEEL

STEP 1 STEP 7
Press new bearing cups (11)ineachsideofthehub(13).ltis recommended Assemble secondary carrier assembly (22) to spindle (8) at splines.
that bearing cups (11) and cones (10 & 16) be replaced in sets. STEP 8
STEP 2 Clean mating surfaces and apply a bead of silicone sealant to face of hub
Assemble bearing cone (10) into cup (11) at seal end of hub (13) and press (13) that mates with ring gear (21). (See instructions on sealant package)
a new seal (9) into hub (13). Hub (13) is attached to ring gear (21) with either60r 123/8-24 grade 8 hex
STEP 3 head cap screws (14) and flat washers (15). Torque cap screws to 52-60
Position spindle (8) upright on bench. lubricate lips of seal (9) and lower lb. ft. (70-81 Nm).
hub (13) onto spindle (8). Hub (13) should be centered as itis lowered over STEP 9
spindle (8) to prevent seal damage. Assemble the primary carrier assembly (23) into the ring gear (21). It will be
STEP 4 necessary to rotate carrier to align secondary sun gear (part of primary
Assemble bearing cone (16) over spindle (8) and into bearing cup (11). If carrier assembly (23» with planet gear teeth in secondary carrier assembly
bearings (10,11, & 16), hub (13)or spindle (8) is replaced. a new retaining (22). Assemble primary sun gear (24) over input shaft (6). Rotate primary
ring (17) is required for proper bearing setting. Select the thickest retaining sun gear (24) to align input shalt (6) to gear splines and gear teeth in primary
ring (17) that can be assembled into the ring groove of the splined end of carrier assembly (23).
spindle (8) above bearing cone (16). Bearing should have from .000-.006 STEP 10
inches of end play when proper retaining ring (17) is installed. Assemble the small thrust washer (25) over input shalt (6) and against
STEPS shoulder of input shaft (6).
Assemble a retaining ring (18) in groove opposite pilot end of input shaft (6). STEP 11
Assemble a washer (19), spring(20), a second washer (19), andasecond For units with the aluminum cover (29), lubricate '0' (28) ring and assemble
retaining ring (18) in the middle grooves of input shaft (6). Some shafts have in groove of the disengage plunger (27). Assemble disengage plunger (27)
a shoulder and require only one retaining ring (18). over endof input shaft (6) and against thrust washer (25). For units with cast
STEP 6 iron cover (29), lubricate '0' ring (28) and assemble in groove inside cover
Assemble the splined end of the input shaft (6) down into spindle (8). hole, push plunger (27) into cover with pointed end facing inside of unit.
,...
STEP 12 Also. the spline on the friction discs should be aligned with the spline on the
Assemble the thrust washer (26) with tangs engaged with cover (29). NOTE: Power Wheel adapter coupling (4). Check to make sure that the disc pac:k
A small amount of grease applied to the back side of thrustwasher (26) will is properly seated.
hold washer in place. Apply a bead of silicone sealant to end face of ring gear STEP 17
(21). Assemble cover (29) alining holes of cover and ring gear. Assemble Clean seal surface of the drive and piston assembly (2) of any old sealant
the eight 5/16-18x1 inch hex head bolts (30). Torque bolts to 20-25 lb. ft. and wipe any oil from seal surface 01 spindle or cover. Apply a continuous
(27-34 Nm). 1132 bead of silicone sealant to seal surface on inside of the bolt circle
STEP 13 NOTE: Do not use excessive amount of sealant as this can interfere will
Assemble the disengage cover (32) with dimpled center protruding out if proper operation of the parking brake.
wheel is to be used to drive the vehicle. Assemble and torque the two 5/16- STEP 18
18x3/4 inch bolts (33). Torque bolts to 10-20 lb. ft. (13-27Nm). SAE A MOUNT BRAKES-Align the four brake assembly holes with the
STEP 14 four holes in the Power Wheel spindle or cover. Apply Locktite 262 to the
Invert the Power Wheel assembly and assemble the sleeve bearing (7). lour screws to be installed and torque to 110-125 lb. ft. (148-169 Nm).
coupling (4) and retaining ring (5 ) with counterbore out to the input shaft (6). SAE B MOUNT BRAKES-Align the four piston assembly holes with the low
STEP 15 holes in the Power Wheel spindle or cover. Apply Locktite 262 to the
The proper disc pack and piston cylinder assemll1y • ':'1 depend on the Power four screws to be installed and torque to 80-94 lb. 1.. \ :"'3-127 Nm).
Wheel brake model number: Contact Auburn Gear for specific part num- STEP 19
bers. Disc packs are supplied as a matched set. Replacement packs are SAE B MOUNTS ONLV-Remove the two screws installed in motor
fUrnished with a twist-tie to retain the matched characteristics. Pre-soak the mounting holes.
disc pack in tr'J oil used in the Power Wheel drive before placing into the unit. STEP 20
Do not remove the twist-tie until just before inserting the disc pack into the Before using the brake. it is recommended that a pressure release chet*
drive. be performed. Using a suitable hydraulic source. bleed the air from the brake
STEP 16 and pressurize the brake to the specified release pressure. The brake plates
Align the tangs on the steel separator plates and carefully remove the should now turn freely. II the hydraulic source will provide at least 1000 PSt
twist-tie. Place the complete disc pack (3) into the Power Wheel drive so pressure. apply 1000 PSI and check to make sure that the pressure doee
that the tangs on the separator plates are within the slots in the drive. not decay more than 30 PSI in 60 seconds.
NOTE: When installing a hydraulic motor to the Power Wheel Drive it is necessary to place an '0' ring or gasket (not supplied by Auburn Gear) between
the motor and the planetary drive. '0' ring sizes: SAE A 2-042. SAE B 2-155. SAE C 2-159.
CARRIER ASSEMBLIES
It is recommended that the primary and secondary carrier assemblies (22 & 23) be serviced in their entirety to protect the integrity 01 the Power Wheel drive.
LUBRICATION RECOMMENDATIONS
IMPORTANT: POWER WHEEL PLANETARY DRIVES ARE SHIPPED WITHOUT LUBRICANT AND MUST BE FILLED TO THE PROPER LEVEL
PRIOR TO START UP.
Observe lubrication recommendations given by the original equipment manufacturer. When specific recommendations are not available. use mild extreme
pressure lubricant API-GL-5. No. 80 or 90 when filling the Power Wheel under normal temperature ranges between 0-120oF (-18 to 49 0 C). Power Wheet
is to be half lull of oil when unit is mounted level and horizontal. Use drain and fill plug located in cover. Oil to be changed after first 50 hours of operation
with subsequent changes every 1000 hours or yearly. which ever comes first. If unit is to be operated vertically. if ambient conditions are outside the specified
range. or if the oil temperature exceeds 200 0 F (93°C) contact Aubum Gear for oil and level recommendations.
TOWING VEHICLE
C~UTlON: The Power Wheel will not normally be damaged by tOWing; however. the hydraulic drive components may be damaged unless the Power Wheel
is disengaged Irom the drive motor. Road speeds in excess of 25 MPH should be avoided unless clearly specified to be permissible by the equipment
manufacturer.
TO DISENGAGE POWER WHEEL

CAUTION: For units equipped with the standard spring disconnect. assemble the disengage cover (32) with the dimpled center protruding inward. For unilS
equipped with the optional quick disconnect. push in center plunger of disconnect. PARKING BRAKE WILL NOT FUNCTION IF UNIT IS DISENGAGED.
STORAGE
A protective film is applied to the Power Wheel at the factory to prevent rust during shipment. Additional protection may be required il the Power Wheel is
to be stored for an extended period of time.
SEALING COMPOUND
Silastic RTV732 sealer and General Electric Silimate RTV No.1473 or RTV No. 1503are currently recommended for sealing gasketsurfaces. Sealantshoulcl
be applied in a continuous bead. which should be centered on the surface to be sealed but should move to the inside 01 the hole at each bolt hole location.
For service requirements order Auburn Gear part number 604101.
SPECIFICATIONS
Maximum intermittent output torque ................................................................................................................................................ 50.000 lb. in. (5650 Nmt
Maximum input speed .......................................................................................................................................................................................... 2,500 RPM
Oil capacity ..................................................................................................................................................................................................... 350z (1035 mt)
Maximum parking brake release pressure ..............................................................................................................................................2.000 PSI (137 bar)
3
HYDRAULICS, INC.
RS SERIES MOTORS
SERVICE PROCi::DURES
PC992.001
SEPTEMBER 1993
INTRODUCTION
IMPORTANT: PLEASE READ THIS SECTION BEFORE ATTEMPTING ANY SERVICE
PROCEDURES.
The service procedures given in this section are specifically for all RS Series motors. The proce-
dures given are designed as a guide for the instailation of seal kits and are not intended for trouble-shooting
purposes. The service procedures given have been presented as clearly and accurately as possible.
However, White Hydraulics makes no guarantees that the directions and descriptions are complete or
aC::':~f\te or that following the procedures will result in a properly fl.O. '~'oning motor.
All White Hydraulics' motors are of the highest quality and are guaranteed against defects in workmanship
and materials for four years from the date of manufacture (a copy of the warranty can be obtained from the
distributor or the factory.). However, any disassembly of the motor voids this warranty. If a motor is
suspected of having a warranty problem, the motor should not be disassembled, but should be returned to
White Hydraulics for analysis and warranty consideration. Before returning motors to the factory. White
Hydraulics must be contacted to obtain a Return Authorization number. No returned motors will beac-
cepted at the factory without the RGA number printed on the outside of the box.
Because of the extremely tight tolerances designed into every White HydrauliCS' motor. care should be
taken to provide a clean work area when servicing a motor. Before the motor is removed from any machin-
ery. all fittings and the area around the fittings should be thoroughly brushed and cleaned to remove all dirt.
Care should be taken to insure that no dirt enters the motor through the ports. Once removed from the
machinery. the ports should be plugged and the outside of the motor cleaned in preparation for service.
White Hydraulics recommends that a new seal kit be installed anytime that the motor is disassembled.
Failure to do so could result in leaks when the motor is returned to service.
SEPTEMBER 1993
f1?\
~
I
I
WHITE HYDRAULICS, INC.
110 Bill Bryan Blvd. * P.O. Box 1127* Hopkinsville, KY 42241
Phone (502) 885-1110 * Fax (502) 886-8462
COMPONENT PARTS
Components List
1. dust seal
2. split wire ring
3. metal backup shim
4. high pressure seal
5. metal backup shim
6. teflon backup seal
7. shaft seal
8. body seal (3)
Items 1-8 included in seal kit
9. seal carrier
10. thrust washer
11. thrust bearing
12. drive link
13. wear plate
14. rotor assembly
15. drive link pin
16. endcover ball
17. endcover
Items 16-17 included in kit
18. 1.0. tag assembly
19. assembly bolts (4)
20. housing
21. coaling plug
22. shaft
23. shaft key
Items 20-23 included in housing/shaft kit
TOOLS REQUIRED FOR DISASSEMBLY PROCEDURES
1. bench vise that opens to at least 6"
2. breaker bar no longer than 14"
3. 9/16" socket
4. torque wrench capable of at least 50 tUbs.
5. seal puller
6. small chisel
7. small flat screwdriver
8. plastic headed hammer
9. compressed air source and safety blow-off nozzle (optional)
1('\. petroleum-based solvent
11. permanent marker or paint
12. clean shop towels
13. STP or equivilent
SAFETY PRECAUTIONS
White Hydraulics recommends that all safety guidelines included but not limited to those contained in
OSHA 29 CFR Part 1910 (General Industry Standards) be observed when performing any service proce-
dures.
1. Protective goggles or safety glasses should be worn when performing any service procedures.
2. Steel toed shoes or boots should be worn when performing any service procedures.
3. If using compressed air to dry pans. set maximum air pressure at 30 psi or less.
4. Dispose of oily rags or towels in closed containers.
5. Keep all oils and cleaning solvents away trom sparks or open flames.
6. Keep all tools dry and clean to prevent hands trom slipping off of tool and causing possible injury.
7. Excercise extreme caution when handling machined motor pans.
SEPTEMBER 1993
SEAL KIT INSTALLATION
This section contains the service procedures necessary to install a seal kit in all White Hydraulics' RS series
motors. White Hydraulics recommends that a new seal kit be installed anytime that the motor i~ disas-
sembled
1. Using a marker or paint, make a V-shaped set 2. With the shaft facing down, securely tighten
of lines on the rear assembly of the motor from the motor in a vise by clamping around the ports in
the housing to the endcover as shown. These the housing. Using a breaker bar and a 9116"
lines will aid in part realignment when reassem- socket. loosen and remove the four bolts attaching
bling the motor. Depending on shaft type, remove the rear assembly to the housing.
any keys or nuts from the shaft.
3. Uft the endcover from the motor and remove 4. Uft the rotor set from the motor and remove
the seal and discard. lay the endcover aside. and discard the seal from the face of the rotor set.
Remove the drive link pin from the drive link and lay the rotor set aside. Remove the wear plate
lay aside. from the motor and lay aside. Remove the seal
from the groove in the rear face of the housing
and discard.
SEPTEMBER 1993
5. Remove the drive link frorn the motor and lay 6. Grasping the housing, loosen the vise and
aside. From the flange side of the housing, push the remove the housing. Above a clean surface, rotate
shaft upwards and grasp the rear end of the shaft the housing 1800 and allow the thrust bearing and
with a clean shop towel and remove it from the thrust wash~r to fall from the housing. Clamp the
housing. Turn the output end of the shaft up to allow housing back in the vise with the flange side of the
the cooling plug to drop out of the shaft. Lay both housing facing up.
asidet-_ _ _ _ _ _ _ _ _ _ _ _---.
7. Using a seal puller, carefully pull the dust seal 8. Using a small flat-bladed screwdriver, remove
from the front of the housing and discard. Placing a the split wire ring from the groove in the front of
hand under the housing to catch the seal carrier, the housing. Also use the screwdriver to remove
use a wood or plastic hammer handle to lightly tap the backup shim and high pressure seal from the
on the seal carrier until it faUs out the bottom of the housing. Discard the shim and seal.
housing.
.•.•~.
,
9. If seal kit PS222001 is being used, the seal 10. Using 400 grit wet/dry sandpaper, a sanding
carrier assembly and thrust washer may be block and an oil based solvent, wet sand all mating
discarded. If seal kit PS222002 is being used, use surfaces to remove all dirt, grit, paint, nicks and
a small, flat-bladed screwdriver to pry the seals burrs.
from the seal carrier. Discard the seals and lay
the seal carrier and thrust washer aside.
SEPTEMBER 1993
11. At this point, all parts should be cleaned in an oil 12. Place the shaft on a clean dry surface with
based solvent. After the parts have bean cleaned, the output end of the shaft faCing up and apply a
use compressed air to carefully dry all parts. Make light coat of STP® to the seal area of the shaft.
sure to remove all solvent from the bolt holes in the Install the thrust bearing and then the thrust
housing as failure to do so could result in a cracked washer onto the shaft.
housing when the bolts are reinstalled.
13. Being careful not to cut the new shaft seal on 14. Place the new white teflon backup seal onto
the keyslot or splines on the shaft, push the new the shaft making sure that the lip on the inside
seal down onto the shaft. The flat side of fhe seal diameter faces the shaft seal. Next, place the
should be facing up. (Clear tape may be applied new backup shim onto the shaft over the teflon
over the keyslot to aid in seal in..:;tallation.) backup seal.
15. Place the seal carrier over the shaft making 16. Coat the new high pressure seal in STP ® and
sure that the side with the recess faces the shaft place the seal into the groove in the housing. To
seal. Center the seal in the recess in the seal install the backup shim, squeeze the shim until it
carrier and use a press and a sleeve to gently bows in the middle (do not fold the shim in half).
press the seal carrier down until the seal is seated While maintaining the bow, install it in the groove
in the seal carrier. A plastic headed hammer and next to the high pressure seal in the housing.
sleeve may be used if necessary. (Shim installation continued with step 17.)
SEPTEMBER 1993
17. A portion of the shim will not want to go into the 18. Install the split wire ring into the groove in the
groove. To this portion of the shim, apply pressure hOlJsing. Aun a small screwdriver around the
downward and towards the center of the housing to circumference of the snap ring to make sure it is
expand the shim into the groove. Use a flat screw- fully seated in the groove and that the ends are
driver to push the remaining portion of the shim into butted together.
the groove to fully seat the shim.
IMPORTANT NOTE:
The rotation of the shaft in the AS Series motors is
dependent upon the timing alignment of the shaft,
drive link and rotor set. The rotational code of the
motor is the seventh number (0 or 1) in the model
number which can be found on the motor 1.0. tag
located on the endcover. Before installing the
drive link in the shaft end, be certain of the rota-
tional code of the motor, as this will affect the
orientation of the drive link splines in relation to the
shaft splines.
19. On a clean level work surface, stand the one of the long slots on the outside diameter of the
shaft up so that the output end of the shaft faces shaft. In this alignment, the splines will not mesh. For a
down. Install the coaling plug into the shaft with "0" rotational code motor, slowly rotate the drive link
the small diameter end facing down. Lower the counter-clockwise until the splines engage. For a "1"
drive link into the shaft making sure that the rotational code motor, slowly rotate the drive link
timing mark end of the shaft is up and the timing clockwise until the splines engage.
mark is aligned with
20. TIghten the housing in a vise with the mounting 21. Lightly coat a new body seal in STP® and
flange side of the motor facing down. Using a clean place the seal in the groove on the rear face of the
shop towel, grasp the shaft near the drive link end housing. Place the wear plate onto the housing
and lower the shaft assembly into the housing. Use using the alignment marks as a guide. Lightly coat
a plastic headed hammer to lightly tap the end of a new body seal in STP® and install it in the
the drive link down to seat the seal carrier against groove in the face of the rotor set.
the split wire ring.
SEPTEMBER 1993
22. With the seal side facing down, line up the drive link
timing mark with anyone of the valleys on the rotor and lower ROTOR SET TO DRIVE
the rotor set onto the motor (See drawing at right). Once the LINK ALIGNMENT
splines are engaged, the rotor set should be rotated until the
alignment marks match those on the wear plate. (Check to
make sure that all rollers are in the rotor set.)
23. Install the drive link pin into the end of the shaft 24. Install the four 3/8-24 bolts
with the concave end up. Lightly coat a new body and pre-torque to 5-10 ft.lbs. ®
seal in STP® and place it in the groove in the face using a 9/16" socket and torque
of the endcover. Using the alignment marks as a wrench. Using the bolt torque
guide, place the endcover ante the rotor set making sequence shown at the right, ®
sure that the drive link pin extends into the hole in torque all bolts to 50 ft.lbs.
the center of the endcover.
25. Remove the motor from the vise and set on

the work surface with the shaft end facing up.
Making sure that the flat side of the dust seal
faces up, install the dust seal over the shaft and
use a sleeve and plastic headed hammer to tap
the seal into the front face of the housing.
SEPTEMBER 1993
PRECISION GOVERNORS, INC.
2322 SEVENTH AVENUE ROCKFORD.IL 61104 815-229-5300 FAX; 815-229-5342
ELECTRIC GOVERNOR
INSTALLATION MANUAL
Series K Integral Governor System

Shown with
Model E-~b.L Controller

2
GENERAL
The following information is intended as an aid to properly applying a Precision Governor Electric Governor.
Since these governors are used on a wide range of engines in many different applications, much of the
information is somewhat general in nature. If you need assistance concerning a specific detail on your
application, please consult Precision Qt.".; """ors Application Engineering at 8151229-5300.
These instructions presume no electrical test equipment other than a multimeter for making the electrical
measurements called for on the following pages. If no meter is available, inexpensive but adequate meters,
are available rrom many consumer electronics stores such as Radio Shack. .
Many "governor problems" tum out to be installation problems, particularly in first-time applications. Careful
attention to the directions provided will go far toward a successful installation made in the least amount of
time.
QUICK-START INSTRUCTIONS
If you are experienced in installing and adjusting Electric Governors, follow these steps. Otherwise, refer to
the more detailed instructions which begin on Page 2. starting with "Governor Assembly".
1) Mount the governor assembly to the engine manifold using appropriate gaskets. Connect fuel. vacuum
electrical and air lines
2) Mount Controller in a dry, fairly cool location. Accessibili1y for adjusting is required ..
3) Wire per the attached schematic, using 116 wire. BE SURE TO OBSERVE CORRECT POLARITY.
4) Hold linkage for safe1y. and start engine.
5) Adjust engine speed to desired value using Speed-set pol (See figure on page 4.)
Tum ON to increase, CON to decrease speed.
6) Set Gain as required, using Gain pot (See page 4.) ON increases sensitivity.
load and unload engine to check for proper gain. Also. pull back Governor arm slightly and
release.
MOUNTING-GOVERNOR ASSEMBLY
The governor assembly is a preassembled and pretested unit consisting of a carburetor. actuator. mounting
bracket and linkage. The end user need only mount the unit to the engine intake manifold with any needed
adapter; connect fuel. vacuum. electric lines and the clean air hose to complete the installlation. Appropriate
gaskets should be used.
A ball-end allen wrench or driver is highly recommenced for the fasteners used on the governor assembly.
Typically. these are 6 mm socket head cap screws requiring a 5 mm wrench.
MOUNTING-CONTROLLER
The controller is water and weather resistant when the cover plate is filleted with RTV by the user.
However. attention to the following points will enhance its performance and reliability;
3
Select a reasonably cool. dry, and vibration free location.
The rear cover will probably need to be removed during set-up in order to make adjustments for
speed-setting and gain. You may wish to defer final installation until this is done.
After completing these adjustments. replace cover. and seal with a finger-fillet of RTV.
~ount so that water cannot pool on this cover. Mounting with th;:.. ~r out of sight discourages
RfiddlingN •
WIRING
See wiring diagrams for details of hook-up.
Use 118 wire minimum. 116 is preferred.
If Governor is to be switched through the ignition switch. run power to the Governor directly via a dedicated
116 wire. Check that the wiring from the switch to the battery is at least 114 gage.
Keep all wiring to the Governor as short as is practical.
Go directly from the Controller ground terminal (2 of the 8 pin terminal strip) by dedicated wire. to the battery
-minusn terminal. If this cannot be done. for some reason. go by dedicated wire to a very good engine
ground.
A properly functioning engine electrical system will supply 13.5-14.8 VOC when the engine is running. If
wiring size is adequate. with good connections and proper grounds. you will get this reading between the
wires to terminals 1 & 2 of the 8 pin terminal strip when the Governor is controlling engine ~peed. Verify this.
CAUTION:
Improper hook-up can damage electronics. Re-check wiring before applying power.
CHECK-OUT & INlllAL START-UP PROCEDURES
Assuming that the Governor Assembly and Controller are mounted and the wiring is run and checked.
proceed as follows:
1) Turn ignition switch on. 00 not start engine.
2) Use Multimeter to check battery voltage at battery terminals, and record. Now check voltage at the
machine connection points for terminals 1 & 2 ( 1 is +. 2 is -). This voltage reading should be the same as
at battery. If not. shut down. and correct wiring.
3) Before proceeding. familiarize yourself with the locations of the Speed Set pot and the Gain pot (See
page 4.) Read the section on Adjustments. page 4.
4) Hold the linkage back by hand. so as to control engine speed manually. Start engine. set vehide
controls to obtain high engine speed. gradually release the linkage. and adjust the speed-set as needed to
get the speed desired. If engine speed surges. reduce Gain a little, as required.
5) Re-check voltage between the connections for terminals A & B as in step 2. Voltage reading should be
between 13.5--14.6 VOC. If less. look for undersized wiring somewhere in the system. or for other
components wired in parallel with the Governor.
4
6) Carefully adjust Gain. You are looking for the best compromise between quick response and good
stability. Make very small adjustments. then load and unload engine. or pull linkage back slightty and
release. Usually. a good set-up is one that makes 1 to 3 small bounces and then steadies down after a large
load change. Too much Gain shows up as a rapid (once per second) instability. most commonly at light
loads. Too little Gain shows up in large over-shoots on start-up or large load changes. and generally
sluggish operation.
1) Make final adjustment to the Speed-set This is the highest speed to be run. This adjustment must be
made before the Awe speed adjustments are done.
8) Set machine controls to obtain the Awe speeds (if used). Adjust the Awe speed pots as needed to obtain
the speeds desired.
9) Re-install the back cover on the control unit Add a finger fillet of RTV around the edge of this cover to
seal against dirt and moisture. Final-mount the controller.
E-301 ELECTRONIcs-ADJUSTMENT LOCATIONS
Speed Set Factory Adjust Awe Speed 2
\ PREc,s,oIGOVERNORs, IN .
Pl~(T
~Cl~1 ~p?iP4Q
'uOJ
e
[11~
p
INIEGIW. (]![]
cm::J.mE
C5 [dnlOOE
lN12_ A
R83
AS21N c::S=J
C18
II~ u
~-
0
u
2N6J85 E
:( -
Q "- 1 c·
~11"~ (U(:;~I) &~ :] 'I~;" ~ ~'.".

[Bill
~TIQ: 1i
nrrrJ~~51mJ
~~~ ~
0
~
ASl~ QP3 [m:J O~ ~~
\AUX Speed 1 Gain
GOVERNOR ADJUSTMENTS
MULTl-TURNA£uUSTNENT(SPEE~Scn
This adjustment is made by turning the 118- brass screw clockwise (CW) to increase speed. and
counterclockwise (CCW) to decrease speed. The adjustment range of the pot is 25 full turns. and one full
tum will change speed about 100-200 rpm. This pot is protected by a slip clutch at each end. and will not
be harmed by moderate over-adjustment However. the Governor will not function while the pot is past full
travel.
If ~u suspect ~u may have over-adjusted the Speed-set pot. or have lost track of where you are. tum the
pot 25-30 turns a::N. ttten back 10-12 turns ON to get back into the range of normal adjustment
5
SINGLE-TURN ADJUSTMENT (GAIN, Aux SPEEDS, FACTORY ADJUST)

This pot is 318M square and has a 118" plastic screw in i1s center. Be gende! This pot turns 270·, and over-
turning will break the internal stops, making adjustment impossible. Turning this pot ON increases speed or
governor sensitivi1y, while turning CON decreases speed or sensitivity.
TROUBLESHOOTING
We will discuss Troubleshooting in two general categories:
A) Governor wo,,'t work

B) Governor works. but can't be set up to give satisfactory performance
There is. of course. some overlap between these categories. Read both sections and apply the fIXeS that
seem appropriate.
During troubleshooting. be prepared to control the engine manually to prevent overspeeds. etc.
A. Governor won't work.

No readion from Governor. Actuator output arm never moves, engine off or engine running. Can
be caused by:
1. No power.
2. Incorred linkage, preventing movement
3. Incorred electrical hook-up.
4. No speed signal to Governor.
5. Damaged Controller or Aduator.
1. No power Use a Multimeterto check for 12-15 VDC between terminals 1 & 2 on the ~ntroller. Check
during engine off and engine running conditions. If voltage is absent or low, check for:
a. Wiring error
b. Hook-up on wrong side of ballast resistor
c. Low battery
d. Bad Voltage Regulator
e. Bad ground connection
f. Corroded terminals
g. Undersized wiring
2. Unkage Check linkage and carburetor for freedom of movement and lack of play are important
3. Incorrect Electrical Hook-up Re-check all wiring and connections to the governor assembly and
controller.
4. No speed signal to Controller

a. Check the voltage between terminals 3 or 4 and ground with the engine running. You should
see 5-30 VOC.
b. The above check does not guarantee a good speed signal, but its absence proves that
there is a problem.
5. Internal Governor fauh If steps 1-4 above have not revealed the problem, the Governor may
have been damaged. either in shipping or during hook-up and test.
B. Governor reacts. but can't be set up 10 give proper performance

This kind of trouble usually falls into 3 main categories:
1. Adual Governor malfunction
6
2. Governor installation problems and improper installation

3. Governor not tuned or adjusted for engine/application
1. Actual Governor malfundion The Governor was engine-tested for proper operation just prior
to being shipped. Unless damaged in shipment or by improper handling. it should be
serviceable. To check for proper operation. proceed as follows:
a Control the engine speed manually by holding the linkage.
b. Start engine. hold at a low speed. The linkage should ('1.11 towards a higher speed.
c. Increase engine speed carefully. At some engine speed. tne linkage will try to return to a low-
speed position.
d. By carefully varying engine speed. ~u should be able to feel the linkage come to a neutral
force position. This engine .ipeed is the approximately the set speed for which the Governor is
adjusted. If grossly incorrect. reset Speed set pot.
e. No rubbing or binding should be felt during these movements.
If steps 1a through 1e. can be accomplished as desaibed. the Governor is probably OK. It recognizes
underspeed. overspeed. onspeed. and is not binding internally. If the above steps cannot be accomplished
satisfactorily. there is probably an actual Governor malfunction.
2. Installation and adjustment problems
a If linkage is unable to move freely look for:
1. Unkage binding or misadjusted.
2. Low voltage at Governor during operation (Measure the voltage as discussed previously and
observe voltage during operation.
3. Excessive forces during running
Carburetor butterfly valves are loaded by engine vacuum during
running. which can add considerable force not present when engine isn't
running.
Springs in the system: carburetor return springs. acceleration pump
springs. etc.. are not usually needed and can cause governing problems.
b. Governor experiences sudden. momentary spikes toward max. or min. at random
intervals. then recovers.
1. Look for loose wiring or momentary shorts in wiring.
2. Noise or occasionally missing speed signal.
. 3. Governor not tuned or adjusted for engine/application

The basic adjustment to set sensitivity/stability is the Gain pot A good starting point for many engines is full
CON. then ON 1/3 tum. (See "Governor adjustment" section.) To increase stability. turn CON. If
satisfactory governing cannot be achieved with this one adjustment the factory adjustment may be needed.
Normal starting point for this ..djustment is fully CON. then ON 1/4 tum. (Before changing this pot mark
the original position.)
UNITED EG\..!IPMENT ACCESSORIES
P.O. BOX 817,2103 E. BREMER AVE.

WAVERLY, JA 50677 .
PHONE: 319-352-3946 FAX: 319-351.-2175
REPAIR PARTS
&
SERVICE MANUAL
DESCRIPTION ItJ-CII<CUlT lla1tUCAL 5L1P I.,}/(. Ass'/.
CUSTOMER £ALAVAf< C.bfCP.

~----------------------------
CUSTOMER PART # 711'1/

--------------------------
DATE if -27-'78
UEA MODEL # .s 15AN/{)CAh

UEA WIRING CODE # RCIAtJ82B8'-1 RlV. I
Continuous
Wire Amperage Voltage The circuits are numbered consecutively starting at the
Circuit 1/ Color Ga. Type Rating Rating 'normal' top of the slip ring core.
1* Wht 14 GPT 7.S 28 VDC The rotational speed rating is 100 T)m.
2* Blk 14 GPT 7.5 28 VDC
3** Red 14 GPT 7.S 28 VDC The overall he.ight of the assembly is 5. 7S" (14,6).
4** Yel 14 GPT 7.S 28 VDC I
5*** . Grn 14 GPT . 7.S 28 VDC
6*** Blu 14 GPT 7.S . 28 VDC
7*** Brn 14 GPT 7.S 28 VDC.
8**** Wht 14 GPT 7.S 28 VDC
9**** Blk 14 GPT 7.5 28 VDC
10**** Red 14 GPT 7.5 28 VDC
*, ** ,*** , & **** -5imil~~ly marked circuits are located
in the same core slots.
Assembly includes the following:
(1) RCAA008001X3 core base assembly with
(4) PS61832250B5 (2.50" long) brass core studs.
(1) RCFA008137B reinforcement insulator.
(1) RCPA008066 outboard bearing.
~(l) ACFA008803Al base -casting w/P53508NPT gasket, P859N08 locknut,
(1) RCFA008084RO (0.63" long) nylon bearing and
(1) P152150200 shaft seal.
~(1) P854E0875D (3/4"NPT) liquid tight connector.
(2) RCFA00088Y5J (5.2S" Ipng) 5.5. brush studs.
(10) RCAA008631P brush assemblies.
(1) RCFAOll096-G (4.50" tall) spun aluminum cover.
(1) RCFA013227A rubber seal f/cover.
(1) 5K1510CA6 Pack-Kit:
(10) C027-16 5et screw type connector.
(10) RCFA008024 sleeves.
(10) T099-14 knife disconnects.
(1) RC8460A install. instruction sheet.
(1) RCPA008223 nylon rub disk
UN~TED EQUIPMENT ACCESSORrES INC.
JAIl\\/I='QI V ~()\M f\
SCALE: ,
~
...--7
I
I APPR(!'~£rJBY~· "II;.. i p- iY 1l11l l.
I DRAWN BY D.E.
DATE: 9-1S-97 ftEVISED.tU 3·21~'8 at:.
Wiring Code for S1SANI0CA6
DRAWING NUMB·Eft
(Calavar 1171141) RCIA062RR4
ey, x 11 I>lUNTP~· . 'NO. l000tl CLUltPR1NT •
ORAIIIIG iii
CD
~k
f
y
UNITED EQUIPMENT ACCESSORIES INC."
WAVERLY, IOWA
SCAlE:
DAlE:
1:4
7-]-95
"3-D ,MICROSTATION loRAWN BY: D.E.
S15A STYLE SLIP RING ILLUSTRATION

DRAIING fUllER .
U II i leu E q 1I i. II '\I e II L 1\ c t: ., l II C •
Page 1 of 6
, f I _".
SLlP' (COLLECTOR) RING
PARTS LIST
l11us. Part Quantity .'.~.". I"
Ref. No. Number Required Name and Description
1 SJ5AN lOCAl, Complete Slip Ring Assembly. (Typical

Assty. Shown for Illustration Purpose.
CUS t olne r No. 7/lill Only.) Includes Brushes ~ Arms, Core
and Base Bracket. S~e Wiring Code
1<CIA1J82B8'1 for 0 the r Com p 0 n e n t s
Included in Assembly. May Include
Har~esses and/or HarAware .
• • l
I. •
, "
2 /((FAtJIJ8f1{),]A I I Slip Ring Aluminum Base nrnckct .
1 Ny 1 0 n 8 ear in g 0 n 1 y £ 0 I." IXFAt;(J8803A f

Aluminum Base Bracket.
3 o
2
2 o
.;
3A O· "0" Ring for Inverted Type na~c I\rnl~k(;'l.
fls21StJ2IJIJ f Grease Seal for Invel"ted TYllc nase I\rltl.
2A f8521£lJ875lJ f Connector ~CFAaa8803AI nase Ilrackel.

,
4 1U.86IA-ItJCA' I Slip Ring Core Assembly (Typical Ass'y.
Show'n) Only. Includes All Brass Ring:;
l' With Center Wire & Nylon InsulatorR.
Also Includes Set Screw Connectors for
Center Hartless Termination. Note: Thi.
Assembly Should Not Be Taken Apnrt Excep'
By Authorized UEA Personnel, and Core
Components Are Not Listed.
Order. Complete Core for Repair.
U\uLc(1 1~(ll1J,pIlIC\lL. Act:.., .1 lit:..
Hev.
J!.aqe 2 of 6
, "
.'
.... .
; I I :
• t SLIP (COLLECTOR) RING
PARTS LIST
Illus. "Part Quantity . .i "

, ;:;.S...;;:e..;;:e~W;.;;;i;.,;:r:..;;i;;.;;.n;;..ogt.....,;;C;;..;o;;..;d~e:::..-.;f;;...'o;;...;r~~ nd i v id ua 1 C i rc \l i \:. Ril \:.i ng .
5-6 f(CAA(J{)B6:J1 fD 7.5 Amp Brush & Holder Assembly
(For Circuits "-/~ (Pair) For Compact Circuits.
----) Used on Circuits Rated,Thru
20VDC Only. Brush is .072"
Thick. Knife Disconnect Terminal
On End is for 14-16 Ga. Wire.
Assembly Also Includes:.~CP~2
Spring, (2)T099-14 Knife Disconnects,+
fiCFAOO&l2~ P las tic Sleeve. Shun t
Wire In,ulation is Green.
5-6
(For Circuits
o
~
15 Amp Capac.i..ty Brush & Holder
Assembly (Pair). Used on Cireui t:8
-) Rated 20VDC 'rhru 120VAC. Brush i.s
1/0" 'l'hick. Klii fe Di scollnec t 'l'cnnill:\l
On End is for 14-16 Ga. Wire. hs~em~ly
Also Includes: Spring, (2)
Knife Disconnect Terminals
&. ; Plastic Sleeve. Shunt Wire
Insulation is Yellow. ~ote: If
Wiring Code Sp~cification Lists 10
i\m[.> Capacity, Use '!'hir; I\RSCIIIIJJ.y "'01.'
Replacement.
5-6
(For Circuits -,---
o 20 Amp Capacity Brush & Holder
Assembly (Pair). Used on Circui \:5
--) Rated 20VDC Thru 120VAC. Brush is
I/O" Thick. Knife Disconnect Terminal
On End is for" 10-12 Ga. Wire. Assembly
Also Includes: Spring, (2)
Knife Disconnect Terminals,
& Plastic Sleeve. Shunt
Wire" Insula tion is Red.
5-6 o
20 Amp High Abrasive 'l'ype Brush &
(For Circuits r---
Holder Assembly (Pa.ir). Used on
). Circuits Rated 20VDC Thru l20VAC.
---------- Brush is I/O" Thick. Assembly Also
, Includes:
Wire, &
is I/O" 'rhick.
Spring, (2)
Large Knife Disconnects for 10-12 Gauge
. Plastic Sleeve. Drush
('rhis Brush Used on
Assemblies in Extremely Dirty Conditionn
Shunt Wire Insulation is Orange.
NOTE: 30 AMP CAPACITY CIRCUITS REQUIRg (2) PAIRS
" BRUSH & ARM ASSEMBLIES.
' ' ' •.L'-.'''~.' '.".ju.l.l'"ICIIL I\CC., .tHC
Rev.
Page 3 of 6
: .:.,:1 SLIP (CO~ECTOR) RING

PARTS. LIST J.. ..
Illus. Part Quantity

: ' .
Ref~ 'No. Number Required Name and ,Description
5-6 o 45 Amp Brush & Holder Assembly
(ror Circuits ~ (Pair). Useu ~n Circuits Rated
--)
20VDC 'rhru l20VAC. Brush is " ..
Thick. Assembly Also Includes:
:. Spring, (2)
Jumbo Knife Disconnect Terminals
for 8 Ga. Wires & Plastic
Sleeve. Shunt Wire Ins.ulation is
Black. (Some Early Models of 'This
Assembly May Have Eyelet Terminal
Instead of Knife Disconnect. Use
Knife Disc. Style to Replace.)
5-6
(For Circuits I
o 45 Amp lIigh Abrasive Type Brush &
Holder Assembly (Pair). Used on
-) Circuits Rated 20VDC Thru 120VAC.
Brush is ~"Thick. Assembly Also
Includes: Spring, (2)
Jumbo Knife Disconnect.
Terminal for 8 Gauge Wires, &
. Plastic Sleeve. (This Brush is Used
on Assemblies.in Extremely Dirty
Conditions.) Shunt Wire Insulation
is Black.
NOTE: '75 AMP CAPACITY CIRCUITS REQUIRE (2) PAIRS
OF - - --
- ORUSH AND ARM ASSEMBLIES.
--------.::~:..::..::.:.......::..:.:..:.-=--.:..::..:...::..:...~:....::..::::..:..:...:..::..:..==~
HIGH VOLTAGE CIRCUITS (220-'600V)

BRUSH & ARM ASSEMDLIES
5-6
'(For Circui ts 1--
o Brush & flolder Assembly (Pair)
With Knife Disconnects for 12-10 Ga.
- --) Wire. Brush is 1/0" Thick. 20 Arne
Capacity, 220 Thru_GOO Volts.
Assembly Also Includes:
Spring, (2) '. Knife Disconnect
'·.'erminals, & .. ' Red Insula tin9
, NOTE:
...
.
Slee~e~
30 AMP CAPACITY CIRCUITS REQUIRE (2) PAIRS OF

:\SSEMBLY •
Shunt Wire Insulation is Red.
l\t:'! V •
Page 4 of G
.:'!~' '", I.' I,SLIP (COLLECTOR) lUNG

PARTS LIST·
_llus. ' : Part Quantity " '" . I

Ref. No.' Number Required Name and Description
5-6 o ,Brush fie Holde'r l\ssembly (Pair)
(For Circuits r---
----'")
with Jumbo Kn·ire Disconnect for
8-10 Ga. Wire. Brush is ~~ Thick.
~l\mE Capacity, 220 Thru 600 Volts.
Assem Iy Also Includes: . .
Spring, (2) Jumbo Knife
Disconnects, & Black Sleeve.
Shunt Wire Insulation is Black.
NOTE;. 75 AMP CAPACITY CIRCUITS REQUIRE (2) PAIRS OF
'.' .. > .
ASSEMBLY.
7 ~CFA()"D8aY5:r 2 Brush 1I0lding Stud. Advise Slip' Rin.9,
, (5~·LoNG) Assembly No. or Specify Length When
OrderIng. 5716-10 'l'hread Both J:;llds.
10n Smail Rings, ,Hex lIead Cap SCJ:ew
8 RC.PAIJ/J8tJ~
, May ~e Used.)
Nylon Outboard Bearing. Used At
Top of 12 Circuit and Larger Rings.
Some Large Rings Aiso Use (1) As
Center Support Bearing . .
9 l\R Large Knife Disconnect Terminal.
o For 10-12 Ga. 'Wire. Used on
Brush fie Arm
Assemblies.
9 7tJ99-1'I Small Kni.fe Disc'onnect Terminal.
For 14-16 Ga. Wire. Used on
~A~3/' Brush & Arm 1\ssemblies.
9 AR Jumbo Knife Disconnect 'ferminal,

O. Used on &
Brush & Arm Assemblies.
Not AR· , 110 Stud 0 Ga. Eyelet 'l'erminal
Illus. '0 ,For Brush & Arm 1\ss'y.
10 ,fCPAOtJ8612 AR .1.6' Brush Spring for ~aQ86JI
'~{J/J} Brush & Arm Assembly.
It AR 2 .• 8" Spring for
\. o
10 AR 5.5' Brush Spring for
()
~ A R:: As I<mUJRd)
( ) .. ary. /{i!Z)uJRaJ fl:tl. 'Cd#JPlETJ!: A.s5~
v ..... t..t:::u. L;oy.UJ..pment ACC., Inc.
Rev.
Page 5 of 6
SLIP (COLLECTOR) RING

." PARTS. LIST
Illus-. Part Quantity

11 'C(JZ7 - /~ ~AR Set Screw Type Connector.
~rID}': Includes Brass Threaded Insert
and Yellow Nylon Cap. (For
16-16 Gauge Wire.) Used on
7.5 Amp Circuits.
11 AR Set Screw Type Connector.
o Includes Brass Threaded Insert
and Red Nylon Cap. (For 10 Gauge
Wire.) Used on 30,45, & 75 Amp
.. " . Circuits.
12 . Crimp Type Wire Connector for
12-14 Gauge Wire. Used When
Ring Has Factory Prewired Center
Harness. Order to Replace.
12 Crimp Type Wire Connector for 10
Gauge Wire .. Used When Ring Has
Factory Prewired Center Harness.
Order to Replace.
13 AR ~"I.D. x 3" Long Large Plastic
o Sleeve for Knife Disconnect.
Use with' Knife Disconnect
Terminal on Ring Rated 28VDC
Thru 110VAC.
13 IU'A1J1J802'1 . 'AR 3/16" 1.0. x 3". Long Small Plastic
*(10) Sleeve for Knife Disconnect. Used
wi th 7d).J-ILJ Knife Disconnect
Terminal on Rings Rated 28VDC Thru
110VAC.
13 AR Plastic Sleeve, .330" I.D. x 3"
o Long. Used with Knife
Disconnect Terminal on Rings
Rated 28VDC Thru 110VAC.
13 AR Red Plastic Sleeve. .263" I.D.
o x 3" Long~ Used with
Knife Disconnect Terminals On
Rings 220VAC Thru 600VAC.
~ AR~As RmUlKEtJ
( )::a 07Y. /fcaUlR1:O rLJe {;;,,Mpa.,.r IIss~.
united Equipment Ace., Inc
. Rev .
. .. Page 6. of 6
SLIP (COLLECTOR) RING

PARTS LIST
. '. . :....'
Illus. '. Part Quantity

Ref. No.··Number . Required Name and Description
AR Black Plastic Sleeve. .50" 1.0.

o x 3" Long. Used with
Knife Disconnect Terminals On
Rings 220VAC Thru 600VAC.
14 .Slip Ring .Mounting Tube Ass'y.
15 Center Harness Assembly ..
16 Brush Harness Assembly.
17 RCFNJII{J:J6 - G Sheet Metal or Spun Aluminum Cover.
18 ~ Turntable Base Sracket.
19 o Two Circuit Pneumatic Swivel.
20
21
'.
RCPAd08223
- ,.
() Four Circuit Pneumatic Swivel.
Rub Disk, nylon 5.0" 0.0.

22 P5253118NY I 5/16" Nylon Acorn Nut
23 .~5223118 2 5/16"-18 l1:ocknut Nylon Insert
24 P53531SS 3 Sealing Washer, Neoprene Back

25 P511311805NY I Nylon Hex Head Capscrew
26 P.5233118 2 5/16"-18 jam nut, he~
27 P53131 2 5/l6J1 Washer

28 . P132031AL 2 Set Collar 5/16"
tHSCELLANEOUS PARTS NOT ILLUSTRATED
Not Illustrated C) Connector for Sheet Metal Cover or
Spun Aluminum Cover.
Not Illustrated o Connector for Turntable Base Bracket.

RCFAlJl322?A f
Installation of the' slip ring is relatively simple,
(Ref. to Drawing RC 8460A). In a typical application, a
1.492-1.496" 0.0. mounting tube is fastened to a stationary
lower unit. The ring core (or center stack of brass ringp)
is secured to the mounting tube by a set screw collar located
at the base of the core. The set screws are tightened to
45-55 in./lbs. to keep the core stationary. If this is not
done, the core can turn, twisting the center harness wires.
The cente~ ;arness is attached to the core by set ~crew
connectors, and normally runs through the center of the core
to exit at the bottom of the drive tube. This harness is
connected to the electrical components in the s,tationary
member. Typically the brushes, base 'bracket, and cover
will turn with the rotating member of the equipment upon
which it is located and can move continuously around the
ring core, providing uninterrupted electrical contact.
Rotating the brushes around the core is accomplished by

the use of,a boss in the base bracket. This is normally
tapped to ~-l3(UNC) thread and a threaded pin inserted.
The other end of the pin must not be fastened tightly to
the rotating member, but must 'be' allowed to "float". This
is very important on many machines that may acquire an orbiting
condition as the equipment ages. This type of wear will
put stress on the ring and may ultimately break the base
if it'is bolted ~ightly. If the turning pin is tightly
mounted on the rotating member, it must then be small
enough on the opposite end to float within the bos~.
The brush shunt wires are attached to the brush harness
with mating knife disconnect terminals and are protected
by a plastic sleeve. The brush harness then exits through
the base bracket and is connected to the electrical components
in the rotating member.
.
"
, IMPORTANT'':''DANGERI
00 NOT REMOVE COVER OR ATTEMPT MAINTENANCE

UNTIL PO~ER IS DISCONNECTED AND LOCKED.
(CRITICAL on 120VAC to 600 VAC rated circuits)
'Page 1 of 3
SLIP RING MAINTENANCE AND SERVICE

SERIES l~" BORE
.
Located on the 'center of rotation, slip rings (or collector
rings) maintain full electrical contact at all times between
a rotating member with continuous 360 0 rotation, and a stationary
member. Without 'the slip ring, the wire harness would twist
off and electrical contact would be lost.
U.B.A. slip rings have long been recognized as leaders in
the construction equipment field. Because of their reliability,
applications have spread to other markets. They are now widel~
used on utility, forestry, fire fighting, and irrigation equipment,
along with rotating signs, emergency lighting, and in plant
production machinery, etc. {Rotation limited to lOORPM maximum.}
The slip ring is designed for maximum efficiency with a minimum
of maintenance. The self-cleaning brushes will last the life
of the equipment, in most cases under normal conditions and
useage. On all circuits from 10 to 30 Amp capacity, the brushes
ride on a 3/l6 h wide brass ring.! One brush pair per circuit
is used on 10 to 20 Amp circuits. For circuits requiring up
to 30 Amp capacity, two pair of brushes per circuit are used.
For 45 Amp capacity, a 3/8 h wide brass ring and a single pair
of wide brushes is used. Two pair of wide brushes are used
on 75 Amp capacity. The special 7~ Amp capacity circuits
ride on a 3/32" brass ring. (See note on page 2 concerning
service and replacement of these.) The brushes are fastened
to the brush arms to allow pivoting of the brushes. This
assures complete contact at all times between the brush and
the brass ring. This is especially important if an orbiting
condition develops as the equipment ages.
The brushes are normally attached to the 'brush' harness with
knife disconnect terminals. This allows ,for quick disconnect
of the harness, should removal of the ring be required. Terminals
of this type are protected by a plastic sleeve. When installing
the ring assembly, care should be taken to insure complete coverage
of the terminals by this sleeve. Some slip ring harnesses use
multiple circuit electrical connectors or plugs. These should
be disconnected and connected carefully to avoid damaging the
contacts.
In the case of customer attachment, the center harness is

normally connected to the core leads on the slip ring by
the set screw connectors provided with the ring. These
connectors have proven to be superior to the twist on type,
especially in field installations, because they are a positive
type installation. The brass sleeve is slipped over the
stripped wire ends, and the set screw tightened with a straight
uluted El,lulpmelll l\cc., lllc.
Page 2 of 3
SLIP RING MAINTENANCE AND SERVICE

SERIES l~" BORE
s~rewdriver. The nylon cover is then screwed down over

the sleeve for protection. Care should be taken to keep
the center leads as short as possible when connecting
the center harness to prevent the wires from catching
on any moving parts.
Some U.E.A. slip rings are prewired during manufacture
and the center core leads are permanently fastenee to
the center harness with machine crimped terminals. If
it becomes necessary to remove these, the set screw type
connectors should be used for replacement.
If not revolved for some time, under some conditions, the

slip ring will have a tendenct to collect fine silt, or
a salt atmosphere will cause corrosion. If this happens,
the equipment should be rotated through several revolutions
if possible. The cleaning action ,of the brushes should
clean the ring surfaces. If it does not, or it is not
practical to revolve the machine, it may be necessary to
use a standard non-residue solvent to clean the ring. Then
lightly sand the brushes and rings with a fine grade of
sandpaper and dust off with compressed air.
To replace a brush and arm assembly, remove the hex nuts
and washers at the top of the brush stud along with the
outboard bearing, if uRed. This will allow 81e brush assemblies
to be removed. Note: Some smaller rings use cap screws,
or may be equipped with socket screw type set collars instead
of hex nuts. Carefully remove the brushes without 'over'
stretching the brush springs and arrange in order of removal
with the spacers. Replace the damaged brush assembly and
then reassemble the brushes and spacers in reverse the removal
order. This will ensure the correct spacing between electrically
live parts which is critical on higher voltages of llOVAC or
over. Be sure that all brushes are snapped in tight and making
full contact with their corresponding brass ring. Also check
that all springs are hooked correctly through the brush arm.
NOTE: Special care should be exercised when handling or

replacing the 7~ Amp brush and arm assemblies. Because of
their small size, they can be broken if forced up or down.
In the correctly installed position, the possibility of
breakage is minimal.
The series slip rings normally include a nylon bearing
in the base, eliminating the need for lubrication. The
series slip ring assemblies with spun aluminum covers, can be
mounted either upright or inverted. The upright mounted assembly,
with the cover on top, would also include a nylon bearing in the
base, similar to the series. If the ring is supplied for
uni ted 5r~uipmen t Acc., Inc.
Rev. 4-B8
Page 3 of 3
, .• ! .",: '.:. I'
SLIP lUNG HAINTENANCF. AND SERVICE

I' ,SF.RIF.S l~ BORE
inverted mounting, the base will contain a 'grease' seal and a

shortened nylon bearing. The seal excludes most contaminants
and fluids from running down the mounting tube into the sli~
ring asseh::'ly. A liquid tight connector for the .:>rush harness
exit is also supplied in the base of ,an assembly for inverted
usage.
Previous to 1987, on . series assemblies sup~lied for in-

verted mounting, the bases contained an '0' ring rather than a
nylon bearing. The newer style base with seal and bearinq pro-
vides both a good seal and the superior bearing properties of
the nylon bearing. There are some RC 050 series slip, rings e~uip
ped with '0' ring bases that hve coveis provided by the custo~er.
If it should become necessary to remove the slip ring from the

machine, do so by loosening the ~ocket screws at the base of the
ring. This will allow the ring to be lifted off the mounting
tube. When replacing it, make sure these set screws are again
tightened. (Recommended torque: 45-55 in.-lbs.) I.f the set
screws are not tight, the core can turn or be held by the brushes,
and brist off the core leads or center harness. The mounting
tube should be 1.492"-1.496" 0.0. and approximately 14 gauge
thickness. This allows for proper fit along ~ith ~aximum inside
clearance, while maintaining necessary strength. Care should be
taken to abide by these tolerances if mounting tube replacement
is required. The grease seal or '0' ring in the o~tional base
for inverted mountina should be lubricated with GE G322L Versi-
lube or equivalent silicone grease before the insertion of the
rr.ounting tube.
In most cases, slip ring assemblies should not be fastened down

tightly. If they are riot attached perfectly to the center of
rotation or if wear causes an orbiting condition as the equip-
ment ages, excess strain is applied to the slip ting assembly.
Therefore, the slip ring drive pins for the series slip
rings should be at least l/B" smaller in diameter than the 3/4"
cHao holes in the base casting of the ring. The drive hole in
the base of the RC B50A series slip ring is tapped ~-13 UNC. A
!.(-13 UNC oin in this hole should be allowed to 'float' on the
~ppo!3ite end, The same result is achieved by using a 7/16" dia.
or srnalle~ p~n fastened tightly on the driven end and with a
ioo~e lib in the hole. (~ome special series round base
slip rings contain (1) 0.500" dia. hole in the drive boss. The
drive pin inserted into this hole should also be at least 1/8"
smaller than the 0.500" hole dia.)
SL Governor/Carburetor Assembly Instructions
fusert the M6 bolts into the bracket from the bottom
Place the gasket over the bolts
Mount the carburetor on the bolts with nylok nuts - leaving the nuts &tightly loose at this time
Using gage SL-A ~tween the slot in the bracket and the carburetor shaft, align ille carburetor with
the bracket and tighten the nylok nuts
Install the shoulder bolt in the arm with the tapped hole pJacing the bolt head away from the short
side of the ann using a nylok nut to lock the assembly
Install the arm on the carburetor. shaft with the shoulder bolt head away from the carburetor and
the ann flush with the end of the shaft - pOSition the arm to swing approximately equidistant on
either side ofvet1icaJ·1ighten the
r
!
, arm clamp boh with nylok nut
Install the actuator by sliding th~ slotted arm under the shoulder bolt on the carburetor arm and
fitting the actuator in the matcbiDg radius of the bracket
I Loosely assemble the s1rap using 2 screws with Loctite to the bracket
1 Rotate the actuator to just close the carburetor buttetfly against the idle stop screw"" hold this
,
)
position
\ Mark the side (away from the arm) of the actuator at the bracket top edge with pencil. Further
rotate the actuator in the direction of closing the butterfly until the pencil mark is above the bracket
edge by approximately .20 inches
Visually check that the slotted ann is centered on the length of the shoulder bolt and that there is
no intelference between the armS or shafts
Tighten the strap screws
Cheek the arm movement - there must be no binding throughout the full stroke and there must be
ai spring preload holding the cartiuretor in its throttle closed position
Install the wire clamp to the side; of the bracket making approximately a 1" loop between the
actuator and bracket - tighten Ih~ clamp screw
10/12195
, TOTAL P.02
-
Actuator
Actuator Tach S'gnal
Aux Speed 1 Grounu
Aux Speed 2 ~ Power + 12VDC
8 7 6 543 2 1
o o
o E-301 o
Notes:
1. Polarity at terminals 1 and 2 must be correct·
2. The tach signal comes from the distributor
Precision Governors. Inc.
Part Nome
3. Terminals 3 and 4 are connected at the control box
4. Aux speeds (if used) are obtained by applying 12 VOC to
9/23/97 I None FDS
one or the other of terminals 7 or 8 Materlol or Speclflcatton I Part Number IRev
5. The actuator (terminals 5 and 6) is not polarity sensitive
Series 40 - M3S Introduction
Introduction
The purpose of this manual is to provide information Sundstrand-Sauer provides a complete repair service
useful in the normal servicing of the Series 40 - M35 for its products. Contact any Sundstran'd-Sauer
Hydrostatic Pumps and Motors. This manual includes Authorized Service Center for details. (See pages 35
unit and component description, troubleshooting, ad- and 36.
justment, and minor repair procedures. Following the
procedures in this manual, the minor repairs may be The torque values, pressures, and dimensions used
performed without affecting the unit warranty. throughout this manual are given in English and metric
measurements.
A Series 40 Transmission does occasionally require
servicing, and these units have been designed with
this in mind. Some repairs and adjustments can be ac-
complished without removing the unit from its installed
location, provided that the unit is accessible and can
be thoroughly cleaned before beginning any proce-
dures. Since dirt or contamination is the greatest
enemy of any hydraulic equipment, the greatest pos-
sible cleanliness is necessary.
Variable Displacement Pump Variable Displacement Tandem Pump
,.
Fixed Displacement Motor Variable Displacement Motor
Series 40 - M35 ;~~en~ral De.scription
General Description
The Series 40 - M35 pumps and motors can be applied A charge relief valve and charge check valves are in-
separately or combined in a system to transfer and cluded in the pump end cap to control the makeup and
control power. When combined in such a system, cooling oil flow for the system. The charge check
these units provide an infinitely variable speed range valves also incorporate the bypass valve function and
between zero and maximum, in both forward and high pressure relief valve function into their design.
reverse modes of operation.
The Series 4;:: M35 variable displacement pump is
Series 40 - M35 variable displacement pumps are a available with a 0.72 in3/rev (11.8 cc/rev) integral gero-
compact, state-of-the-art design, using the parallel axial tor type charge pump. The Series 40 - M35 tandem
piston I slipper design in conjunction with a tiltable pump is available with a 1.00 in3/rev (16.4 cclrev) inte-
swash plate to vary the pump's displacement. Revers- gral gerotor type charge pump.
ing the direction of tilt of the swashplate reverses the
flow of oil from the pump and thus reverses the direc- The fixed and variable displacement motors also incor-
tion of the motor output rotation. porate the parallel axial piston I slipper design. Fixed
displacement motors utilize a fixed swashplate angle.
A direct displacement control system is used on the The variable displacement motors use a variable angle
Series 40 - M35 variable displacement pump and tan- swashplate with a direct displacement control system,
dem pump. The swashplate control shaft is connected similar to the variable displacement pumps.
directly to the swashplate. Movement of the control
shaft causes a proportional swashplate movement and
change in pump flow. This control can be located on
either side of the unit.
Input
Shaft
o Suction Flow
Displacement o Charge Pressure
Pump • High Pressure
o Case Flow
Fig. 1 - Typical Series 40 - M35 Variable Pump -- Fixed Motor Transmission

Schematic
2
Series 40 - M3S Transmission Hydraulic Support· System
Transmission Hydraulic Support System
The Series 40 - M35 Pumps and Motors are easy to

install, requiring no adjustments and few auxiliary
components. They have their own hydraulic support
system which is discussed in this section.
Basic Closed Circuit

..
The main ports of the pump are connected by hy-
draulic lines to the main ports of the motor. Fluid flows,
in either r.iirection, from the pump to the motor then
back to the pump in this closed circuit. Either of the
hydraulic lines can be under high pressure. The direc-
tion and speed of fluid flow (and the motor output shaft
rotation) depends on the position of the pump swash-
plate. The system pressure is determined by the ma-
chine load.
.. .. Case Drain and Heat Exchanger
FLOW (BI-DIRECTIONAL)
HEAT EXCHANGER WI BYPASS The pump and motor require case drain lines to re-
move hot fluid from the system. The pump case
RESERVOIR should be drained from its upper drain port to insure
the case remains full of fluid. The pump case drain is
Fig. 2 - Basic Closed Circuit then connected to the lower drain port on the motor
housing. The upper motor housing drain port is then
connected to the reservoir.
A heat exchanger, with a bypass valve, may be re-

quired to cool the case drain fluid before it returns to
the reservoir.
CAUTION
Continuous case pressure should not ex-
ceed 25 PSI (1.7 BAR).
Charge System and Inlet Filter
The charge pump supplies cool fluid to the system and

keeps the closed loop charged to prevent cavitation.
The charge pump draws its fluid from the system
reservoir. An inlet filter is required to insure that only
clean fluid enters the system.
CAUTION
The inlet vacuum, measured at the charge
pump inlet should not exceed 5 in. Hg (.S
BAR abs.), except during cold starts.
CHARGE CHECK &
H.P. RELIEF
VALVES
- Fig. 3 - Charge System
3
Series 40 - M3S Transmission Hydraulic Support System
Since either of the main hydraulic lines can be higl:l
pressure, two (2) charge check valves are used to di-
rect the charge supply into the low pressure line.
These check valves (located in the pump eAd cap) also
incorporate the optional high pressure relief valve
function. Any charge flow not being used for the
closed circuit is discharged over a direct operating
charge relief valve, through the pump and motor
housings, and back to the system reservoir. The
charge pressure relief valve is factory set for 100 ,1PSI
(7 BAR) above case pressure under test conditions.
Exact charge pressure may vary in various applications.
NOTE: Certain M35 pumps have a charge pressure

relief valve setting of 200 ,1PSI (14 BAR)
High Pressure Relief Valves
Two (2) optional combination check / high pressure re-

lief valves may be provided in the pump end cap for
overload protection. These cartridge type relief valves
are factory set, and are not field adjustable. Changing
the maximum system pressure can be accomplished
by installing different cartridges with the desired set-
ting.
Fig. 4 - Charge Check and High Pressure

Relief Valves
Safety Precautions
• The loss of hydrostatic drive line power in • Use caution when dealing with hydraulic
an acceleration, deceleration, or neutral fluid under pressure. Escaping hydraulic
mode may cause a loss of hydrostatic braking fluid under pressure can have sufficient
capacity. A braking system, redundant to force to penetrate your skin causing serious
the hydrostatic transmission must, therefore, injury. This fluid may also be hot enough to
be provided which is adequate to stop burn. Serious infection or reactions can de-
and/or hold the system should the condition velop if proper medical treatment is not ad-
develop. ministered immediately.
• Certain service procedures may require • Some cleaning solvents are flammable. To
the vehicle/machine to be disabled (wheels avoid possible fire, do not use cleaning sol-
raised off the ground, work function discon- vents in an area where a source of ignition
nected, etc.) while performing them in. order may be present.
to prevent injury to the technician and by-
standers.
4
Series 40 - M3S Product Specifications
Technical Data - Fixed Displacement Motor / Variable Displacement Motor
Product Type M35 Fixed Motor M35 Variable Motor
Displacement
In3 /Rev 2.1 2.1 (Maximum)
cc/Rev 35 35 (Maximum)
Output Sppe~~_______________________________________
Full Angle (17~) Max - RPM 4500 450.:-::0:------------
Continuous - RPM 3600 3600
Low Angle « 11°) Max - RPM 5300
Continuous - RPM 4100
Output Mounting Flange (per SAE J744)

SAE SAE
B B
Output Shaft (Std. Spline)

Number of Teeth 15 ___.wALL!=!=.!:Ua.;N::..llT~S:....__ _ _ •
Pitch 16/32
Weight
LBS 26 47
KG 11.5 21
Pressure
Maximum PSI 5000 ____~ALL~U~N=lT~S~_____ •
BAR 345
Continuous PSI 3000 ____~ALL~U~N=ITS~______ •
BAR 210
Case Pressure
Continuous PSI 25 ____~ALL~U~N=ITS~______ •
BAR 1.7
Maximum PSI 75 ____~ALL~UN~lT~S~_____ •
(Cold Start) BAR 5.2
·Temperature at Hottest Point in Transmission (normally at case drain)

Maximum ~
'C
220
104
ALL UNITS
•
Continuous ~
'C
180
82
ALL UNITS
•
Fluid Viscosity Limits -- SUS (CST)
Optimum 70 (13)
Min. Continuous 55 (9.0)
Min. Intermittent 47 (6.4) --,-,ALL==-:.U",-N".,lT~S~_____ •
Max. Continuous 500 (110)
Max. Cold Start 7500 (1600)
Suggested Filtration
Dedicated Reservoir Beta 10 = 1.5 to 2.0 ALL UNITS •
Common Reservoir Beta 10 = 10 to 20
-
6
Series 40 - M3S Start-Up & Maintenance
Start-Up & Maintenance
Fluids
WARNING
Hydraulic fluids used with Sundstrand-Sauer products
Do not start prime mover unless pump is in l
should be carefully selected with assistance from a
neutral position (0 swashplate angle). Take
reputable supplier, following the guidelines presented
precautions to prevent machine movement in
in the "Fluid Quality Requirements" bulletin, BLN-
case pump is actuated during initial .,.tart up.
9887.
Start-Up Procedure Once charge pressure has been established, increase

speed to normal operating RPM. Charge pressure
The following start-up procedure should always be should be 100 PSI (7 BAR) minimum. If charge pres-
followed when starting-up a new installation or when sure is incorrect, shut down and determine cause for
restarting an installation in which either the pump or improper pressure.
motor had been removed from the system.
With motor output shaft disconnected or drive wheels
raised off of the ground, run system at full input and
WARNING output speeds in both directions. Operate system for
at least fifteen (15) minutes.
The following procedure may require the ve-
hicle/machine to be disabled (wheels raised
Shut down prime mover, remove gauges, and plug
off the ground, work function disconnected,
ports. Check reservoir level and add fluid if necessary.
etc.) while performing the procedure in order
to prevent injury to the technician and by-
The transmission is now ready for operation.
standers.
Maintenance
Prior to instalfing the pump and/or motor, inspect the
units for damage incurred during shipping and han- To insure optimum service life on Series 40 - M35
dling. Make certain all system components (reservoir, products, regular maintenance of the fluid and filter
hoses, valves, fittings, heat exchanger, etc.) are clean must be performed.
prior to filling with fluid.
Check the reservoir daily for proper fluid level, the
Fill the reservoir with recommended hydraulic fluid presence of water (noted by a cloudy to milky appear-
which should be passed through a 10 micron (nominal, ance, or free water in bottom of reservoir), and rancid
no bypass) filter prior to entering the reservoir. fluid odor (indicating excessive heat).
The inlet line leading from the reservoir to the pump It is recommended that the fluid and filter be changed
must be filled prior to start up. Check inlet line for per the vehicle/machine manufacturer's recommenda-
properly tightened fittings and make sure it is free of tions or at the following intervals:
restrictions and air leaks.
• System with a sealed type reservoir - 2000 hrs.
Be certain to fill the pump and/or motor • System with a breathing type reservoir - 500 hrs.
housing with clean hydraulic fluid prior to
start up. Fill the housing by pouring filtered oil into It may be necessary to change the fluid more fre-
the upper case drain port. quently than the above intervals if the fluid becomes
contaminated with foreign matter (dirt, water, grease,
Install a 0 to 500 PSI (35 BAR) pressure gauge in the etc.) or if the fluid has been subjected to temperature
charge pressure gauge port to monitor the charge levels greater than the maximum recommended.
pressure during start-up. Never reuse fluid.
With the pump swash plate in its neutral (0 angle) posi- The filter should be changed whenever the fluid is
tion, "jog" or slowly rotate prime mover until charge changed or whenever the filter indicator shows that it is
pressure starts to rise. Start the prime mover and run at necessary to change the filter.
the lowest possible RPM until charge pressure has
been established. Excess air may be bled from the
high pressure lines through the high pressure gauge
ports.
8
Series 40 - M3S Troubleshooting
Troubleshooting
Gauge Installation
A Various pressure and vacuum gauge readings can be a
great asset in troubleshooting problems with the
C Series 40 - M35 transmission or support system.
o It will be necessary to install a high pressure gauge into

the system pressure gauge ports (or tee into the high
pressure lines) to check the setting of the system
8 pressure relief valves.
Fig. 8 - Gauge Connections Measuring the charge pump inlet vacuum will help
locate restrictions in the inlet lines, filter, etc.
Variable Pump (Top View)
Case pressure readings can help locate restrictions in
the return lines, oil cooler, and return filter.
o o Gauae Information
System 10,000 PSI (690 BAR) - Gauge
A Pressure -----------------------------
Port "A" 9/16 - 18 O-Rina Fittina
CHARGE PUMP) System 10,000 PSI (690 BAR) - Gauge
8 REAR
B Pressure ------------------------
Port "B" 9/16 - 18 O-Rina Fittina
Charge 5QO PSI (35 BAR} - ~auge
Fig. 9 - Gauge Connections
Pressure Suction Filtration: 7/8 - 14 O-Ring
Tandem Pump (Top View)
C Fitting
Pressure Filtration: Tee into Charge
8 REAR Pressure Filter Outlet Line
'----"~cE-~~~hv---.i.(:.._O~PPOSITE SIDE) Case 5QQ PSI (J5 BABl - GaL!g~
0 Pressure 1-1/16 - 12 O-Ring Fitting (PV, PT,
MV)
7/8 - 14 O-Rina Fittina (MF)
Charge Vacuum Gauge
E Pump Inlet -----------------------
Vacuum Tee into Charae Pumo Inlet Line
8
NOTE: Tandem pumps have two (2) additional system
pressure gauge ports (for system ports "C"
Fig. 10 - Gauge Connections and "0") in the rear section.
Tandem Pump (Side View)
Snubbers are recommended to protect pressure
gauges. Frequent gauge calibration is necessary to
insure accuracy.
Fig. 11 - Gauge Connections

Variable Motor (Rear View)
9
Series 40 - M3S Troubleshooting
Fault-Logic Diagrams
Check Control Inspect Check/Relief Valves Replace

Unkage - OK--~ or Check Valves ~ OK--~ Transmission
I L...-----r--I-----I (Pump and Motor)
Defective Defective
Repair or Repair or
Replace Replace TRANSMISSION OPERATES IN
ONE DIRECTION ONLY
ec Inspect Check
Check
Oil Level OK Heat OK OK System
Charge
in Reservoir Exchanger Pressure
Pressure
Low Defective (No Load and
Under Load)
Low
Inspect
Inspect
ChargePump OK Charge Relief Reduce
Valve
Transmission
Clogged Load
OK
t
Replace Replace
Transmission
(Pump & Motor)
TRANSMISSION OPERATING HOT
Check Check Check

Oil Level OK OK Charge OK System Hi h
Pressure Pressure
(No Load and Reduce
Under Load) Transmission
L W Load
Low
Inspect Check/Relief Valves or
Inspect Charge Check Valves
OK Charge Relief --uK Defective
Valve
~
Defe tive OK
OK
Replace
Replace
Transmission
LOSS OF POWER OR (Pump & Motor)
TRANSMISSON WILL NOT OPERATE IN EITHER DIRECTION
10
Series 40 - M35 Inspections and Adjustments
Inspections and Adjustments
Direct Displacement Control
Inspect the connection of the control linkage to the

swashplate control shaft to insure that the linkage is
properly attached. Neutral position of the swashplate
is determined by the vehicle/machine control linkage.
Check I High Pressure Relief Valves
When a problem occurs in one direction, interchange

the charge check or check/relief valves to see if the
problem changes to the other direction. If so, one
valve is malfunctioning or the check/relief valve car-
tridge does not have the proper setting.
CAUTION
The relief valves are factory set and should
not be tampered with except for replacing
the entire cartridge. Disassembly may
change the setting and cause erratic unit
operation or premature failure.
Fig. 12 - Check I High Pressure Relief
Valves The pressure setting of the valve (in BAR) is indicated
by a three (3) digit code stamped on the cartridge. The
cartridge must be removed from the special plug in
order to read the code.
Pump Charge Relief Valve
If charge pressure is low, the charge relief valve should

be inspected .. Inspect for foreign material holding the
poppet open, and for scoring or wear on the poppet
and seat in the housing.
Adjustment of the charge pressure is accomplished by

changing the shim thickness behind the spring. The
charge relief valve is factory set for 100 to 120 LlPSI (7
to 8 BAR) above case pressure at 1800 RPM.
NOTE: Certain M35 pumps have a charge pressure

relief valve setting of 200 to 220 LlPSI (14 to
15 BAR).
Fig. 13 - Pump Charge Relief Valve Bypass Valve
The bypass function is accomplished by manually

opening the charge check / high pressure relief valves.
If the system is operating hot, check that the valves are
fully seated by turning the special plugs (two [2] on
variable pumps, four [4] on tandem pumps) clockwise
with a 5/16" internal hex wrench. Torque the plugs to
30 to 50 ft.lbs. (41 to 68 Nm).
-
11
Series 40 - M3S Minor Repair and Replacement
Minor Repair and Replacement
General
Minor Repairs may be performed, following the proce- Protect all exposed sealing surfaces and open cavities
dures in this section, without voiding the unit warranty. from damage and foreign material.
Cleanliness ic; ~ primary means of assuring satisfactory It is recommended that all gaskets and O-rings be
transmission lite, on either new or repaired units. replaced. Lightly lubl i.:ate all O-rings with clean pet-
Cleaning parts by using a clean solvent wash and air roleum jelly prior to assembly. All gasket sealing sur-
drying is usually adequate. As with any preCision faces must be cleaned prior to installing new gaskets.
equipment, all parts must be kept free of foreign mate-
rials and chemicals.
Charge Pump and

Auxiliary Pump Mounting Pad Auxiliary Pump Mounting Pad . Charge Relief Valve
Shaft Seal
Charge Check and

High Pressure Relief Valves Charge Check and
With Bypass High Pressure Relief Valves
With Bypass
Variable Displacement Pump Variable Displacement Tandem Pump
Shaft Seal Shaft Seal
Fixed Displacement Motor Variable Displacement Motor

Fig. 14 - Minor Repairs
12
Series 40 - M35 Minor Repair and Replacement
Shaft Seal
lip type shaft seals are used on the Series 40 - M35

pumps and motors. These seals can be repJaced with-
out major disassembly of the unit. However, replace-
ment of the shaft seal generally requires removal of the
pump or motor from the machine.
Remove the retaining ring from the housing.
Carefully pull the seal cover out of the housing using

pliers. Care must be taken so as not to damage the
housing bore or shaft.
Fig. 15 - Remove Seal Cover Retaining
Ring CAUTION
After the seal cover Is removed, the shaft
may be free in the housing. DO NOT PULL
SHAFT OUT. The slipper hold down pins
could become dislodged, requiring major
disassembly of the unit.
Remove the a-ring from the seal cover or the housing.
Place the seal cover in an arbor press and press out

the old seal. An appropriately sized pipe spacer or
socket wrench can be used as a press tool. Once re-
moved, the seal is not reusable.
Fig. 16 - Remove Seal Cover from Inspect the seal cover, the new seal, and the a-ring for
Housing damage. Inspect the sealing area on the shaft for rust,
wear, or contamination. Polish the sealing area on the
shaft if necessary.
Using the arbor press, press the new seal into the seal
cover. Be careful not to damage seal.
NOTE: New seals are lubricated with an assembly

grease
Wrap the spline or key end of shaft with thin plastic to

prevent damage to the seal lip during installation.
Install the a-ring onto the seal cover and retain with
petroleum jelly.
Fig. 17 - Shaft Seal Removed
Slide the seal cover assembly over the shaft and into
the housing bore. Install the retaining ring.
NOTE: If a beveled retaining ring is used, install the

ring with its beveled side out.
- Fig. 18 - Install Seal Cover with O-Ring

13
Series 40 - M35 General Parts Identification
M35 Fixed Displacement Motor MF (Minor Repair)
COMMON PARTS OUTPUT SHAFT/AUXILIARY DRIVE GROUP

ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY
802 SEAL-LIP 1 D02N KEY 1
844 PLUG. PLASTIC 2 D02S KEY SQUARE 1
845 PLUG 1
847 PLUG. PLASTIC 1 END CAP GROUP
006 O-RING 1 ITEM DESCRIPTION QTY
007 CARRIER-SEAL 1 E02C SEAL LIP 1
008 RING. RETAINING 1 E12C RING RETAINING 1
M35 Variable Displacement Motor MV (Minor Repair)
COMMON PARTS COMMON PARTS (CON'D

ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY
802 SEAL·UP 1 N09 CARRIER. TRUNNION SEAL 1
844 PLUG PLASTIC 3 N10 SCREW 8
845 PLUG STTHD 1
848 PLUG STTHD 2 OUTPUT SHAFT/AUXILIARY DRIVE GROUP
851 SEAL·LlP 1 ITEM DESCRIPTION QTY
006 O-RING 1 D02J KEY 1
D07 CARRIER·SEAL 1 D02S KEY SQUARE 1
008 RINGRETG 1
E03 NUT, METRIC JAM 1 END CAP GROUP
N05 SHIM, TRUNNION 1 ITEM DESCRIPTION QTY
N06 SPACER 1 G10R PLUG-END CAP 1
N07 '", O-RING 2 G11R ().RING 1
NOS COVER. TRUNNION 1 G12R RING-RETAINING 1
G02W SEAL-LIP 1
G12W RING-RETAINING 1
26
ILLUSTRATED PARTS MANUAL
MODELS T60 & T66J

(~~~)
o 0

TIME CONDOR® TIME CONDOR®
VVACO, TEXAS 76712 VVAco,TEXAS76702-1447
(254)420-5200 (254)420-5200
MANUAL 92375-003
April 1998
i
INTRODUCTION
operating procedures necessary to comply with the intended use of the CONDOR®, and to provide the
information necessary to maintain and service the CONDOR®.
THE OPERATOR'S MANUAL MUST BE RETAINED ON THE CONDOR® AT ALL TIMES.
Do not attempt to operate or service the CONDOR® until you have read and
understood all information provided in this manual. Familiarize yourself with
the functions and operations of the upper and lower controls. A good under-
standing of the controls, their limitations, and their capabilities will maximize
operating efficiency. The various decals attached to this CONDOR® also
contain vital operational instructions. Read the decals before operating this
CONDOR®.
It is YOUR RESPONSIBILITY to follow procedures while operating the CONDOR®. The manufacturer
ofthis CONDOR® cannot control the wide range of applications that may be used in carrying out a variety
ofjobs. Therefore, it is THE USER'S RESPONSIBILITY to consider all personnel when making decisions
regarding the CONDOR®'s intended use.
It is also YOUR RESPONSIBILITY to understand and obey all federal, state, and local regulations regarding
the operation and use ofaerial work platforms. A copy ofthe ANSI!SIA Manual ofResponsibilities is attached
for your use: ANSI/SIA A92.5-1992 is provided for Boom-Supported Elevating Work Platforms, and ANSI!
SIA A92.6-1990 is provided for Self-Propelled Elevating Work Platforms.
TIME CONDOR Corporation reserves the right to modify, improve, add, and/or delete certain design features
ofits products without any obligation to incorporate new features into products previously sold. Our manuals
are continually updated to reflect these changes.
DO NOT ALTER OR MODIFY THIS CONDOR® WITHOUT PRIOR WRITTEN APPROVAL

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

(817) 420-5298 Voice Mail
(800) 443-5803 FAX
2. There are numerous written Maintenance Procedures available for this machine. These procedures
are available through the TIME CONDOR Corporation Service Departmentto anyone who
requests them.
3. Service and maintenance are not a substitute for trained, qualified service technicians. TIME
CONDOR Corporation conducts service schools on a continuing basis. Call any ofour service or
sales persons for a schedule. Remember, training ofmechanics is the responsibility of their
employer, but TIME CONDOR Corporation. Service Schools help you provide this training.
4. TIMECONDORCorporationServiceSchoolTrainingManualsareavailableforpurchasethrough
the parts department. The part numbers for these manuals are: #92333 for self-propelled models;
and #92334 for truck-mounted models.
8300 IMPERIAL DRIVE, P.o. Box 21447, WACO, TEXAS 76702-1447- 817-666-4545, 817-666-4544 FAX
CONDOR® Model T60-0 1
ILLUSTRATED PARTS BREAKDOWN
TABLE OF CONTENTS
•
) INTRODUCTION ........................................................................................................................ i
Service Information ....................................................................................................................... i
Table of Contents .......................................................................................................................... 1
FIGURE NO. DESCRIPTION PAGE
A ......................................... How To Order Parts .............................................................. 3

B ......................................... Serial Number Location ......................................................... 5
1.1 ....................................... FinalAssembly ...................................................................... 6
2.1 ....................................... Tire Installation ...................................................................... 8
3.1 ....................................... Chassis Installation ................................................................. 10

3.2 ....................................... Chassis Rotation Assembly ................................................... 12
3.3 ....................................... HydraulicSwivel .................................................................... 16
3.4 ............................. ;......... Electrical Slip Ring ................................................................. 18
3.5 ............................. :......... Non-Drive Front Axle Assembly ........................................... 20
3.6 ....................................... Tie Rod Assembly ................................................................. 22
3.7 ....................................... Steer Cylinder ........................................................................ 24
3.8 ....................................... Stationary Block Assembly .................................................... 26
3.9 ....................................... Non-Steer Rear Axle Assembly ............................................ 28
3.10 ............,: ........................ 2WD Drive Manifold Assembly ............................................ 30
3.11 ..................................... Drive Manifold ....................................................................... 31
3.12 ..................................... 2 STR Valve Assembly ......................................................... 32
3.13 ..................................... Check Valve ........................................................................... 33
4.1 ....................................... Turret Installation ................................................................... 34

4.2 ....................................... Tray Installation ..................................................................... 36
4.3 ....................................... Turret Rotation Assembly ...................................................... 40
4.4 ....................................... Battery Assembly .................................................................. 42
4.5 ....................................... Engine Pump Filter Assembly ................................................ 44
4.6 ....................................... Air Cleaner Installation .......................................................... 45
4.7 ....................................... Engine Installation .................................................................. 46
4.8 ....................................... EngineAssembly ................................................................... 48
4.9 ....................................... Engine Electric Panel Assembly ............................................ 50
4.10 ..................................... Nissan Engine Panel Schematic ............................................ 52
4.11 ..................................... Muffler Installation ................................................................. 54
4.12 ..................................... Lift Cylinder Installation ......................................................... 55
4.13 ..................................... Boom Lift Telescope Cylinder ............................................... 56
4.14 ..................................... Master Cylinder Installation ................................................... 58
4.15 ..................................... Master Level Cylinder ........................................................... 60
4.16 ..................................... EpromInstallation .................................................................. 62
4.17 ..................................... Lower Control Box Assembly ............................................... 64
5.1 ....................................... Counterweight Assembly ....................................................... 70
MANUAL 92375-003
April 1998
• FIGURE NO. DESCRIPTION
6.1 ..................................... BoomlSkirtInstallation ........................................................... 72

6.2 ..................................... Main Boom Assembly ...........................................................
PAGE
74
6.3 ..................................... Base Boom Assembly ........................................................... 76
6.4 ..................................... Hose Carrier Installation .. ,..................................................... 77
6.5 ..................................... Boom Extension Cylilnder Assembly ..................................... 78
6.6 ..................................... Boom Extension Cylinder ...................................................... 79
6.7 ..................................... Mid Boom Assembly ............................................................. 80
6.8 ..................................... Tip Boom Assembly ..............•............................................... 81
6.9 ..................................... Slave Cylinder Assembly ....................................................... 82
6.10 ................................... Slave Level Cylinder .............................................................. 83
6.11 ................................... Angle Sensor Installation ....................................................... 85
6.12 ................................... Skirt Installation ..................................................................... 86
6.13 ................................... BoomlSkirtInstallation ........................................................... 88
6.14 ................................... lib/SkirtInstallation ................................................................ 90
7.1 ..................................... PlatformInstallation ............................................................... 92

7.2 ..................................... PlatformElectricaIInstallation ............................................... 94
7.3 ..................................... 110VoitLineto Platform Assembly ...................................... 95
7.4 ..................................... Platform Control Box Assembly ............................................ 96
7.5 ..................................... Foot Switch Installation ............................. ........... ....... ... ....... 100
8.1 ..................................... Chassis Cover Assembly ....................................................... 101
9.1 ..................................... Fiberglass Door Assembly ..................................................... 102

9.2 ..................................... Gas Cover Shock Assembly .................................................. 103
10.1 ................................... ManuaIInstallation ................................................................. 104
11.1 ................................... Decal Kit ............................................................................... 106
12.1 ................................... LP/Gas Dual Fuel (Liquid) .................................................... 112

12.2 ................................... 4WDManifoid ....................................................................... 114
Electrical Schematic ......... 71675

Hydraulic Schematic ......... 71674
Chassis Hose Kit .............. 71015
Turret Hose Kit ................ 71619
Boom Hose Kit ................. 71620
Skirt Hose Kit ................... 71621
MANUAL 92375-003
April 1998
FIGURE A: How to Order Parts •
1. When ordering parts for your CONDOR®, ensure that you are able to give the model and
serial numbers of all units for which parts are needed. The serial number(s) will assist the
Condor Parts Department in providing the correct parts for your machine(s).
2. If known, please specify the Condor part number(s) for the part(s) you require, and always
provide a complete description of all parts.
3. Fax orders are preferable, though parts may also be ordered by mail and telephone. A sample
parts order (with fax number) follows this page.
4. Parts needed for a warranty repair must be purchased through the Condor Parts Department.
Credit will be authorized through the Service Department after a Warranty Claim has been
submitted to Condor. A Warranty Claim is to be filed for any part received as "defective".
5. Condor will ship parts as per our customers' request at the time ofthe order-i.e., UPS,
Federal Express, or preferred truck line. When shipping Federal Express, your customer
account must be given at the time of the order.
6. Condor classifies its orders in the following ways:
Emergency Top priority. All efforts are made to ship the order the day the order is
received; when possible, parts may be pulled off of the assembly line.
Standard Order to be shipped within a 48-hour period.
Order to be shipped within 2 weeks.
7. Condor has a $25.00 Net Minimum Billing charge per order.
8. All price quotations will be valid for 90 days.
9. Parts shown as shipped on the Condor packing list and subsequent invoice but not received by
the dealer/customer MUST be reported within 10 days after the date of shipment. If the parts
are still required, a NEW parts order must be submitted. Shortages and discrepancies will be
reviewed on an individual basis by the Parts staff and adjustments will be made accordingly.
10. Invoice discrepancies regarding incorrect prices or discounts should be reported immediately
to the Parts Department. Report the Sales Order number, Purchase Order number, and
Invoice number. Your request will be reviewed and adjustments will be made accordingly.
MANUAL 92375-003
April 1998
• FIGURE A: How to Order Parts
CONDOR PARTS DEPARTMENT

FAX ORDER FORM FAX NO. 800-443-5803
,
ACCOUNT # IPURCHASER SALES ORDER #
I NAME
NAME
C N
U F
S 0 ADDRESS S iADDRESS
T R H T
0 M I 0
M A CITY STATE ZIP P ~ITY STATE ZIP
E T
R I
PHONE FAX PHONE FAX
0
N ( ) ( ) ( ) ( )
CUST. PURCHASE ORDER NO. I ORDER DATE I REQUEST DATE SPECIAL MARKS & NUMBERS
I I
SHIPPING INSTRUCTIONS
PART NUMBER QTY. DESCRIPTION NOTES
FOR ORDER STATUS PLEASE CHECK

APPROPRIATE BOX BELOW
EMERGENCY
STOCK
MANUAL 92375-003
April 1998
FIGUREB: Serial Number Location •
Data 2
Plate
The CONDOR® Model T60 Serial Number is stamped in two locations on the machine.
1. The first place to find the serial number is on the top side of the front axle.
2. The second place to find the serial number is on the left side ofthe turret
weldment adjacent to the ring gear bolts.
The Data Plate is located on the left side of the chassis.
MANUAL 92375-003
April 1998
• FIGURE 1.1: Final Assemhly
I :I
'I
! /
ao-t-t-+--I--
~~ 0 --+---4-- 3
10
i
! !
I II
/
g
LJ
9
i~ d C
MANUAL 92375-003
April 1998
FIGURE 1.1: Final Assembly •
ITEM PART NUMBER DESCRIPTION OTY
Ref. M-T60-01 ...................... CondorModeI60 ...................................................................... Ref.

-1 71000-DWG ................. FinaIAssemblyDWG;M-T60-01 ................................................. 1
2 71129 ............................ Tire Installation .............................................................................. 1
3 71014 ............................ Chassis Installation ........................................................................ 1
4 71235-T60 ..................... Turretlnstallation; T60-01 ............................................................. 1
5 71391 ............................ CounterweightAssembly .............................................................. 1
6 71 016-T60 ..................... BoomlSkirtInstallation; T60 .......................................................... 1
7 71513 ............................ Platform Installation; 36x60 ......................................................... 1
8 71019-002 ..................... PlatformElectinstallation ............................................................. 1
9 71451 ............................ ChassisCoverInstallation ............................................................. 1
10 71392 ............................ FiberglassDoorInstallation; Turret ............................................... 1
-11 71491 ............................ Decal Installation; T60 ................................................................... 1
-12 71519 ............................ ManualsInstallation ....................................................................... 1
-13 15843 ............................ Nameplate ..................................................................................... 1
-14 71675 ............................ Schematic; Electrical ..................................................................... 1
-15 71674 ............................ Schematic; Hydraulic .................................................................... 1
-16 67470-002 ..................... HydraulicOil ......................................................................... 45GL.
-17 67472-001 ..................... MotorOil ........................................................................................ .
-18 67471 ............................ Fuel Type ............................................................................... 40GL.
MANUAL 92375-003
April 1998
8
-
"!j
~
2
~-
tv
§'
-~
REF g:
g
VALVE STEM N
MOUNTING SIDE ~ ~
if:~ L-A
-'"
~tl
......
~
NOTE:
1. AIR PRESSURE TO BE 80 PSI.
SECTION A-A 12 X 16.5 TIRE
3
2
ITEM
71168
71148
71066-DWG
PART NUMBER
1~0 ~
1.00
1.00
QTY
<t-
r [,
~
C:!X-
10C
1.00
1.00
QTY
EA
EA
UM
TIRE, 12
WHEEL, 16.5
x 16.5 AIR TRACTION
x 9.75
INST DWG, TIRE/WHEEL TRACTION
DESCRIPTION
UNLESS OTHERWISE NOTED
TIME CONDOR CORPORATION
C lU12
TOLERANCES:
tRACTIONS ±
ANGLES ±
1/16
l'
DECIMALS
.x
.XX
± .1
± .03
~ 8.300 IMPERIAL DRIVE
WACO. TEXAS 76712
12~
.XXX ± .010 TiTLE
SURFACE fiNISH
~;~~~
B 12/1.1/97 -JB
PROJECTION OF VIEWS @c..::J TIRE/WHEEL ASSY, 12x16.5
A 12/10/97 ,JHB ALL DIMENSIONS ARE IN INCHES
-
TR. D.C.N. NO. DATE APPR. DRAWN K SNYDER I 9/V97 is.. I DRAWING NO.
PMR 10/14/97 .JHB CHECKED I 71066 IREB
TR. I D.R.N. NO. DATE APPR. APPROVED ,JHB I 10/14/97 SCALE 1/10 I SHEET 1 OF 1
FIGURE 2.1 :Tire Installation 2 WD •
Ref. 71129 ............................ Tire Installation2WD .............................................. :................ Ref.
-1 71129-DWG ................. Tire Installation; 2WD 12x16.5 Air EA ......................................... 1
-2 71066-RH ..................... Tire & Wheel Assembly 12x16.5 RH ........................................... 2
71148 ............................ Wheel; 16.5x9.75 ........................................................................... 1
71168 ............................ Tire; 12x16.5 Air Traction ............................................................. 1
-3 71066-LH ...................... Tire & Wheel Assembly 12x16.5 LH ........................................... 2
71148 ............................ Wheel; 16.5x9.75 ........................................................................... 1
71168 ............................ Tire; 12x16.5 Air Traction ............................................................. 1
MANUAL 92375-003
April 1998
• FIGURE 3.11: Chassis Installation
12
o
10
, 12
MANUAL 92375-003
April 1998
FIGURE3.1: Chassis Installation •

Ref. 71014 ............................ ChassisInstallation ................................................................... Ref.
-1 71014-DWG ................. ChassisInstallation DWG ............................................................. 1
-2 71014-HW .................... Hardware Kit ................................................................................ 1
3 71031 ............................ Chassis Weldment ......................................................................... 1
4 71453 ............................ Chassis Rotation Assembly ........................................................... 1
5 71549 ............................ Valve Assembly ............................................................................ 1
6 71 032 ............................ Axle Assembly; Rear Non-Steer ................................................... 1
7 71035 ............................ Axle Assembly; Front Non-Drive ................................................. 1
8 71483 ............................ StationaryBlockAssembly ........................................................... 2
9 71490 ............................ ManifoldAssembly ........................................................................ 1
10 66770-250 ..................... Thrust Bearing ............................................................................... 2
11 7110 IS-SID ................. Hose Kit, SID Chassis ................................................................. 1
12 71686 ............................ Hardline #10, Rear Axle ................................................................ 4
13 71687 ............................ Hardline#16,ManifoldIRotator ..................................................... 1
71014-HW .................... Hardware Kit ........................................................................... Ref.

-1 71014-DWG ................. ChassisInstallationDrawing ......................................................... 1
2 65099-022 ..................... Clamp, Wire Loom ........................................................................ 3
3 BOW34272 ................... Nut ................................................................................................. 3
4 BOW¥701 ................... Washer .......................................................................................... 3
5 ..... ./.............................. Tie Raps ................................................................................... Ref.
IM6t- 110-L/ OS(! fit Ie (}ph.

(s.&- ();tfv.r ')
MANUAL 9237S'()()3
April 1998
FIGURE 3.2: Chassis Rotation Assembly
'\. FRONT ENGINE SIDE OF CHASSIS REAR

'~-----------------------------------------------~
'\--------lr------------------------1r------------~
,II " \
) i ~ i )~
i !!
/:: i /
A I (,~,~ II ~ U A
/) i II r.'1
I
/
::
39
i
--J /'
g' /
\ II Ii:
\.--__________ JL ___ __ ___ ___ ___ ___ ___ __It _________ ~
\---------------- '\
'.
\ G.:XD<:D 4PL
\
7 . 6
(JXi)2PL
[22::@J 2PL
--------~~~~
NOTES:
1. (::}s ust:iJ ,0 CALL OUT PiECe: PAR,S FOR THE HARDy'vARE KIT.
2. [:::}S USED TO CALL OUT PIECE PARTS FOR THE FITTING KIT.
3. lUBRICATE THREADS, BOLT SHOULDERS AND FL.A. T SURFACES OF ·/,jASHER WITH ENGI~
4. USE iMPACT WRENCH ONLY FOR INITIAL ASSEMBLY POSITIONING. DO NOT TORQUE OVE
DO NOT TORQUE OVER VALUE SHOWN IN 1ST STEP.
5. APPLY TORQUE IN TWO ADDTIONAl STEPS USING CRISS-CROSS ALTERNATING TORQUE
6. ITEMS 14 & 15 USE FOR 4WD OPTION QTY (2.00) ON #4 SIDE PORT.
USE FOR 4STR OPTION QTY ( .CO) ON # SIDE PORT.
MANUAL 92375-003
April 1998
FIGURE 3.2: Chassis Rotation Assembly . ,
Ref. 71453 ............................ Chassis Rotation Assembly ...................................................... Ref.

-1 71453-DWG ................. Chassis Rotation Assembly DWG ................................................. 1
2 71453-HW .................... Hardware Kit; Chassis Rotation .................................................... 1
3 71453-FTG .................... FittingKit,ChassisRotation .......................................................... 1
4 71140 ............................ Hydraulic Swivel ............................................................................ 1
5 71141 ............................ Electrical Slip Ring ......................................................................... 1
6 37737 ............................ Motor, 10CIPRSwingRotation .................................................... 1
7 71142 ............................ SwingBearing ............................................................................... 1
Ref. 71453-HW .................... Hardware Kit Chassis Rotation ................................................ Ref.

-1 71453-DWG ................. Chassis Rotation AssemblyDWG ................................................. 1
2 BOW39159 ................... Bolt, Hex 5/8-11 UNC-2B 5"L GR8 ........................................... 20
3 BOW36707-HD ........... Washer, 5/8 Hard Flat ................................................................. 20
4 BOW33636 .......... :........ Bolt .38-16UNC x 1.25 GR8 ........................................................ .4
5 BOW31327 ................... Washer 3/8 Lock ........................................................................... 4
6 BOW36703 ................... Washer .371D .810D GR8 SAE Flat.. ......................................... .4
7 BOW36106 ................... Bolt, Hex HD II2-13UNC x I 1I2"L ............................................. 1
8 BOW31329 ................... Washer, .50 Gr 5 Split Lock .......................................................... I
-9 BOW30108 ................... Bolt, Hex HD 1/2-13UNC x 2"L ................................................... 1
-10 BOW36784 ................... Nut, 1/2 Jam .................................................................................. 1
Ref. 71453-FTG .................... FittingKit,ChassisRotationAssembly ..................................... Ref.

-1 71453-DWG ................. AssemblyDWG,ChassisRotation ................................................ 1
2 02579 ............................ Straight MJ16 M016 .................................................................... 4
3 00267 ............................ Straight MJ12 M012 .................................................................... 2
4 04563 ............................ Straight MJ06 M006 Long .......................................................... 4
5 02662 ............................ Elbow 90° MJ06 M006 ................................................................ 1
6 02447 ............................ Plug M006 .................................................................................... 2
7 00353 ............................ Tee MJ06 MJ06 FJ06 ................................................................... 1
8 00485 ............................ StraightFJI2 MJ06 ....................................................................... 1
9 02328 ............................ Elbow 45° MJ12 FJ12 ................................................................. 1
10 02312 ............................ Elbow45° MJ16 FJ16 ................................................................. 2
11 04070 ............................ Straight MJ06 MO 10 ................................................................... 2
12 00425 ............................ FittingFJ06 MJ04 ................................................... 2
J••••••••••••••••••••••
13 02337 ............................ Elbow 45° MJ06 M006 .............................................................. 1

14 00488 ............................ Tee MJ06 FJ06 MJ06 ......................................................... 2Ref.
15 02662 ............................ Elbow 90° MJ06 M006 ......................................................... 2Ref.
MANUAL 92375-003
April 1998
• FIGURE 3 .2: Chassis Rotation Assembly
\
SIZE STEP BOLT HEADS
5/8-11UNC 1st 50±5 lB. FT.

2nd 100±5 LB.FT.
3rd 170±5 lB.FT.
7 5
18 9
4 17
REF CRISS-CROSS
13-1
l ALTERNATING TORQUE SEQUENCE
SEE NOTE 5.
6 14
10 11
PORT DATA FOR 71140 HYDRAULIC SIJIVEl

PORT DATA i Pressures (PSI)
Port Angle BCD Din. Type Fluid ! Test Opern ting
I 0' 2 3/4' 7/8 #16 SAE '0'- RING OIL 8000 4500
2 270' 2 3/4' 7/8 #16 SAE '0'- RING OIL I 8000 4500
3 180' 2 5/8' 5/8 rtl2 SAE '0'- RiNG Oil 8000 4JOO
4 100' 3 5/8' 3/8 #6 SAE '0' - RING OIL 8000 4500
5 55' 3 5/8' 3/8 #6 SAE '0'- RING OIL I 8000 4500
6 133' 3 S/8" 3/8 #6 SAE '0' - RING OIL I 8000 4500
7 I 80' I -:/8' 3/8 #6 SAE '0' - RING OIL I 8000 4500
MANUAL 92375-003
April 1998
FIGURE3 .2: Chassis Rotation Assembly . •
Ref. 71453 ............................ ChassisRotationAssembly ......................... :............................ Ref.

2 71453-HW .................... Hardware Kit; Chassis Rotation .................................................... 1
3 71453-FTG .................... FittingKit,ChassisRotation .......................................................... 1
4 71140 ............................ HydraulicSwivel ............................................................................ 1
5 71141 ............................ Electrical Slip Ring ......................................................................... 1
6 37737 ............................ Motor, 10CIPRSwingRotation ................................................. ,.. 1
7 71142 ............................ Swing Bearing ............................................................................... 1
Ref. 71453-HW .................... Hardware Kit Chassis Rotation ................................................ Ref.

2 BOW39159 ................... Bolt, Hex 5/8-11 UNC-2B 5"L GR8 ........................................... 20
3 BOW36707-HD ........... Washer, 5/8 Hard Flat ................................................................. 20
4 BOW33636 ................... Bolt .38-16UNC x 1.25 GR8 ......................................................... 4
5 BOW31327 ................... Washer 3/8 Lock ........................................................................... 4
6 BOW36703 ................... Washer .37ID .810D GR8 SAB Flat ............................................ 4
7 BOW36106 ................... Bolt,HexHDII2-13UNCxlI12"L ............................................. 1
8 BOW31329 ................... Washer, .50 Gr 5 Split Lock .......................................................... I
-9 BOW30 108 ................... Bolt, Hex HD I12-13UNC x 2"L ................................................... I
-10 BOW36784 ................... Nut, li2 Jam .................................................................................. 1
Ref. 7 I453-FTG .................... FittingKit, Chassis Rotation Assembly ..................................... Ref.

-I 71453-DWG ................. Assembly DWG, Chassis Rotation ................................................ I
2 02579 ............................ StraightMJI6 MOl6 .................................................................... 4
3 00267 ............................ Straight MJI2 MOl2 .................................................................... 2
4 04563 ............................ Straight MJ06 M006 Long .......................................................... 4
5 02662 ............................ Elbow 90° MJ06 M006 ................................................................ 1
6 02447 ............................ PlugM006 .................................................................................... 2
7 00353 ............................ Tee MJ06 MJ06 FJ06 ................................................................... 1
8 00485 ............................ Straight FJ12 MJ06 ....................................................................... 1
9 02328 ............................ Elbow45° MJ12 FJ12 ................................................................. 1
10 02312 ............................ Elbow 45° MJ16 FJ16 ................................................................. 2
11 04070 ............................ Straight MJ06 MO 10 ................................................................... 2
12 00425 ............................ FittingFJ06 MJ04 ......................................................................... 2
13 02337 ............................ Elbow 45° MJ06 M006 .............................................................. 1
14 00488 ............................ Tee MJ06 FJ06 MJ06 ......................................................... 2Ref.
15 02662 ............................ Elbow 90° MJ06 M006 ......................................................... 2Ref.
MANUAL 92375-003
April 1998
e
'T.1
IIIMIIliT IT 1111{ II!ITITIIli

THIS VI[V fiR CLARITY
i
w
W
w ~
--~-~--- 0.97 0.97 0.94 [....
(')
_1- en
~.
-
~
BU'
m
~
>~ -
'III' 110'
T :\ ___ [(](l)(1)
\
2:!!= <D
---\\ \
II ,
(l)
\\
\';y" "--'S;::
/~~, '~'=
~ ~. ~l;J~OO
r------ ./
(l)
~-- - & ---

100'
llJ(l) D'SP(][l o ' HOUSING
PORT DATA PrP55ur~5 (PSD
Port Angl~ BCD D~ Typ~ flu~ T~5t Op~rnting
=r=
2
0'
270'
23/4'
2 3/4'
718
7/B
"16 SAE '0'- RING
"16 SAE '0'- RING
Oil
Oil
BOOO
BOOO
4500
4500
3 180' 2 SIB' 5/8 Kl2 SAE 'W - RING Oil 8000 4500
4 100' 3 SIB' 3/8 U6 SA[ '0'- RING Oil 8000 4500
5 55' 35/8' 3/8 "6 SAE '0'- RING Oil BOOO 4500
6 /33' 3 SIB' 3/8 16 SAC '0'- RING Oil 8000 4500
7 80' 17/8' 318 U6\A['O'- .RING OIl_ 8000 4500
FIGURE 3.3: Hydraulic Swivel •
Ref. 71140 ............ ;............... Hydraulic Swivel ....................................................................... Ref.

1 ...................................... HousingAssembly ......................................................................... 1
2 ...................................... Spool .............................................................................................. 1
3 ...................................... Keeper Plate ................................................................................. 1
4 ...................................... Wear Ring ..................................................................................... 1
5 ...................................... WearRing ..................................................................................... 1
6 ...................................... SeaIKit .......................................................................................... 6
7 ...................................... Crown Seal .................................................................................... 2
8 ...................................... O-RingSeal ................................................................................... 2
9 ...................................... Lock Washer ................................................................................. 4
10 ...................................... Hex Head Cap Screw ................................................................... 4
11 ...................................... Lock Washer ................................................................................. 2
12 ...................................... Hex Head Cap Screw ................................................................... 2
13 ...................................... Torque Arm ................................................................................... 1
MANUAL 92375-003
April 1998
• FIGURE3.4:Electrica1SlipRing
:::::
Ov
MANUAL 92375-003
April 1998
FIGURE 3.4: Electrical Slip Ring . ,

Ref. 71141 ............................ Electrical Slip Ring .................................................................... Ref.
1 ...................................... Shaft Seal ...................................................................................... 1
2 ...................................... Nylon Bearing ................................................................................ 1
3 ...................................... Aluminum Base Bracket ............................................................... 1
4 ...................................... Cover Seal ..................................................................................... 1
5 ...................................... Nylon Outboard Bearing ................................................................ 1
6 ...................................... Spun Aluminum Cover ................................................................... 1
7 ...................................... Nylon Rub Disk ............................................................................. 1
8 ...................................... Vinyl Sleeves Cover Knife Disconnect Terminals ........................ 2
9 ...................................... Drain Holes In Cover .................................................................... 2
10 ...................................... 5/16-18 UNC Brush Studs ............................................................. 2
11 ...................................... Set Screws .................................................................................... 3
12 ...................................... 1/2-13 UNCRetainingHole .......................................................... 1
13 ...................................... 3/4" NPTLiquid Tight Connector .................................................. 1
MANUAL 92375-003
April 1998
o-
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LEFT SIDE RIGHT SIDE NOTE: r:\

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1:""ITEMS CALLED OUT WITH D ;;
ARE HARDWARE KIT ITEMS. ~
2. ITEMS CALLED OUT WITH

ARE FITTING KIT ITEMS.
c::J ~
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2,~
9 ) 2 PL i
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PL ( 5
13) 2 PL
1---- 2 PL
6 17
FIGURE 3.5: Non-Drive Front Axle Assembly •
Ref. 71 035 ............................ Non-Drive Front Axle Assembly .............................................. Ref.

-1 71 035-DWG ................. Assembly DWG, Front Axle Non-Drive ....................................... 1
2 71034-HW .................... Hardware Kit, Front Axle ............................................................. 1
3 71035-FTG .................... Fitting Kit, Front Axle SID ........................................................... 1
4 71085 ............................ Pivot Pin, Axle ............................................................................... 1
5 71095 ............................ Yoke, Steering Weldment R.H...................................................... 1
6 71096 ............................ Yoke, Steering Weldment L.H...................................................... 1
7 71097 ............................ KingPin ......................................................................................... 2
8 71126 ............................ Idler Hub wlLug Nuts ................................................................... 2
9 65260 ............................ Grease Seal ................................................................................... 2
10 30289 ............................ Dust Cover .................................................................................... 2
11 71547 ............................ Tie Rod Assembly ......................................................................... 1
12 71115 ............................ Cylinder, Steer ............................................................................... 2
13 92097 ............................ Bearing .......................................................................................... 2
14 65239 ............................ Bearing .......................................................................................... 2
15 80119 ............................ Bearing, Thrust .............................................................................. 4
16 92105 .........,................... Nut,Spindle ................................................................................... 2
17 71113 ............................ Axle Weldment, Front ................................................................... 1
18 81368-40-32 .................. SIeve Bearing, 2 112 x 3 x 2" L ...................................................... 2
19 34145 ............................ Bushing(R#81368) ........................................................................ 4
See Note 1
1 71035-HW .................... Hardware Kit ........................................................................... Ref.
2 BOW36720 ................... Washer, Flat 1.06 ID x 2.00 OD ................................................... 2
3 BOW38232 ................... Pin, .12 x 1/75 L Cotter ................................................................. 2
4 BOW39068 ................... Bolt, Hex HD 3/8-16UNC x 5 GR8 .............................................. 2
5 BOW34274 ................... Nut,3/8-16Lock ............................................................................ 2
6 BOW35300 ................... Snap Ring #5160-150 Truarc ........................................................ 2
7 91029 ............................ LugNut, 1/2-20UNF Wheel ........................................................ 18
8 BOW30 170-450 ............ Bolt, Hex HD 1-8 UNC x 4 112 Gr 8 ............................................ 2
9 BOW34280 ................... Nut, Hex 1-8 UNC ........................................................................ 2
10 BOW39 I 17 ................... Bolt, Hex HD 112-13 UNC x 4112 Gr 8 ....................................... 2
II BOW34276 ................... Nut, Hex 1/2-13 UNC ................................................................... 2
12 BOW38240 ................... Cotter Pin .156 Dia x 1.75 ............................................................. 4
13 65240 ............................ Clevis Pin, I" Dia ........................................................................... 4
See Note 2
1 7 1035-FTG .................... FittingKit .................................................................................. Ref.
2 02662 ............................ Elbow, 90° M006 MJ06 ................................................................ 4
3 00488 ............................ Tee, MJ06 FJ06 MJ06 ................................................................... 2
MANUAL 92375-003
April 1998
• FIGURE 3.6: Tie Rod Assembly
6 5
Ref. 71547 ............................ Tie Rod Assembly .................................................................... Ref.

-1 71547-DWG ................. DWG, Tie Rod Assembly .............................................................. 1
2 65238 ............................ Rod End, Male 1" LH .................................................................... 1
3 51226 ............................ Rod End, Male 1" RH R#67821 .................................................... 1
4 71090 ............................ Tie Rod ;Steering Knuckle ............................................................ 1
5 68486 ............................ Nut HEX Jam 1.25-12VNF RH .................................................... 1
6 68487 ............................ Nut, HEX Jam 1.25-12UNF LH ................................................... 1
MANUAL 92375-003
April 1998
MANUAL 92375-003
April 1998
• FIGURE 3.7:Steer Cylinder
MANUAL 92375-003
April 1998
FIGURE 3.7:Steer Cylinder •

Ref. 71115 ............................ Steer, Cylinder .......................................................................... Ref.
1 * .................................... Wiper ............................................................................................. 1
2 * .................................... U-Cup (Dual Lip) .......................................................................... 1
3 * .................................... O-Ring ........................................................................................... 1
4 * .................................... O-Ring ........................................................................................... 1
5 * .................................... Back-Up ........................................................................................ 1
6 * .................................... CapSeal ........................................................................................ 1
7 * .................................... O-Ring ........................................................................................... 1
8 * .................................... Wear Ring ..................................................................................... 1
-9 71115-101 ..................... Seal Kit .......................................................................................... 1
10 71115-102 ..................... Locknut .......................................................................................... 1
11 71115-103 ..................... Setscrew ........................................................................................ 1
12 71115-104 ..................... RetainingRing ............................................................................... 1
13 71115-105 ..................... NylonPlug ..................................................................................... 1
14 71115-106 ..................... Port Plug ........................................................................................ 2
15 71115-107 ..................... Tube Assembly .............................................................................. 1
16 71115-108 ..................... Rod ................................................................................................ 1
17 71115-109 ..................... RodClevis ..................................................................................... 1
18 71115-110 ..................... Head .............................................................................................. 1
19 71115-111 ..................... Piston ............................................................................................. 1
-20 71115-100 ..................... Seal Kit (indicated by *) ................................................................ 1
MANUAL 92375-003
April 1998
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CHASSIS WLDMNT SHOWN FOR REF ONL Y -~ ~ NOTES:

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2. PIECE PARTS FOR HARDWARE KIT ARE CALLED OUT USING
--1 11 1 11 ILl 8TO IOENTIFY THEM.
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4) SEE NOTE 1
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FIGURE3.8:StationaryBlockAssembly •
Ref. 71483 ............................ StationaryBlockAssembly ...................................................... Ref.

-1 71483-DWG ................. DWG Assembly, Stationary Block ................................................ 1
2 71483-HW .................... Hardware Kit, Stationary Block .................................................... 1
3 71106 ............................ StationaryWeldmentBlock ........................................................... 1
4 71105 ............................ Shim Pack ...................................................................................... 2
Ref. 71483-HW .................... Stationary Block Installation - Hardware Kit .......................... Ref.
1 BOW39108 ................... Bolt 1/2-13 c2"LGGR8 Hex ....................................................... .4
2 BOW36705-HD ........... Washer, .50 x 1.06 O.D. HD Flat ................................................. 8
3 BOW34276 ................... Nut, .SO-13UNC Hex Lock .......................................................... .4
4 71483-DWG ................. InstallationDWG,StationaryBlock ............................................... 1
MANUAL 92375-003
April 1998
FIGURE 3.9:AxleAssembly, Rear Non-Steer
~
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a.
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NOTES
1. ITEMS CALLED OUT WITH A 8

ARE HARDWARE KIT ITEMS
2. INSERT ITEM 8 TO FILL.
3. ITEMS CALLED OUT WITH A
ARE FITTING KIT ITEMS.
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MANUAL 92375-003
April 1998
FIGURE 3.9:AxleAssembly, Rear Non-Steer . ,
Ref. 71032 ........................ :...Axle Assembly, Rear Non-Steer .............................................. Ref.
-1 7l032-DWG ................. Assembly DWG, Rear Axle .......................................................... 1
2 71032-HW .................... Hardware Kit, Rear Axle .............................................................. 1
3 71 032-FTG .................... Fitting Kit; Rear Axle Assembly ................................................... 1
4 71043 ............................ Planetary Wheel Drive .................................................................. 2
5 71042 ............................ HydraulicMotor ............................................................................ 2
6 71100 ............................ Rear Axle Backing Plate ............................................................... 2
7 71094 ............................ Spacer, Rear Axle ......................................................................... 2
8 71171 ............................ Spacer, Rear Axle ......................................................................... 4
9 71075 ............................ Axle Weldment, Rear .................................................................... 1
See Note 1
2 BOW36149 ................... Bolt, .63-11 UNC x 2" Hex ......................................................... 16
3 BOW39729 ................... Lockwasher 1/2" ............................................................................ 4
4 BOW39172 ................... Bolt, .75-10 UNC x 2.00" Gr 8 Hex .............................................. 2
5 BOW30160-850 ............ Bolt, .75-10 UNC x 8.50" Lg Hex ................................................. 2
6 BOW34278 ................... Nut, 3/4-10 UNC Elastic Stop ....................................................... 2
7 BOW36708 ................... Washer, .750 Flat .......................................................................... 4
8 BOW3610S ................... Bolt, 112-13 UNC x 2 Gr 8 ........................................................... .4
9 BOW31331 ................... Washer, 5/8 Gr 5 Lock ................................................................ 16
10 BOW31415 ................... 1/2" Flatwasher .............................................................................. 4
11 91029 ............................ Nut .50-20 UNF Wheel ............................................................... 18
See Note 3
1 71032-FTG .................... FittingKit .................................................................................. Ref.
2 03197 ............................ Elbow,90oMOI0MJ06 ................................................................ 2
3 04051 ............................ Straight, M012MJI0 .................................................................... 4
4 04733 ............................ Elbow, 45° M004 MJ04 ................................................................ 2
MANUAL 92375-003
April 1998
• FIGURE3.1 0: 2WD Manifold Installation
" 52PL
----------
. !! --1~
--~
, "
S______ JJ________ : ~-,.

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II "
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NOTES
1. c::::J IS USED TO CALL OUT PIECE P"RTS FOR THE fIlmljC 1(11.
2. <:> IS US(O TO CAll. OUT FIECE FAATS FOR THE H"RDw"R( KIT.

Ref. 71490 ............................ 2WDManifoldlnstallation ........................................................ Ref.
-1 71490-DWG ................. AssemblyDrawing, Drive Manifold .............................................. 1
-2 71490-FTG .................... Fitting Kit ....................................................................................... 1
-3 71490-HW .................... Hardware Kit ................................................................................ 1
4 71424 ............................ Drive Manifold Bracket Weldment ............................................... 1
5 71047 ............................ DriveManifold,2WD .................................................................... 1

-1 71455-DWG ................. 4WDManifoldlnstallationDrawing .............................................. 1
2 BOW39106 ................... Bolt, I12-13UNC x 1.50"L ............................................................. 4
3 BOW34284 ................... Nut, I12-13UNC Stop Elastic ........................................................ 4
4 BOW30053 ................... Bolt,3/8-16UNCx 7/8"L ............................................................... 2
5 BOW31327 ................... Washer, 3/8"ID Split Lock ............................................................. 2
71490-FTG .................... FittingKit .................................................................................. Ref.

-1 71455-DWG ................. 4WDManifoldlnstallationDrawing .............................................. 1
2 04051 ............................ Straight,MJI0 M012 .................................................................... 2
3 00267 ............................ Straight,MJI2MOI2 .................................................................... 2
4 02579 ............................ Straight,MJI6M016 .................................................................... 2
5 00456 ............................ Straight, MJ04 M006 .................................................................... 2
6 00344 ............................ Tee, MJ04 FJ04 MJ04 ................................................................... 1

MANUAL 92375-003
April 1998
FIGURE 3.11: DriveManifold •
PDl
03 ..." M2 04 M3 M4
(-F Kf50101
xxxx
xxxx
G5
eRAKE 1---"-0--_
Gl~-+---' '---------:)----------7--1----J1( G2
Ref. 71047 ............................ DriveManifold .......................................................................... Ref.

PLG 12 ...................................... Port Plug ........................................................................................ 1
PLG6 ...................................... Port Plug ........................................................................................ 9
PLG4 ...................................... Port Plug ........................................................................................ 1
ORF1 ,ORF2 .................................. OrificePlug ................................................................................... 2
PD1,PD2 ...................................... PDI2-44-0-P-I10 .......................................................................... 2
HSI ...................................... HS50-42-0-P ................................................................................. 1
FDI ...................................... FDI6-42-0-P-66 ............................................................................ 1
CL8 ...................................... COil ................................................................................................ 2
SV1,SV2 ...................................... SV08-30-0-N-00 ............................................................................ 2
MANUAL 92375-003
April 1998
FIGURE 3.12:2STRValveAssembly
Ref. 71549 ............................ 2 STR Valve Assembly ............................................................ Ref.

-1 71549-DWG ................. 2 STR Valve Assembly Drawing .................................................. 1
-2 71549-FTG .................... FittingKit; 2 STR Valve Assembly ............................................... 1
-3 71554 ............................ Dual P.O. Check Valve ................................................................ 1

Drawing not available at this time
MANUAL 92375-003
April 1998
FIGURE3.13:CheckValve . ,
Ref. 71554 ............................ Dual P.O. Check Valve ........................................................... Ref.

1 ...................................... BlockMlC ..................................................................................... 1
2 ...................................... Check Valve .................................................................................. 2
3 ...................................... Pilot Piston ..................................................................................... 1
2A
LB1-0139A
[1 [2
V1 V2
MANUAL 92375-003
April 1998
• FIGURE 4.1: Turret Installation
14
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MANUAL 92375-003
April 1998
FIGURE 4.1: TurretInstallation •

,t Ref. 71235-T60 ..................... Turret Installation ..................................................................... Ref.
-1 71235-DWG ................. Installation DWG, Turret T60 ........................................................ 1
2 71619-STD ................... Hose Kit T60 ................................................................................. 1
71619-Jib ....................... Hose Kit T66J ............................. ,................................................. 1
3 71235-HW .................... Hardware Kit; Turret Installation .................................................. 1
4 71045-001 ..................... TrayInstaliation,2WD .................................................................. 1
71045-003 ..................... TrayInstaliation,2WD/Jib ............................................................. 1
5 71492 ............................ Turret Rotation Assembly ............................................................. 1
6 71386 ............................ Battery Assembly .......................................................................... 1
~~ 71387 ............................ Filter Assembly, Engine Pump ....................................................... 1

71495 ............................ Air Cleaner Assembly ................................................................... 1
9 71 0 18 ............................ Engine Installation, Nissan H2O Gas .............................................. 1
10 71389 ............................ Master Cylinder Installation ........................................................... 1
11 71390 ............................ LiftCylinderInstallation ................................................................ 1
12 71538 ............................ Stop Pin; Turret Rotation ............................................................... 1
13 65328-013 ..................... Sash Chain; 13 Links ..................................................................... 1
14 71622-T60-T66J ........... EpromInstallation; T60LowerControis ....................................... 1
15 71058 ............................ Turret Weldment; Telescope ......................................................... 1
16 51036 ............................ Switch, Limit Body Only ................................................................ 1
17 51037 ............................ Offset Head Limit Switch ............................................................. 1
18 71691 ............................ ArmMod;LimitSwitch ................................................................. 1
19 67114-002 ..................... Strain Relief 112 NPT .251.38 ........................................................ 1
20 67123-001 ..................... Seal, Connector Elect 112" ............................................................. 1
21 71173 ............................ Locking Tube, Turret ..................................................................... 2
-22 71796 ............................ Ground Strap ................................................................................. 1
-23 71859 ............................ Turret Hardline Kit ........................................................................ 1
-1 71235-HW .................... Hardware Kit; Turret Installation ............................................. Ref.

-2 BOW31145 ................... Screw, #10-32 UNF 3/4 RD HD SIt ............................................. 2
-3 BOW31323 ................... Washer, #10 ID Split Lock ............................................................ 2
"* 1. '1l?~ ( J;'lwA~ ~

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MANUAL 92J7S"()()3
April 1998
Hycl t;nk~4~
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TURRET WLDMNT
SHOWN FOR REF ONLY
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·~~··::::·~·::,~·=;:::~::~~~::·::~::::·::·:t::::::::·
, PL 12 :::: _ _ _ _ •_ _ _ _ _ ~
~
R Pl.
~ ir 0 i_I SX13, 6 PL
~
L .. _.. _.. _.. _.. _.. _.. _.._.. _.. _.. _.. _.. _.. _.. _.. j
--~ 115\1 ~-------,
11/ 12 PL
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~ 4 ';(7} 2 PL
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, PL
15
tlll.l(!k
1. 015 USED TO CALL OUT PIECE PARTS FOR THE HARDWARE Kit
2. [~]S USED TO CALL OUT PIECE PARTS FOR THE F"lTT1NC KIT.
o
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R PL
USED ON T40-01 & T60-01

FIGURE 4.2: Tray Installation •

Ref. 71045-001 ...................... Tray Installation ............................................................................ Ref.
-1 71045-DWG .................. Tray Assembly DWG; Telescope Hyd.............................................. 1
-2 71045-HW ..................... Hardware Kit ...................................................................................... 1
-3 71045-FTG-l ................. FittingKit ........................................................................................... 1
4 71059 ............................. Tray Weldment .................................................................................. 1
5 71060 ............................. Bracket Weldment; Ground Box ........................................................ 1
6 71041 ............................. Fuel Tank; 40 Gallons ........................................................................ 1
7 71040 ............................. Hydraulic Tank; 45 Gallons ............................................................... 1
8 CLL00650-004 ............... Tube Rd 1" OD .25W .50"L .............................................................. 4
9 35659 ............................. MotorlPump 12 VDC Electric ........................................................... 1
10 71039 ............................. Turret Tray/Door Lock Plate ............................................................. 2
11 71261 ............................. Front Brace Tray Plate ....................................................................... 1
12 71023 ............................. Rear Brace Tray Plate ........................................................................ 1
13 '. 33430 ............................. FilterAssembly,Hydraulic ................................................................. 1
14 69327 ............................. Gauge, Fuel Tank Magnetic ............................................................... 1
15 71550 ............................. Control Valve w/o Axle Lpck ............................................................ 1
16 37042 ............................. Filter, R# 66445 Suction .................................................................... 1
17 67585-005 ...................... Valve,3/4"NPTBall .......................................................................... 1
18 67585-006 ...................... Valve, 1" NPTBall ............................................................................. 1
19
20 04625-001 ...................... Valve,MiniBall .................................................................................. 1
PI II 7!OVI- / (fou
, I (,) I L!:.
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MANUAL 92375-003
April 1998
181 \ \ \I~I~ II ,(IRI), I ~l / lLL --11_ / e
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~ 1~~y\
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......
SECTION A-A
SCALE x 3 OSCILLATING VALVE
~i
NOTES:
1. (;:>5 USED TO CALL OUT PIECE PARTS FOR THE HARDWARE KIT.
2:t"'" 2. [~}S USED TO CALL OUT PIECE PARTS FOR THE FITTING KIT.
-'"
:!It;!
oo~
2§
SECTION A-A
SCALE x 3 NON-OSCILLATING VALV
.. >,
......,J.
The main control valve is located on the same side as the ground controls on the hydraulic tray
•
assembly. The location of the different hydraulic functions' solenoids, relief valves (if applicable), .
and flow controllers are located on the isometric drawing below. The individual hydraulic functions
that the main hydraulic control valve regulates are described in more detail in the following pages.
and the isometric drawing below shows the location of the individual solenoids, reliefvalves
(if applicable), and flow controllers.
+t? Ii 144"'1
fI/l a..h J I:r
7/$""SI-
-<
800M RETRACT FLOW CON TRCLLER
71S"SO
800M EXTEND RELIEF VALVE
PLA TFORM RC TATE CC''';
eCOM E.X TEND --7'T-''''''''-
THIS SOLENOte :$ FOR THE CSC:LLA TlNG

AXLE LOCK CP T,CK CO NO T INSTALL IF THIS
OPTION 15 \lOT USED
LC::~ VAt.ve:;'1
.,,
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MANUAL92375-002
March 1998
7/SS/
The main control vaive is located on the same side as the ground controls on the hydraulic tray
assembly. The location of the different hydraulic functions' solenoids, relief valves, and flow
I controllers are located on the isometric drawing below. The individual hydraulic functions that
the main hydraulic control valve regulates are described in more detail in the following pages and
the isometric drawing below shows the location of the individual solenoids, relief valves, and
I flow controllers.
BOOM RETRACT fLOW CONTROLLER
715"S 1-01.3
6001.1 EXTEND RELIEf VALVE
715S. - /)) 'i
"'LATFORM ROTATE CCW _
Coil jISSI-'OlO
800M EXTEND---
STEER LEfT (ON/OFf)

TURRET SWING REUl;f VALVE
eOOM' RETRACT ~'---
715SI-O"JS' - f [ ' ; : ; ' I t P - - - - - - - STEER RIGHT (ON/OFF)
111------- UNLOADER
THIS SOLENOID IS fOR THE OSCILLATING
AXLE LOCK OPTION. DO NOT INSTALL If THIS - - - - , . - - PLATfORM LEVEL UP (ON/Ofr)
OPTION IS NOT USED
LOCi< VALVE 61
- - - - - PLATfORM LEVEL DOWN (ON/Off)
~~.::!';;;;:::~~-----::-PLATfORM ROTATE CW
~ff~~~-- BOOM EXTEND/RETRACT ~e>,'1

PROPORTIONAL 7'..5'SI- ozo
SYSTEM RELIEf VALVE (J
BOOM UPJ" jJ!l-n- DQ J
toi, 7lsn-oZI
BOOM DOWN
TURRET SWING RIGHT cC
TURRET SWING LEfT cw

l ,
7
JSl'/-O
340.
(;I
7/~-S1- 0 Z I C.,/1 fJ/17;....
7/S~-I-/OOCt;/1 TIJP
",~S"3
---.. JIB UP (DO NOT INSTALL ON T40 AND T60)
JIB DOWN (DO NOT INSTALL ON T40 AND t60)

\ 7/5>1-011
0fb \\ tl- J01
MANUAL92384-002
June1999
<D
[I
"
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9DD000864
DESCRIPTION TORQUE I SEAL KIT
PORTS:
A7.B7 ..... SAE 66
P.LS ....... flI6.9c:Y
T............ flI9.90
r.3S1BII.JNO
I::..t H'IIlRAUI.JCS INC.
PART No. 9S000586-E
SERIAL No.
_
-
.....
LllCAlID_
.......
.... I I I fill I
~---~
,-._~HDLD
A7 B7
"PROCE!I!!RI TO ATTACH JIB IIANI'OIJr
2.1--
1.)CUANGENERALAREAAROUND1HIENDPI.ATETOI'REVENT
CCINT_11ON_1HII!NDPLATI!. _
IOL1.. a WAlHlR8THATlII!CUMntI!l!NDPLATI!TO
1HI IIIAIN -.JIAND_I!NDPLATI!.
If' 1
' - - - - - - - - NOlI!:
ntIS SURFACE MUST BE
PROTECTED AT ALL lIMES
FROM NICKS, SCRATCHES ..
8LEIII8H1!8. AREAS THAT ARE
ENCIRCLED ARE OF HIGHE8T
IMPORTANCEI
I.) ENIUIU!lIfAT1HI MA11NG IURFACU0F1HIJIB~~
AND 1HI IIIAIN MANIFOLD ARE CI.IAII, FIAT AND _ OF IIICICI,
111< Ii lilli" .'71
8CRA_AND_.III!PIRTOAIIOVII_·_THATARE
IIHCIRCU!DARE l H l ! _ OF HlClHIIIT ~AIICI!I
4.) I!N8URElIfAT'O'_AREIN _ _ _
I.) APPLY1 _ OF LOCI1TI! 241 TOIIf'IEIUW.. MOUNTING HOU!_

1
1 . Ci"-S53-]
1 (7) 1(1)
L~~
ON 1HE MA11NO IURFACE OFntI! IIIAIN BLOCK. DO NOT APPLYI,OClITI!
----
DIREC11.YTO lHIMIIUN11NGIIOI.T8.
I.)ATTACllJlBIIANII'OLD _ _ WAIHIRI ANDIIOI.TI. HAND ALUMINUM 8081
'IIGIIn;N 1HUE_ 1IOI.1'I1!CIUN.LY.
7~ TORQUI! _Il0l.1'1 TO 10 1JI.fT. .......

__ 111. I
1:':1 -=:~ .. I '__'._v, r.::-t ~"._ '-111._

....... FlLU .; 900000864
FIGURE 4.2: Tray Installation . ,

Ref. 71045-001 ...................... Tray Installation ............................................................................ Ref.
See Note 1 ................................................................................................................................... .
1 71045-HW ..................... Hardware Kit ................................................................................. Ref.
2 BOW30029 .................... Bolt, .31-18 UNC x 1.00 Gr 5 Hex .................................................... 8
3 BOW30030 .................... Bolt, Hex .31-18 UNC x 1.25 ............................... ;.......................... 12
4 BOW30054 .................... Bolt, .38-16 UNC x 1.00" Gr 5 Hex .................................................. 2
5 BOW30056 .................... Bolt, .38-16 UNC x 1.50" LgHex ................................................... 10
6 BOW30 I06 .................... Bolt, .sO-l3UNC x 1.50" Gr 5 Hex .................................................. 4
7 BOW31327 .................... Washer, 3/8" 10 Split Lock ............................................................... 6
8 BOW31412 .................... Washer, 5/16"10 Flat ......................................................................... 8
9 BOW31415 .................... Washer,.50 1.38"00 USS Gr 5 Flat ............................................... 8
10 BOW31432 .................... Washer, .31"10 x .68"00 Flat ........................................................ 32
11 BOW31433 .................... Washer, .38 .81 "00 SAE Gr 5 Flat ................................................ 16
12 BOW34273 .................... Nut, 5/16-18 UNC Hex Lock ........................................................... 20
13 BOW34274 .................... Nut, 3/8-16 UNC Hex Lock ............................................................... 6
14 BOW34276 .................... Nut, .50-13 UNC Hex Lock ............................................................... 4
See Note 2 ....................................................................................................................................

1 71045-FTG .................... FittingKit ................................................ ~ ..................................... Ref.
2 00222 ............................. Straight, MJI0 MOI0 ........................................................................ 2
3 00281 ............................. Straight, MP20 FP16 ............ ~..........................................·.................. 1
4 00328 ............................. Tee MJ12 FJ12 MJI2 ........................................................................ 3
5 00342 ............................. Straight, FJI0 MJ08 .......................................................................... 1
6 00423 ............................. Straight, FJ12 MJ08 .......................................................................... 1
7 00456 ............................. Straight, MJ04 M006 ........................................................................ 6
8 00458 ............................. Straight, MJ08 M008 ........................................................................ I
9 00485 ............................. Straight, FJI2 MJ06 .......................................................................... I
10 00498 ............................. Elbow, 90 0 MJ06 MP06 .................................................................... 1
11 02234 ............................. Elbow, MJ08 M008 .......................................................................... 1
12 02314 ............................. Elbow, 900 MJ16 FJI6 ...................................................................... 1
13 02315 ............................. Straight, MP16 FP12 ......................................................................... I
14 02320 ............................. Elbow, 90 0 MJ12 FJI2 ...................................................................... 2
IS 02387 ............................. Tee, MJ16 FJI6 MJI6 ....................................................................... 1
16 02447 ............................. Plug, M006 ........................................................................................ 1
17 02448 ............................. Straight, MJ06 M006 ........................................................................ 2
18 02473 ............................. Straight, MJ06 M008 ........................................................................ 3
19 02675 ............................. Elbow, 90 0 MJ12 MP12 .................................................................... I
20 02803 ............................. Straight, MJ08 MP12 ........................................................................ I
21 02807 ............................. Straight, MJI2 MP12 ........................................................................ I
22 02810 ............................. Straight, MJI6 MPI6 ........................................................................ 1
23 04055 ............................. Tee, MJIO FJIO MJIO ....................................................................... I
24 04087 ............................. Reducer FJ12 MJ04 .......................................................................... I
25 04100 ............................. Straight, MP06 FJ06 .......................................................................... I
26 04122 ............................. Straight, MP16 MP16 ........................................................................ 1
27 04176 ............................. Straight, MP12 MPI2 ........................................................................ 2
28 04210 ............................. Straight, MJ06 MP06 ........................................................................ I
29 04523 ............................. Elbow, 900 MJ08 Moo8 ................................................................... I
30 04525 ............................. Straight, FJI6 MJ12 .......................................................................... I
31 04699-06 ........................ Plug, .38 NPT Socket Hex ................................................................ I

MANUAL 92375-003
April 1998
• FIGURE 4.3:TurretRotationAssembly
g.
REF
. i
l"-----./~ ..\:I
I
-----1
I 1
MANUAL 92375-003
April 1998
FIGURE 4.3:TurretRotationAssembly •
Ref. 71492 ............................ Turret Rotation Assembly ........................................................ Ref.

-1 71492-0WG ................. OWG, Turret Rotation Assembly .................................................. 1
2 71351 ............................ Position Fork Hydraulic Rotator .................................................... 1
3 71492-HW .................... Hardware Kit, Turret Rotation ...................................................... 1
Ref. 71492-HW .................... Hardware Kit Turret Rotation .................................................. Ref.

-1 71492-DWG ................. TurretRotationAssemblyDWG ................................................... 1
2 BOW46159 ................... Bolt, 5/S-11 UNC-2Bx5.00"LGRS ........................................... 20
3 BOW36707-HD ........... Washer, Flat .6310 Hard ............................................................. 20
7 5
18 9
17
REF CRISS-CROSS
ALTERNATING TORQUE SEQUENCE
SEE NOTE).
13 3
6 14
1C 11
2
NOTES: 16
1. LU6RiCA TE THREADS, 60L T SHOULDERS AND FLAT

SURF ACES OF WASHERS WITH ENGINE OIL.
2. USE IMPACT WRENCH ONLY FOR INITIAL ASSEM6L Y
POSITIONING. DO NOT TORQUE OVER VALUE
SHOWN IN 1ST STEP.
3. APPLY TORQUE IN TWO ADDTIONAL STEPS USING
CRISS-CROSS AL TERN A TING TORQUE SEQUENCE.
MANUAL 92375..003
April 1998
• FIGURE 4.4: Battery Assembly
2PL
,--------------------------,
n
I I
II
I I
I I
I I
II
I I
II
I I
I I
I I
::::::==::::::==::::::==::::::-::::::==:::-==::::::==::::::~
MANUAL 92375-003
April 1998
FIGURE 4.4: Battery Assembly •
Ref. 71386 ............................ Battery Assembly ..................................................................... Ref.

-I 71386-DWG ................. DWG, Battery Assembly .............................................................. 1
2 65176 ............................ Battery - 12 Volt 1000 CCA ......................................................... 1
3 71282 ............................ Hold-down, 141/2"LBattery ........................................................ 1
4 66270 ............................ J-Bolt.31-18UNCx 10.00"LG ...................................................... 2
5 BOW31239 ................... Nut, HEX Keps .31-18UNC ......................................................... 2
MANUAL 92375-003
April 1998
\
(8 FIGURE 4.5: Engine Pump Filter Assembly
I 2
NOTES:
1. (:::}S USED TO CALL OUT PIECE PARTS FOR THE HARDWARE KIT.
2. [~}s USED TO CALL OUT PIECE PARTS FOR THE FITTING KIT.

Ref. 71387 ............................ EnginePumpFilter Assembly .................................................. Ref.
-1 71387-DWG ................. Filter Assembly Dwg; Engine Pump ............................................. 1
2 81254 ............................ Filter ............................................................................................... 1
71387-HW .................... Hardware Kit ................................................................................ 1
71387-FTG .................... Fitting Kit ....................................................................................... 1

1 BOW39052 ................... Bolt,3/8-16x 1.00 ......................................................................... 4
2 BOW31327 ................... Washer, 3/8" IDSplit Lock ........................................................... 4

1 04051 ............................ Straight,MJI0MOI2 .................................................................... 1
2 02333 ............................ Elbow, 90° MJI0 M012 ................................................................ 1
- Indicates Items Not Shown .
MANUAL 92315-003
April 1998
FIGURE 4.6: Air Cleaner Installation •
Ref. 71495 ............................ AirCleanerlnstallation ............................................................. Ref.

-1 71495-DWG ................. AirCleanerlnstallationDwg ......................................................... 1
-2 71495-HW .................... Hardware Kit ................................................................................ 1
-3 65278 ............................ Air Cleaner Kit .............................................................................. 1
65278-001 ..................... Air Cleaner .................................................................................... 1
65278-003 ..................... Mounting Bracket .......................................................................... 2

MANUAL 92375.003
Aprill99S
\
,
• FIGURE 4.7: Engine Installation
h bI --1 b I I
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I
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elc ~~
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10 1 10 1 -+ [- - ----4 I- h
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10 1 101 ~
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MANUAL 92375-003
April 1998
FIGURE 4.7: Engine Installation •
Ref. 71018 ............................ EngineInstallation ..................................................................... Ref.

-1 71018-DWG ................. EngineInstallation;NissanH-25 ................................................... 1
2 71018-HW .................... Hardware Kit ................................................................................ 1
3 71559 ............................ Engine Assenbly; Nissan H-25 Gas .............................................. 1
4 71494 ............................ Electric Panel Assembly ................................................................ 1
5 71574 ............................ MufflerInstallation ........................................................................ 1
6 71366 ............................ Engine Support Brace .................................................................... 1
-1 71018-HW .................... Hardware Kit ........................................................................... Ref.

-2 BOW36705-HD ........... Washer, .50 x 1.06 OD HD Flat ................................................... 2
-3 BOW39105 ................... Bolt, 1/2-13 x 1114 Gr 8 HD Hex ................................................. 2
116~' -,1/'3
7/b 'iQ - III
Dev-f\. (),'e"S vi dp-i ioV'\ AS7XJ --1- f
O-ltvn ~j"~ 7/f JLf
MANUAL 92375-003
April 1998
-..
" ' " FIGURE 4.8: Engine Assembly
o
o o
-B
o o
o , o
o \
- ---+--0--+ - -- - -- - -- --
o o
o o LLW Y p:J
o
I
'I I
II I
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II I
j'
"
I 6
:1 I
110 1
II I I 9
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if I
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/
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h------'
G ~!--------~
I
MANUAL 92375-003
April 1998
FIGURE4.8:EngineAssembly . ,

Ref. 71559 ............................ EngineAssembly ...................................................................... Ref.
-1 71559-DWG ................. Engine Assembly Dwg ................................................................... 1
2 71559-HW .................... Hardware Kit ................................................................................ 1
3 71559-FTG .................... FittingKit ....................................................................................... 1
4 71049 ............................ Engine; Nissan H-25 Gas .............................................................. 1
5 21368 ............................ Check Valve .................................................................................. 1
6 71718 ............................ ExhaustPipeAssembly ................................................................. 1
7 71051 ............................ Pump;Hydraulic ............................................................................ 1
8 71052 ............................ PumpHydraulic ............................................................................. 1
9 71631 ............................ ManifoldAdapter .......................................................................... 1
10 69203-001 ..................... Mount,EngineStud ....................................................................... 4

-2 BOW39000 ................... Bolt, 114-20 x 112 Gr 8 Hex Hd ..................................................... 4
-3 BOW31325 ................... Washer, .25 ID Split Lock ............................................................. 4
-4 BOW39027 ................... Bolt, 5116-18 x 3/4 Gr 8 Hex Hd .................................................. .4
-5 BOW34273 ................... Nut, 5116-18 UNC Hex Lock ....................................................... .4
-6 BOW39054 ................... Bolt, 3/8-16 x 1 Gr 8 Hex Hd ....................................................... .4
-7 BOW39055 ................... Bolt, 3/8-16 x 1114" HexHd ......................................................... 2
-8 BOW31327 ................... Washer, 3/8" ID Split Lock ........................................................... 6
-9 BOW31403 ................... Washer, .38 x 1 00 USS Gr 5 Flat ............................................... 2
-10 BOW36106 ................... Bolt, .50-13 UNC x 1.50 Gr 8 Hex ................................................ 2
-11 BOW31329 ................... Washer, .50 Or 5 Split Lock .......................................................... 2
-12 BOW36784 ................... Nut, .50-13 UNC Lock Hex .................................. f ..................... ·l
-13 BOW31415 ................... Washer, .50 1.3800 USS Gr 5 Flat .............................................. 1
-1 71559-FTG .................... FittingKit .................................................................................. Ref.

-2 02579 ............................ Straight, MJ16 M016 .................................................................... 3
-3 00267 ............................ Straight,MJl2 M012 .................................................................... 2
-4 00222 ............................ Straight, MJl 0 MO 10 .................................................................... 2
-5 04051 ............................ Straight,MJI0M012 .................................................................... 1
-6 02333 ............................ Elbow, 90° MJl 0 MO 12 ................................................................ 1
-7 04693 ............................ Elbow, 90° MJ10 M010 LL .......................................................... 1
-1 71718 ............................ ExhaustPipe Assembly ............................................................ Ref.

-2 71721 ............................ Tube Weldment ............................................................................. 1
-3 71722 ............................ 2" 00 Flexible Tubing ........................................................... 79LF.
-4 71709 ............................ Reducer; 1.7500 x 2.0000 ....................................................... 1
-5 80399 ............................ MuffierClamp, 2" .......................................................................... 2
MANUAL 92375-003
April 1998
\
'-
e-
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~
~
~
is·
G
~
-:~
~ f ~~
, ~
-
G
)-
~i B
~ 2 til
@ 81 til
-~
12L 2L
2S 2S
>~
l~
21
12
21
12
'<
--0
:8tl 25 25
...... .31 31
~ 1.3 13
14 14
8 TO TO
OP OP
1 1
.~
I 8'-,
\,_ 'I
I
L____ _
NOTES: /\
1. HARDWARE USED IN 71494-HW WILL BE CALLED OUT WITH ~
FIGURE 4.9: Engine Electric Panel Assembly G
Ref. 71494 ............................ Engine Electric Panel Assembly ............................................... Ref.
-1 71494-DWG ................. Electric Panel Assembly Drawing; Nissan Eng ............................ 1
-2 71494-HW .................... Hardware Kit ................................................................................ 1
3 71676 ............................ Extension; Electric Panel ............................................................... 4
4 71354 ............................ Electric Engine Panel Plate ........................................................... 1
5 34552-012 ..................... Terminal Strip ................................................................................ 1
6 67280 ............................ Relay, Anti-Restart ........................................................................ 1
7 CLROOII0-038 ............. Tube,Hyd.3750D.049Wx1.75"Lg ............................................ 4
8 71704 ............................ Nissan Engine Panel Schematic .................................................... 1
9 71571 ............................ Cover, Engine Electric Plate .......................................................... 1
10 71572 ............................ Standoff; Engine Elec Plate ........................................................... 4
11 71588 ............................ Decal, Electric Panel Tags ............................................................ 1

1 BOW31126 ................... Screw, #6-32 x 3/4 Lg Round Head .............................................. 2
2 BOW31144 ................... Screw, 10-32 UNF x.50 Round Sit ............................................... 1
3 BOW30009 ................... Bolt, .25-20 UNC x 2.250 Gr 5 Hex .............................................. 4
4 BOW34376 ................... Screw, 114-20 x 112 Round Hd SIt ................................................. 4
5 BOW31401 ................... Washer, .25 ID x .63 OD Flat ...................................................... .4
6 BOW31142 ................... Bolt, SItd. Mach. #10-32 x2 3/8 .................................................... 4
7 BOW31233 ................... Nut, #10-32 Keps Hex .................................................................. 5
8 BOW31400 ................... Washer, #10 Flat ........................................................................... 8
9 BOW31244 ................... Nut, Hex #6-32 .............................................................................. 2
Af,fv,,-~r
e~~/'{,-
MANUAL 92375-003
April 1998
e
RED/WH I
BLlJ/WHT BA TTERY "+"
~
-
- : ) BATTERY "+"
BLK/RED
16 '16
CA lLE FROM
~
LO VER
CO HROL BOX
S>
GRN/WHT = SA TTERY "-"
BLU = BATTERY "-"
....
Z
C/.I
RED/BLK
RED
=
=
HI RPM
MID RPM
16/16 CAB LE
TO ENGINE
§
BLU/WHT = SPARE
,-----
eP
0'Cl
CRl ,.-- ~.
@ @
~J IOY30 l0 ~"'" '"'C:I
i I----
-~
Cl-25 OJ
11 -
87
r ( Cl 19 67 80 I GRN ~ CIl
= n
8 18 -= :::=-
2
2L
2
2L
GRN IGN
RED /BLK AL T "L" ~
I RED AU "s" 8
I 25 25
....
~
>~
Cl-17 BLU/BLK BLU/BLK - POWER (PUMP SPEED)
21 21 n
1~ I
\0
N
I
"NI I
Cl 20 WHT
12 12 WHT = SIGNAL (PUMP SPEED)
G G WHT/BLK WHT/BLK STAR TER SOLEN 01 D

-'I> ~
25 25
.~
:8t1
I I ( ~ GRN/BKL
31 31 GRN/BKL - CHOKE/GLOWPLUG
<.:> Cl 24 ORN ORN = FWD
:3 13 13
I I "'-
~::s:
Cl-23 ORN/BLK 14 14 ORN/BLK - REV
8l N
- , j8 00
:I:--'
U<.:>
Cl 18 BLK/WHT
TO TO BLK/WHT OIL/WA TER SWITCH
.
x x
"' ~
=> ~ ;l U o !li
r
;:; ij
r J:
u
Q ",,,,
NO Cl-22 BLK
OP OP BLK = OIL PRESSURE GAUGE
GRN WHT GROUND PUMP SPEED
V f;r ""'"
I I
118171615141312111 ~N
uu 1 1 RED/WHT = GROUND (PUMP DRIVE)
'U' 'U' 'U''QJU' 'U1 U
@
~ -~
~U r ~
eo", """
-=:h
BLL) = TCH TO DISTRIBUTOR PLUG RIGHT SIDE
0
""
--'
[]J
w
a:
TO ENGINE
(ACTUATOR
ON CARB)
BU TT SPLICE RED TO RED
BUTT SPLICE BLK TO BLK
NEED A PART NUMBER
1)
TO ENGINE TERMINAL
10 BATTERY STRIP #25 SEE -------;,-;-;;7;"-=;;---1--'<--1-
POSiTIVE TE.RMINAl SHE,-, 1 TACHOMETER WIRE
1/0 Awe ___ (BLUE) FROM THE
PRECISION GOVERNOR
L _____ LOW[R CONTROL BDX CI-25 SEE SHEET 1
ENGINE IGNITION
GREEN TO ENGINE-
TERMINAL STRIP 2
SEE SHEET 1
(>
~' ~V -- -----
DISTRIBUTOR PLUG
~-l{-~ ~ERMINAL
THIS PLUG WILL DNL Y
PLUG IN DNE WAY
~
NGINf [ERMINAl STRIP
_ 21 (AS DRAWN)
:.::: 21 BlU/BlK TO E STRIP 12
»~»
'C
-:---:-~~
'"
<,., -
I 12 WH I TO ENGINE
1 GRN/WHT TO ENGINE TER
MINAl STRIP 1
2.:r
-'<>
~~
"'-"
~
STARTER AND SDLENOID PUMP :;PEED SENSOR PLUG
(11-IIS PLUG WILI_ DNL Y ASSEMBLE lONE WAY)
-
'Tj
~
f\ /j - ------1 RED/WHT TO GROUND STUD
1:\ ORN TO ENGINE TERMINAL STRIP U
14 ORN/8lK TO ENGINE TERMINAL STRIP 14
-Z_.
~
o
ron
ron
y/// - - 1 BlK/REO TO GROUND STlJD §
[0 FNCINE TERMINAI_
';TRIP 2S (SEF SfifTT 1)
AL TEf\NA TOR
I"UMP FORWARD/REVERSE PLUC
(THIS PLUG WILL DNL Y ASSEMBLE lONE WAY) E
~.
"t:l
[
TD ENCINf_ I f_RMINAL r/l
STrw 2L (SEE SHEET 1)
f
e_.
,
(j
• FIGURE 4.11: Muffler Installation
\
(
\
-------.
\
\
\
Ref. 71574 ............................ Mufflerlnstallation ................................................................... Ref.

-1 71574-DWG ................. MufflerlnstallationDrawing ......................................................... 1
-2 71574-HW .................... Hardware Kit ................................................................................ 1
3 65279-001 ..................... Muffler .......................................................................................... 1
4 65279-002 ..................... Mounting Bracket .......................................................................... 2
5 71695 ............................ Tailpipe .......................................................................................... 1
6 80399 ............................ MufflerClamp2" ........................................................................... 1
MANUAL 9237S'()()3
April 1998
FIGURE 4.12: Lift Cylinder Installation . ,
n f7
LJ II
II
4
2PL
NOTES:
1. C:}S USED TO CALL OUT PIECE PARTS FOR THE HARDWARE KIT.
2. [::}S USED TO CALL OUT PIECE PI\.RTS FOR THE FITTING KIT.
Ref. 71390 ............................ LiftCylinderInstallation ........................................................... Ref.

-1 71390-DWG ................. DWG,LiftCylinderInstallation ..................................................... 1
-2 71390-HW .................... Hardware Kit ................................................................................ 1
3 71144 ............................ Boom Lift Cylinder ........................................................................ 1
4 71212 ............................ Pin, Turret Lift Cylinder ................................................................ 1
-5 71390-FTG .................... FittingKit ....................................................................................... 1

-1 71390-DWG ................. Drawing,LiftCylinderInstallation ................................................. 1
2 BOW39066 ................... Hex Hd Bolt 3/800-16 x 4" Gr 8 .................................................... 2
3 BOW34274 ................... Nut, 3/8-16UNC Hex Lock ........................................................... 2

-1 71390-DWG ................. Drawing, LiftCylinderInstallation ....................................•............ 1
2 01397 ............................ Elbow, MJ06 MOI0 ...................................................................... 2
- Indicates Items Not Shown MANUAL 92375-003

April 1998
• FIGURE 4. 13: Cylinder, Boom Lift Telescope
MANUAL 92315-003
April 1998
FIGURE 4.13: Cylinder,BoomLiftTelescope •

Ref. 71144 ............................ Cylinder, Boom Lift Telescope ................................................. Ref.
1 * .................................... Wiper ............................................................................................. 1
2 * .................................... O-Cup (Dual Lip) .......................................................................... 1
3 * .................................... O-Ring ........................................................................................... 1
4 * .................................... Back Up .......... ;............................................................................. 1
5 * .................................... Cast Iron Ring ............................................................................... 1
6 * .................................... O-Ring ........................................................................................... 1
7 * .................................... AQ Seal ......................................................................................... 1
8 * .................................... O-Ring ........................................................................................... 1
9 * .................................... Wear Ring ..................................................................................... 1
10 * .................................... WearRing ..................................................................................... 2
-11 71144-101 ..................... Seal Kit .......................................................................................... 1
12 71144-102 ..................... Washer Seal .................................................................................. 1
13 71144-103 ..................... Locknut .......................................................................................... 1
-14 71144-104 ..................... Port Plug ........................................................................................ 2
15 71144-105 ..................... Cartridge Valve ............................................................................. 1
16 71144-106 ..................... Bushing .......................................................................................... 4
17 71144-107 ..................... Throttle Check Valve .................................................................... 1
18 71144-108 ..................... Bleeder Plug .................................................................................. 1
-19 71144-109 ..................... Tube Assembly .............................................................................. 1
-20 71144-110 ..................... RodAssembly ............................................................................... 1
21 71144-111 ..................... Head .............................................................................................. 1
22 71144-112 ..................... Piston ............................................................................................. 1
23 71144-113 ..................... Bushing .......................................................................................... 1
MANUAL 92375-003
April 1998
• FIGURE 4. 14: Master Cylinder Installation
\
o
Fl
LJ
2PL&i/
NOTES:
1. C::}S USED TO CALL OUT PIECE PARTS FOR THE HARDWARE KIT.
2.
n iS USED TO CALL OuT PIECE PARTS FOR THE FITTING KIT.
MANUAL 92375-003
April 1998
FIGURE 4.14: Master Cylinder Installation •
Ref. 71389 ............................ Master Cylinder Installation ..................................................... Ref.

-1 71389-DWG ................. Master Cylinder Installation Drawing ............................................ 1
-2 71389-HW .................... Hardware Kit ................................................................................ 1
3 71145 ............................ Master Level Cylinder ................................................................... 1
4 71211 ............................ Pin, Turret Master Cylinder ........................................................... 1
-5 71389-FfG .................... FittingKit ....................................................................................... 1

-1 71389-DWG ................. MasterCylinderInstallationDrawing ............................................ 1
2 BOW39064 ................... HexHdBolt 3/8-16x3 112 Gr 8 ................................................... 2
3 BOW34274 ................... Nut, 3/8-16 UNC Hex Lock .......................................................... 2
71389-FfG .................... FittingKit .................................................................................. Ref.

-1 71389-DWG ................. MasterCylinderInstallationDrawing ............................................ 1
2 02793 ............................ Straight, MJ04 MP06 ..................................................................... 3
MANUAL 92375-003
April 1998
(8 FIGURE 4.15: Cylinder, Master Level \
MANUAL 9237S"()()3
April 1998
FIGURE 4.15: Cylinder, Master Level •
Ref. 71145 ............................ Cylinder,MasterLevel ............................................................. Ref.
1 * .................................... Wiper ............................................................................................. 1
2 * .................................... O-Cup (Dual Lip) .......................................................................... 1
3 * .................................... O-Ring ........................................................................................... 1
4 * .................................... Back Up ........................................................................................ 1
5 * .................................... O-Ring ........................................................................................... 1
6 * .................................... O-Ring ........................................................................................... 1
7 * .................................... AQ Seal ......................................................................................... 1
8 * .................................... Wear Ring ..................................................................................... 1
9 * .................................... Wear Ring ..................................................................................... 2
-10 71145-101 ..................... 55ASealKit .................................................................................. 1
11 71145-102 ..................... Locknut .......................................................................................... 1
-12 71145-103 ..................... Port Plug (Steel) ............................................................................ 3
13 71145-104 ..................... Bushing .......................................................................................... 4
14 71145-105 ..................... ReliefValve ................................................................................... 2
15 71145-106 ..................... Tube Assembly .............................................................................. 1
16 71145-107 ..................... RodAssembly ............................................................................... 1
17 71145-108 ..................... Head .............................................................................................. 1
18 71145-109 ..................... Piston ............................................................................................. 1
MANUAL 92375..003
April 1998
FIGURE 4.16:EpromInstallation

Ref. 71622-T60 ..................... Eprom InstallationLowerControl ........................................... , Ref.
-1 71622-DWG ................. Eprom Installation DWG; Lower Control Box ............................. 1
2 71046-001 ..................... Box Assembly, Lower Control Box .............................................. 1
3 71603 ............................ Eprom; T60 ................................................................................... 1
o o
MANUAL 92375-003
April 1998
MANUAL 92375-003
April 1998
e-
42
NOTES:
1, ITEM 40 IS USED ONLY WITH
OPTION A652, OSCILLATING AXLE.
"rj
CL
TO P1-35
§
42 G;
OPG
TO C1-22
1A
SEE NOTE 2
81 TO
C1-16
\Q!'S2j/I9'
THIS IS THE FUEL SELECTION

UI ADD 1 TO JIB
AND NON JIB
IF FUEL OPTION
SWITCH IS USED-
-
~
~
~
o
SWITCH REFER TO DWG #71797
3 TO C1-2 C1-19 FOR SOLENOID HOOKUP LI)
~
I
o '"1
~I
S TO C1-09,17,C2-22
,JUMPERED
U Q
o~
BLK AND GRN WIRES
FROM SR CABLE <.0
5 1217AWG 1['
TO Pl-22 o
f'H nl") )
IB
1 .-
[) to
~
FROM AXLE LOCK LIGHT (OPTION)
~
C1-28 C1-14 C1-07 ~
5A 5A 90 WHT 5 RED <J g.
i;~ -<
TO P2-11
L E G SIDE OF
SLOPE SENSOR
8HS, TO P2-14 BATTERY
2.:t"'" .---t--::-==-'-
-'"
..~t:l..., r:::::;;;::=~T2=-=5=S,
rt:, TO P 2 - 4 GROlJND RETURN DETAil
~ 2B
<>:
N
o 01
:s: :s:
<>:
61, TO C1-1
<>: 12AWG
N Ni
5A 5, TD P1-17,P1-12,P2-17 5
,_ _ _ _ _------;2<'-,""""T.;;-0 C1-29 12AWG SEE NOTE 3
2A
' -_ _ _ _ _~2~TO~ C1-30
~C1-31
,--_ _ _ _9"",S"---"'TO P1-13
~UTTSPLICE
40, TO P1-5
42
CR5
685, TO P2-22 51
1C TO C1-32
195 SEEI'fOTE2.
TO
P2-34
RELAYS ON PANEL INSIDE BOX
2B 2B
42
FIGURE 4.17: Lower Control Box Assembly •
OUTSIDE
CONNECTOR CIRCUIT
PIN # # CABLE COLOR FUNCTION
CI-Ol 61 BC GRN ESTOP SwITCH SIGNAL
CI-02 3 BC RED 12V POwER TO PL TFRM
CI-03 02 BC YEL DATA TRANSMIT TO PLTFRM
CI-04 01 BC I.'HT DATA RECEIVE FROM PLTFRM
CI-05 25 BC BLK GROUND TO PL TFRM
CI-06 EC BLU GROUND TO BA HERY
CI-07 1 BC SHIELD SHIELD GROUND - Bo OM CABLE
CI-08 80 GAS SHUT OFF VAL VE SOLENOID
* CI-09 5 BLS BLK POwER TO BOOM L1MI T S'WITCHES
CI-1O 58 BLS "HT SIGNAL RETURN FROM BM LIM SI.'
C1-11 AS ASC I.'HT SIGNAL FROM ANGLE SENSOR
C1-12 LS LSC I.'HT SIGNAL FROM LENGTH SENSOR
C1-13 SP ASC&LSC RED POwER TO ANG/LNGT H SENSORS
C1-14 1 ASC&LSC BLK GRND TO LNGTH/ ANG SENSORS
C1-15 5T TLS I.'HT TELESCOPE LIMIT S'W ITCH
C1-16 81 LP VACUUM S'WITCH
* CI-17 5 EC BLU/BLK POwER TO PUMP SEN SDR
C1-18 TOS EC BLKNHT TEMP /OIL PRESSURE S'WITCHES
CI-19 42 EC GRN ENGINE IGNITION
CI-20 12 EC I.'HT SIGNAL RETURN FROM PUMP SENSOR
CI-21 oPB EC BLK OIL PRESSURE SENSo R
CI-22 oPG EC BLK SPLICED TO oPB I
CI-23 13 EC ORN/BLK DRIVE REVERSE
CI-24 14 EC ORN DRIVE FORwARD
CI-25 25 EC I.'HTlBLK START ENGINE
CI-26 8L EC RED LOw SPEED THROTTL E
CI-27 8H EC RED/BLK HIGH SPEED THRoHL E
CI-28 1 EC GRN GROUND FROM BA HER Y
CI-29 2 EC REDNHT POwER
CI-30 2 EC BLUNHT PO'WER
CI-31 2 EC BLK PO'WER
CI-32 51 EC GRN/BLK CHOKE
C2-01 UL VH BLUNHT UNLOADER VAL VE
C2-02 68 VH \JHT RUN EMERGENCY PUMP
C2-03 16 VH BLU STEER RIGHT
C2-04 15 VH BLU/BLK STEER LEFT
C2-05 27 VH ORN PLA TFoRM ROT ATIoN RIGHHCCw)
C2-06 26 VH ORN/BLK PLATFORM ROTATION LEFHC'J)
C2-07 24 VH 8LK/RED PLATFORM LEVEL UP
C2-08 23 VH REDNHT PLATFORM LEVEL DO 'WN
C2-09 17 VH RED/BLK BOOM UP
C2-1O 18 VH RED BOOM Do'WN
C2-11 22 VH BLK SWING RIGHHCC'W)
C2-12 21 VH BLKIWHT S'WING LErHCI.')
C2-13
C2-14
TLl
TL2
VH GRNNHT
GRNNHT
BOOM EXT/RET PRoPORTloNAL
SPLICED TO TLl
=1
C2-15 19 VH GRN/BLK BOOM EXTEND
C2-16 20 VH GRN BOOM RETRACT
C2-17 34 VH \JHTlBLK AXLE LOCK 1 VALVE
* C2-18 35 SR ORN/BLK AXLE LOCK 2 VALVE
C2-19
C2-20
C2-21
10
9
62
SR
SR
SR
RED/BLK
GRNiBLK
\JHT
STEER VALVE I
STEER VALVE 2
BRAKE VALVE
-1
C2-22 5 SR BLU PO'WER TO AXLE PROXIMITY S'WITCH
* C2-23 5P SR ORN SIGNAL RETURN AXLE PRoX SwITCH
* C2-24 49 SR RED DRIVE SERIES/PARALLEL VALVE
C2-25 69 DC BLK MOTION ALARM <OPTION)
* C2-26 59 DC SIGNAL HORN<OPTION)
* C2-27 65 DC
"HT
GRN LIGHTS <OPT ION)
* C2-28 66 JVC BLK JIB UP CT 46J/T66J ONLY)
* C2-29 67 JVC wHT JIB DOI<N CT 46J/T66J ONLY)
* C2-30 51 EC GRN/BLK GLO'JPLUG RELAY
* C2-31 SPARE CHASSIS GROUNDS
C2-32 SPARE SYSTEM VOLTAGE (OPTION)
L. OPTION L JUMPERED CoNNECTlONS
BUTT SPLICE
BOOM ANGLE SHIELD
-:::;=3 ,,,we
~C1-07
BOOM EXTENSION SHIELD
:
BOOM CABLE SHIELD
MANUAL 92375-003
April 1998
(8 FIGURE 4.17: Lower Control Box Assembly
CONNECT TO INSIDE OF BOX CONNECT TO OUTSIDE OF BOX
CR6-8S PLATFORM Cj-2
GROUND/PLATFORM S~ITCH PLATFORM CH
pj-28 PLATFORM CI-5
pj-24 PLATFORM CI-4
PLATFORM CI-8
BA TTERY NEGATIVE
BOOM CABLE SHIELD, BOOM EXTENSION SHIELD, BOOM ANGLE SHIELD (SEE DETAIL AT BOTTOM OF SHEET)
FUEL SELECTION S~ITCH GAS SHUT OFF VALVE SOLENOID
GROUND PLATFORM S~ITCH t 12V TO BOOM LIMIT SIJITCHES
P2-32 OUTPUT FROM BOOM ANGLE LIMIT SlJlTCH
P2-2S B ON ANGLE SENSOR
P2-3S VHITE ON LENGTH SENSOR
pj-37 ANGLE SENSOR A LENGTH SENSOR RED
ANGLE SENSOR C LENGTH SENSOR BLACK
P2-2j OUTPUT FROM BOOM EXT LIMIT SVlTCH
FEUL SELECTION SWITCH LP VACUUM SWITCH
POIJER TO PUMP SENSOR
P2-S TEMPERATURE OIL PRESSURE SIJJTCH
HOUR METER ENGINE TERMINAL STRIP 2
P2-j5 OUTPUT FROM PUMP SPEED SENSOR
P2-36
OIL PRESSURE GAUGE OIL PRESSURE SENSOR
P2-38 ENGINE TERMINAL STRIP 14
P2-28 ENGINE TERMINAL STRIP 13
pj-2 CRI-85 (STARTER RELAY)
pj-6 PRECISION GOVERNOR AUX 1
PHD PRECISION GOVERNOR AUX 2
BUTT SPLICE BA TTERY NEGATIVE
CIRCUIT BREAKER BA TTERY POSITIVE
CIRCUIT BREAKER BATTERY POSITIVE
CIRCUIT BREAKER BA TTERY POSITIVE
CRS-87 CHOKE
P2-32 UNLOADER SOLENOID
PHS EMERGENCY PUMP
PH9 STEER RIGHT SOLENOID
pj-ll STEER LEFT SOLENOID
pj-4 PLA TFORM ROTATE RIGHT (CCIJ) SOLENOID
Pi-36 PLATFORM ROTATE LEFT (C'J) SOLENOID
pj-9 PLA TFORM LEVEL UP SOLENOID
Pl-21 PLATFORM LEVEL DO\JN SOLENDlD
P2-8 BOOM UP SOLENDlD
P2-18 BOOM DO\JN SOLENOID
P2-29 TURRET SIJING RIGHT (CCIJ) SOLENOID
P2-39 TURRET S\,IING LEFT (CIJ) SOLENOID
P2-9 BOOM EXT IRFT PROPORTIONAl. SOLENOl!)
P2-19
P2-10 BOOM EXTEND SOLENOID
P2-20 BOOM RETRACT SOLENOID
PI-34 AXLE VALVE VALVE #1 SOLENOID
PH8 SLIP RING #6
Pl-31 SLIP RING #8
Pl-3 SLIP RING #9
PI-8 SLIP RING 1110
Pl-7 GROUND/PLA TFORM S'tIITCH
P2-1 SIGNAL RETURN AXLE PRO X SIJITCH
PI-26 SLIP RING ~4
PH MOTION ALARM
PI-14 HORN
PI-20 LGHTS RELAY COIL
P2-30 JIB UP SOLENOID
P2-40 JIB DOwN SOLENOID
PH6 GLO~PLUG RELAY
TO BUTT SPLICE (SHT 1) CHASSIS GROUNDS
MANUAL 92375-003
April 1998
• OPTION + BOARD
CONNECTOR
PIN ~
CIRCUIT
~ COLOR FUNCTION
FIGURE 4.17: Lower Control Box Assembly
CONNECT m
•
• PHI 69 WHT SOUND MOTION ALARM (008) C2-25
Pl-02 25 'w'HT RUN STARTER RELAY (000) CI-25
PH3 9 'w'HT RUN STEER VALVE 2 (002» C2-20
PI-04 27 IJHT ROT ATE PLATFORM RIGHT (0013) C2-05
PI-OS 40 WHT RUN ENGINE (DOS) CR5 RELAY COIL
PI-06 8L WHT RUN LOW SPEED THROTTLE (D06) CI-26
PH7 5 RED +12VDC/D08-11 SEE 71046 SHT 2 OF 3
PH8 62 VHT RUN BRAKE VALVE (D023) C2-21
PI-09 24 WHT PLA TFORM LEVEL UP (D0I5) C2-07
PHO 8H WHT RUN HIGH SPEED THROTTLE (007) CI-27
PHI IS WHT STEER LEFT (0012) C2-04
PH2 5 RED +12VDC/DoO-3 SEE 71046 SHT 2 OF 3
• PH3 95 GRN ILLUMINATE AXLE UGHT <oom AXLE LOCK UGHT
• PI-14 59 WHT SOUND SIGNAL HORN (D09) C2-26
PHS 68 WHT RUN EMERG, PUMP(DO» C2-02
• PH6 51 WHT GLo"'PLUG RELAY (JSUZU ONLY) C2-30
PH7 5 RED +12VDClD020-23 SEE 71046 SHT 2 OF 3
• PH8 35 WHT RUN AXLE LOCK VALVE 2 (0019) C2-18
PH9 16 "'HT STEER RIGHT (DDlJ) C2-03
• PI-20 65 WHT RUN UGHTS <OD3) C2-27
PI-21 23 WHT PLATFORM LEVEL DOWN (0016) C2-08
PI-22 5 RED +12VDCISYSTEM SEE 71046 SHT 2 OF 3
PI-23 5 RED +12VDC/DDl6-19 SEE 71046 SHT 2 OF 3
PI-24 DT YEL DATA RECEIVE FROM PLTFRM CI-04
PI-25 5 RED +12VDClD04-7 SEE 71046 SHT 2 OF 3
PI-26 49 WHT DRIVE SER.lPAR, VALVE <DOlO) C2-24
PI-28 5 'w'HT DATA TRANMIT TO PLTFRM CI-03
PI-30 5 RED +12VDClDDl2-15 SEE 71046 SHT 2 OF 3
PI-31 10 WHT RUN STEER VAL VE I (0020) C2-19
PI-32 UL 'w'HT RUN UNLOADER VALVE (004) C2-0I
• PI-34 34 'w'HT RUN AXLE LOCK VALVE I (0018) C2-17
,.... :z PI-3S .'HT ILLUMINATE CALIBRATION LIGHT (0022) CALI BRA TIoN LIGHT
",'=l PI-36 26 'w'HT ROTATE PLATFORM LEFT (0014) C2-06
,...,,...,
-r-,
PI-37 SP BLK +SVDC FOR SENSORS C1-13
'"
r-, --
PI-38 BLK GROUND SEE 71046 SHT I OF 3
'"
l>
PHO I BLK GROUND SEE 71046 SHT I OF 3
'"n
'" • P2-DI 5P BLU AXLE PRoX, SlJlTCH SIGNAL INPUT (Dl2) C2-23
Cl
r • P2-02 BLU JIB UP SIGNAL INPUT (08) JIB UFT SI,/ITCH (})
Cl
P2-D3 BLU BOOM UP SIGNAL INPUT (D4) BOOM UFT SWITCH (})
'" P2-04 BLU START SIGNAL INPUHDO) START SIJITCH (3)
'"
,...,
r-,
P2-05 TOS BLU OIL/TEMP S"'ITCH (A3) CH8
i3
:z P2-06 I BLK GROUND SEE 71046 SHT I OF 3
~ P2-08 17 GRN UFT BOOM (P"'MITl C2-09
Ci
:z P2-09 TLI GRN TELESCOPE (PI,/M3Tl C2-13
=
r-, P2-1O 19 GRN EXTEND BOOM (P"'MSTl C2-15
n P2-1!
l> BLU CHASSIS TILT SENSOR SIGNAL INPUT (013) SLOPE SENSOR ('w'HI)
[;i • P2-12 BLU JIB DOWN SIGNAL INPUT (09)
r; JIB LIFT SIJITCH (3)
P2-13 BLU BOOM DOliN SIGNAL INPUT (05) BOOM LIFT SWITCH (3)
i"= P2-14 8HS
r BLU HI THROTTLE SIGNAL INPUT (DD CHOKE S"'ITCH (3)
-4
I
P2-15 12 BLU PUMP SPEED SENSOR SIGNAL INPUT (A2) CI-20
r-,
P2-1& 5 RED +12VDClPIJMO-2 SEE 71046 SHT 2 OF 3
.:: P2-17 5 RED +12VDC/PIIM3-5
;0 SEE 71046 SHT 2 OF 3
Z P2-IB 18 GRN LO'w'ER BOOM (P'w'MIB) C2-1O
'"
Z
P2-i9 TL2 GRN Tt:Lt:SCQrE (PwM3B) C2-14
P2-20 20 GRN RETRACT BOOM (PI,/M5B) C2-16
P2-21 BLU TELESCOPE LIMIT SWITCH SIGNAL INPUT (014) CHS ST
"=
,..., P2-22 68S BLU EMERGENCY PUMP SIGNAL INPUT (DlD) MAIN/EMERG PUMP SII (3)
=
Cl P2-23 BLU SWING RIGHT (CC"') SIGNAL INPUT (D6) SIJING SIJITCH (])
x
P2-24 BLU BOOM EXTEND SIGNAL INPUT (D2) TELESCOPE SWITCH (D
C;;;
P2-25 AS BLU ANGLE SENSOR SIGNAL INPUT (AD CHI
.::
"= • P2-26 BLU HYD, OIL TEMP (AS) C2-30
-4
r"" • P2-27 BLU SYSTEM VOLTAGE (All C2-32
P2-28 14 GRN DRIVE FORWARD (PWMOTl CI-24 <THRU A 36 OHM 21,1 RESISTOR)
P2-29 22 GRN SIJING RIGHT (CCIJ) (PIJM2Tl C2-11
• P2-30 66 GRN JIB UP C2-28
P2-31 4 GRN GROUND ENGINE ON GRoUND/PLATFORM S'w'ITCH 4 & EMERGENCY PUMP S'w'ITCH & START ICHoKE SWITCH 4&2
P2-32 5B GRN BOOM LIMIT S\!ITCH CI-1O
P2-33 GRN GROUND SlJING S'w'ING S"'ITCH 3
P2-34 GRN GROUND BOOM RETRACT TELESCOPE SWITCH 3
P2-35 LS GRN LENGTH SENSOR CI-12
P2-36 oPB GRN ENGINE OIL PRESSURE CI-21
P2-37 GRN FUEL LEVEL C2-31
P2-38 13 GRN DRIVE REVERSE CI-23 <THRU A 36 OHM 2\: RESISTOR)
P2-39 21 GRN SIJING LEFT C2-12
• P2-40 67 GRN JIB Do"'N C2-29
MANUAL 92375-003
April 1998
2 ) / ~ ~~~
e
I~
§
~
r-
I
I
-
1(31181
- - - - - --- - -
0
- - I
I
I
-
f0-
~
t""1
0
I I
~
~'81
I I >-t
I I ()
0
I I
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m- ~ I ~
-
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m~m
I I
I
to
I 0
I I x
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I ~a§D l~ I
(Il
('D
I I g.
~ ~ ~ ~
ill.....
-'"
~t:l
1/
1
~ _____________ JI -<
~
I
-----
27
L.", . .,
Pl PO' .- .... -
18 AIJG
~ 18 AVIG ROM C5 RELAY

-H""" .,,"_"
PLATFORM $W'ITCH
12 AW'G --
I
\1'
Ie AVG
~~:o
, ~ '1'2 '3 ., ·5
eo _7 -8 1':1 *10
-11 12 -13 -\4 -15 -16 17 -\8 119 -20 III -12 -13 .\4 -15 ~IB'19'2D UNl£SS OTHERWISE NOTED:
'21 22 23 '24 2S -26 -27 '2B '29 30 -21 -22 -23 '24 -25 *26 *27 -28 -29 *30
~
TOt.£RANCES;
, ,-
nv.cnQNS:I: 1/l6
"'CU:S
-x
,Xl(
...
OECiMM.S
:t .OJ
.XIOI:I:.010 TITLE
~
TIME C9NOOR CORPORA. TlON
8Joo IMPERIAt. DRIVE
WACO, TEXAS 16712
";: *31 -32 -33 *34 *35 '3. '37 '38 '39 140 *31 -32 133 _34 *35 -36 '37 -38 -39 -40 SUfU'ACE FINISH 12\!o/
PROJECTION OF VIEWS @ c:::] LOWER CONTROL BOX ASSY
::" ~
L1R.1 D.C.N. NoT OATE T
ALL DIMENSIONS ARE IN INCHES
APPRToRAWM Me. 2/24/911
BIDR"'NONo 71046 IREVI
~
-----
11484 I 2/25/98 JLB CHECKED
llR. ! D.R.N. NO~r DAlE APPR. AP~OY£D .JLB 2/25/98 SCALE 1/4 SHEET 2 or 3
7..$"" <J~ 8)
ITEM PART NUMBER ':1 )'l. 1
DESCRIPTION
FIGURE4.17:LowerControIBoxAssembly
QTY
Ref. 71046 ............................ Lower Control Box Assembly ................................................. Ref.

1 71643-0011002 .............. Lower Control Machine Box,T60 /66J ......................................... 1
2 71534 ............................ Computer Board, Ground Control Box .......................................... 1
3 67280 ............................ Bosch Relay .................. ,............................................................... 2
4 80027 ............................ Hour Meter .................................................................................... 1
5 65393 ............................ Oil Pressure Gauge ........................................................................ 1
6 67830 ............................ Meter, Volt .................................................................................... 1
7 50075 ............................ SwitchR#67760 ............................................................................. 4
8 52671 ............................ Operator Keyswitch 3 Pos ............................................................ 1
9 69146 ............................ Operator, Green Pushbutton .......................................................... 1
10 80025 ............................ Circuit Breaker 20 AMPS ............................................................. 1
11 51913 ............................ P-Pull Button, Emergency Stop ..................................................... 1
12 51914 ............................ Contact Block NC ......................................................................... 1
13 52029 ............................ Contact Block, 2NO WlBase ........................................................ 1
14 34383 ............................ Contact Block, INO ...................................................................... 1
15 52672 ............................ Contact Block, INO WlBase ........................................................ 1
16 67760-002 ..................... Toggle Switch 3POS 2MAN IMOM .......................................... :.1
17 58292 ............................ Wire, 16 GA White ...................................................................... 16
18 66652-001 ..................... Plug - Male 16 Contacts #1-16 ...................................................... 1
19 66652-003 ..................... Plug - Male Contacts #17-32 ......................................................... 1
20 66653-001 ..................... Receptacle Female 16 Cont #1-16 ................................................ 1
21 66653-003 ..................... Receptacle Female 16Cont#17-32 .............................................. 1
22 66654-032 ..................... Base, Panel Mounted 32 Contacts ................................................. 2
23 BVDOI030 .................... Socket ............................................................................................ 2
24 BVDOI031 .................... Lamp .............................................................................................. 2
25 71885 ............................ Lens Green Jeweled ...................................................................... 2
26 71664 ............................ Cover Plate, Lower Control Board ................................................ 1
27 65273 ............................ Slope Sensor .................................................................................. 1
28 71663 ............................ Panel, Lower Control Board MTG ................................................ 1
29 71724 ............................ Plug, Female Pins .......................................................................... 1
30 71725 ............................ Plug, Female Pins .......................................................................... 1
31 71727 ............................ Pins, FamaleCrimp ...................................................................... 80
32 67125 ............................ Seal Switch .................................................................................... 6
33 206-00001-00 ................ Diode ............................................................................................. 1
34 71793 ............................ Resistor, 36 OHM 2 Watt .............................................................. 2
40 54257-005 ..................... Light, Red Indicator ..................................................... :................. 1

41 67758 ............................ Toggle Switch 3 Pos 3 Man ........................................................... 1
42 71789 ............................ Hood wlHub 36 ............................................................................. 1
43 66670-002 ..................... Starin Relieffor Hub 36 ................................................................. I
44 66785-006 ..................... Hood wlHub 29 ............................................................................. 1
45 66670-001 ..................... Strain Relief for Hub 29 ., ............................................................... 1
MANUAL 92375-003
April 1998
• FIGURE 5.1 :CounterweightAssembly
- - - tr
:I
'1
I:
SEE NOTE 3 W
-H-
:l
I:
,I
3
2PL
MANUAL 92375-003
April 1998
FIGURE 5.1 :CounterweightAssembly •
Ref. 71391 .... ,....................... Counterweight Assembly ......................................................... Ref.

-1 71391-DWG ................. CounterweightAssemblyDrawing ................................................ 1
-2 71391-HW .................... Hardware Kit ................................................................................. 1
3 71855 ............................ Counterweight Mod ....................................................................... 1
4 71339 ............................ LevelingBlockCounterweight ....................................................... 1
5 71341 ............................ Bolt Plate, Counterweight .............................................................. 2
6 71839 ............................ Shroud,NissianEngine .................................................................. 1

2 BOW46178 ................... Bolt, HexHD 3/4-10 UNC x3" Lg Gr8 ....................................... 4
3 BOW32278 ................... Nut, 3/4-10 Jam ............................................................................. 2
4 BOW36718-HD ........... Washer, 3/4" SAE Flat ................................................................. .4
5 BOW39178 ................... Bolt, Hex HD 3/4-10 x 3 112 Gr 8 .................................................4
6 BOW30002 ................... Bolt, .25-20 UNC x .75 Hex ......................................................... .4
7 BOW31401 ................... Washer,.25"IDx.63"OD ............................................................. .4
MANUAL 92375-003
April 1998
• FIGURE 6.1 :BoomlSkirtInstallation; T60
.-"
\
I (j) ,
\J o
MANUAL 92375-003
April 1998
FIGURE 6.1 :BoomlSkirtInstallation; T60 •
ITEM PART NUMBER QTY
Ref. 71016-T60 ..................... BoomlSkirtlnstallation ............................................................. Ref.

-I 71016-DWG ................. Boom/SkirtlnstallationDWG;T60 ................................................ 1
-2 71016-HW .................... Hardware Kit, Boom/SkirtT60 ..................................................... 1
3 71562 ............................ Main Boom Assembly; T60 ........................................................... 1
4 71627 ............................ Angle Sensor Installation ............................................................... 1
5 71017 ............................ Skirt Assembly ............................................................................... 1
6 71437 ............................ Pin, Base Boom Pivot T60 ............................................................ 1
7 71456 ............................ Pin,MasterCylinderlBoom ........................................................... 1
8 71438 ............................ Pin, T60 Lift CylinderlBoom .......................................................... 1
9 71498 ............................ Cover, T60/66J Boom Pivot Upper ............................................... 1
10 71504 ............................ Cover, T60/66J Boom Pivot Lower ................~ .............................. 1
11 71435 ............................ Cover, Boom Sheave Access ........................................................ 1
12 71620-T60 ..................... Hose Kit; Boom T60 ..................................................................... 1
66044-672.00 ................ Hose Assembly, #0467685137 ST-ST ......................................... 1
66044-672.00 ................ Hose Assembly, #0467685137 ST-ST ....................................... ~.I
66044-724.00 ................ Hose Assembly, #04 67685 137 ST-ST ......................................... 1
66044-724.00 ................ Hose Assembly, #04 67685 137 ST-ST ......................................... 1
66001-024.00 ................ Hose Assembly, #04 67685 137 ST-90 .......................................... 1
66044-024.00 ................ Hose Assembly, #0467685137 ST-ST ......................................... 1
l3 71778-T60 ..................... Electrical Cable Assembly ............................................................. 1
67295-036 ..................... Cable, 16 Gage/3 Con~uctor SJO ... 7.~~ ......7t:.& .... 76LF.
71537 ............................ Cable & Conductor Shielded ........ t£...COKl.~...................... 75LF.
O~~
MANUAL 9237S-003
April 1998
\
• FIGURE 6.2:MainBoomAssemblyT60
o
i"-!
o
MANUAL 92375-003
April 1998
FIGURE 6.2:MainBoomAssemblyT60 . ,

Ref. 71562 ............................ MainBoomAssembly .............................................................. Ref.
~
-1 71562-DWG ................. BoomAssemblyDWG; T60/66J ................................................... 1
-2 71562-HW .................... Hardware Kit ................................................................................ 1
BOW35241 ................... E-Ring .500 Dia Shaft ................................................................... 4
3 71714 ............................ Base Boom Assembly ................................................................... 1
4 71395 ............................ Hose Carrier Installation ................................................................ 1
5 71628 ............................ Boom Length Sensor Installation ................................................... 1
71536 ............................ Length Sensor ................................................................................ 1
71628-HW .................... Hardware Kit ................................................................................ 1
.6 71629 ............................ Ext. Limit Switch Installation ......................................................... 1
71629-HW .................... Hardware Kit ................................................................................ 1
51036 ............................ Switch,LimitBodyOnly ................................................................ 1
51037 ............................ Offset Head Limit Switch ............................................................. 1
67114-003 ..................... Strain Relief 112 NPT .37/.5 ........................................................... .
51039 ............................ Arm,AdjustableLimitSwitch ....................................................... 1
7 71564 ............................ Ext.CylinderAssembly ................................................................. 1
8 71394 ............................ MidBoomAssembly ..................................................................... 1
9 71393 ............................ TipBoomAssembly ...................................................................... 1
10 71565 ............................ Slave Cylinder Assembly ............................................................... 1
11 68189 ............................ Pin .................................................................................................. 4
12 71323 ............................ Wire Rope Assembly; Extension ................................................... 2
13 71312 ............................ Wire Rope Assembly; Retraction .................................................. 2
14 68228 ............................ Bracket Weldment, Dead End ....................................................... 4

15 'g/~~l- Oo~
A-.tj W4--( f J
w~ Pa..J. f.\--Sfy
lro 7~o 2.,
MANUAL 92375-003
April 1998
., FIGURE 6.3: Base Boom Assembly
\
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ir~:
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I I
~ '''I I
L:::-.J
Ref. 71714 ............................ Base Boom Assembly .............................................................. Ref.

-1 71714-DWG ................. Base Boom Assembly Drawing ................................................... 1
-2 71714-HW .................... Hardware Kit ................................................................................ 1
3 71243 ............................. Boom Weldment, Base .................................................................. 1
4 71665 ............................ Dead End Bracket Weldment ....................................................... 1
5 81587-002 ..................... Bearing Pad; Adj 1 7/8 Lg ............................................................ .4
6 71308 ............................ Wear Pad; BaselMid Top ............................................................. 1
7 7i307 ............................ Wear Pad; BaselMid Bottom ........................................................ 1

MANUAL 92375-003
April 1998
FIGURE 6.4:HoseCarrier Installation
•
SECTION 6-8
,,
A~

Ref. 71395 ............................ Hose Carrier Installation ........................................................... Ref.
-1 71395-DWG ................. HoseCarrierInstallation ................................................................ 1
-2 71395-HW .................... Hardware Kit ................................................................................ 1
3 71407 ............................ Hose Carrier Tu~e Weldment; Tip ................................................ 1
4 71433 ............................ Wear Pad; Tip Hose Tube ............................................................ 2
5 CLV01233-001 ............. Pipe 114 Schedule 80 PVC 5.13"Lg .............................................. 9
6 71404 ............................ Retainer, Wear Pad ....................................................................... 1
7 71403 ............................ Wear Pad, Hose Tube Base Upper .............................................. 1
8 71402 ............................ Wear Pad, Hose Tube Base Lower .............................................. 1
9 71405 ............................ Frame Weldment, Hose Track Cover ........................................... 1
10 71731 ............................ Cover,MountingWeldment ........................................................... 1
11 71236 ............................ Hose Carrier Track ...........................J ..~ ........................................ 1 f{ I-
12" 71260 ............................ Cover, Hose Track ...............q)fi:i<;J.e..-p~~ .... .r..v..t;.. .':::... 1 ft.'? ~
13 71471 ............................ Spacer, Catrac Mounting ......#.)~J:de.:R.~r:. ~w. ..... ............... 1
14 71594 ............................ Support, Hose Track Cover ........................................................... 1
15 71736 ............................ Bracket, Hose Track Cover .......................................................... 1
I
~ J.. 3S-1 - ~v.Lrl f/ClS~ 7r ~
- I. - A'VWI.//l(/A
.t'-\;t j ,."
MANUAL 9237S..()Q3
April 1998
• FIGURE 6.5:BoomExtension Cylinder Assembly
ITEM
Ref.
PART NUMBER DESCRIPTION
71564 ............................ Boom Extension Cylinder Assembly ........................................ Ref.

QTY
\
-1 71564-DWG ................. Extension Cylinder Assembly Drawing ......................................... 1
-2 71564-HW .................... Hardware Kit ................................................................................ 1
-3 71564-FTG .................... FittingKit ....................................................................................... 1
-4 71143 ............................ Cylinder,BoomExtend .................................................................. 1
-5 71322 ............................ Wear Pad, Extension Cylinder ....................................................... 1
-6 71350 ............................ Keeper Block, Extension Cylinder ................................................. 1
-7 71436 ............................ Pin, Extension Cylinder .................................................................. 2
-8 71556 ............................ Keeper Block Weldment ............................................................... 1
-9 BOW35296 ................... Ring, Ext. Retaining 1.25Dia shaft ................................................ 4
Ref. 71564-HW .................... Hardware Kit Extension Cylinder Assembly ........................... Ref.
1 BOW35296 ................... Ring, Extension Retaining 1.25 Shaft ............................................. 4
2 BOW30 145-275 ............ 5/8-11 x 23/4 Bolt ......................................................................... 4
3 BOW31331 ................... 5/8 Lock Washer ........................................................................... 4
4 BOW36030 ................... 5/16-18x?Bolt ............................................................................. 4
5 BOW31326 ................... 5/16 Lock Washer ......................................................................... 4
6 BOW31202 ................... 5/16-18Nut .................................................................................... 4
7 BOW31432 ................... 5/16 Flat Washer ........................................................................... 4
Ref. 71564-FTG .................... Fitting Kit Extension Cylinder Assembly .................................. Ref.
1 02234 ............................ Elbow MJ08 M008 ....................................................................... 1
2 02473 ............................ StraightMJ06 M008 ..................................................................... 1
=8!S USED TO CALL our PIECE FARTS FOR THE HARDWARE KIT.
[::}s USED TO CALL our PIECE PARTS FOR THE FITTING KIT.
@
10
@
01
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! L .• ____ ••, _ _ --!>-l
--_---_---_--';-,
_
6 4 PL
\
~2 PL~2
oh~\7
PL
c/n fu.~~4PL
@ @
MANUAL 92375-003
April 1998
.I:
RE10ISICIII
-1 .......... 1 _ IV ICHlD.I_1 l1li11
IlIl tlDll I_IIIIIIP/I(... _ . _I . lul4l'lt,,"
I
I
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/ / ' _ - - ----~-'--I
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-
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It
tr1
2.52 1.77
~ lEY A-A
S:=~::J
',--
-------------+---r--
.J~
..l__L
I
~'l:,-I
1 - - - - - - - - - 1 / 2 1RA\EL 1/2 1RA\EL----ot
~-----------------------~~1RA\EL----------------------------~
fi
1.32
o
4a
1.82
0
.77 2.57
1.01
=rJ3037 3012 W
KIT TO INCLUDE:
\/ENDOR: IGUS
CONDaI PIN "GUS PIN DESCRIPTION
PLASllC HOSE lRACK
.'.7IITlP. t~ 1 165829-1001311 SEPARATOR

2 165829-101 1350-075-075 CABLE/HOSE CARRIER UNK
T
LJ.28~L.l'
METAL MOUNTING BRACKET. INSIDE (MALE)
1-3032-1 3 r.:==-::::':+.==-=::::::"
PLASTIC MOUNTING BRACKET. INSIDE (MALE)
65829-103
r-
. .. u _ _ ...... 65829-102 4 E==-~=+==~=
METAL MOUNTING BRACKET. OUTSIDE (FEMALE)
PLASTIC MOUNTING BRACKET. OUTSIDE (FEMALE)
~.=&....,..
C--&L_--- KIT TO INCLUDE: PLASllC HOSE lRACK
~.=&- ACCEPTABLE ALTERNATE \/ENDOR: GORlRAC
HOSE CARRIER ASSY PER MOOELS I
CONDOR PIN GORTRAC PIN DESCRIPTION I
65829-201 I KL1-SEP I SEPARATOR
0 0 GB
---
65829-202 I KLl-8.5 CABLE/HOSE CARRIER UNK
CONDOR MODEl.. CONDOR PIN TOTAL lRAVEL LOCATION OF SEPERATORS ,OF UNKS MOUNTING BRACKET ,SPEQFlCATlONS: 65829-203 I KL1-BRNT MOUNTING BRACKETS
180 / T86J
160/ T86J
140/ T46J
65829-001
65829-002
65829-003
556.00"
4Ol5.00"
186.25"
2 IN EVERY 41H UNK
2 IN EVERY 41H UNK
2 IN EVERY 41H UNK
112
83
42
1 PAIR METAL
1 PAIR METAL
1 PAIR METAL
UNK OVERALL v"D1H: 3.74
UNK OVERALL HEIGHT: 2.52
UNK INSIDE v"D1H: 3.95
UNK INSIDE HEIGHT: 1.n
==-:
'RI.IUIaa""""
l'"
...... _ "V
~
:::..t;;;;..-_______ ~ ----
-"'''''-__-__lEXAII
___
........... l11l.I
lm
__2 ____-i
I30D . . . . . . . . .
A42RT 65829-005 ? NONE 29 1 PAIR METAL UNK C/C LENG1H: 2.64 - .. - Oc::J CHART, HOSE CARRIER TRACK ASSY
A38 / A42J 65829-004 72.50" NONE 20 1 PAIR PLASTIC MIN BEND RADIUS: 2.95
A30N 65829-006 60.00" NONE 111 1 PAIR METAL
OVERALL HEIGHT: 8.46
WElGHT/FT: 1.3'LB/FT
SNAPS OPEN ON OUTSIDE RADIUS
--
- sue I ~ I.......... 1_ 65829
IICoU 114 BUT 1 OF 1
CA
101~~)&'- O{O~
r - -_ _ _ FI----,GURE 6.6:Cylinder, Boom Extend . ,
o
o
I
EXT lEI

Ref. 71143 ............................ Cylinder, Boom Extend ............................................................. Ref.
1 * .................................... Wiper ............................................................................................. 1
2 * .................................... O-Ring ........................................................................................... 1
3 * .................................... Back Up ........................................................................................ 1
4 * .................................... AQ Seal ......................................................................................... 1
5 * .................................... O-Ring ........................................................................................... 1
6 * .................................... O-Cup (Dual Lip) .......................................................................... 1
7 * .................................... O-Cup Green Tweed ..................................................................... 1
8 * .................................... Wear Ring ..................................................................................... 4
9 71143-101 ..................... 55ASeaIKit .................................................................................. 1
10 71143-102 ..................... Setscrew ........................................................................................ 1
11 71143-103 ..................... PortPlug ........................................................................................ 2
12 71143-104 ..................... PortPlug ........................................................................................ 2
13 71143-105 ..................... Counterbalance Valve ................................................................... 1
14 71143-106 ..................... Cartridge Valve ............................................................................. 1
15 71143-107 ..................... Tube Assembly .............................................................................. 1
16 71143-108 ..................... Rod-TubeAssembly ...................................................................... 1
17 71143-109 ..................... Head .............................................................................................. 1
18 71143-110 ..................... BearingSleeve ............................................................................... 1
MANUAL 92375-003
April 1998
• FIGURE 6.7:MidBoomAssembly, T60
r---
~ ~ IT~ j IT]
I "I
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)
0 0 \
..... I-"-' I
-----'
r----i I ---- -- -- --
-- -- -- ) --
-- -- -- -- -:::
10 1
1- 10 1
r----~ I ----
-- -- -- -- --.- -- -- -- -:.: 1 1
---- ....
I-
0
. -.
0
I
iI urn ITrn I \\ r:- I-:-l
ITtIl
1° °1
L
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-
6

Ref. 71394 ............................ MidBoomAssembly, T60 ......................................................... Ref.
-1 71394-DWG ................. MidBoomAssemblyDrawing ...................................................... 1
2 71394-HW .................... Hardware Kit ................................................................................ 1
3 71280 ............................ Boom Weldment, Mid .................................................................... 1
4 71305 ............................ Wear Pad, MidITip Bottom ........................................................... 1
5 71304 ............................ Wear Pad, MidITip Top ................................................................. 1
6 71310 ............................ Wear Pad, MidlBase ..................................................................... 2
7 71349 ............................ Tube; Sheave Guard ...................................................................... 8
8 71262 ............................ Pin, Sheave .................................................................................... 4
9 68048 ............................ Sheave; Extension ......................................................................... 4
10 71462 ............................ Bushing; Sheave ............................................................................ 4
11 81587-003 ..................... Bearing Pad, Adj 2 5/8 Lg ............................................................ 4
MANUAL 92375-003
April 1998
FIGURE 6.8:TipBoomAssembly, T60 •
8o
o
8
Ref. 71393 ............................ Tip Boom Assembly, T60 ......................................................... Ref.

-1 71393-DWG ................. TipBoomAssemblyDrawing ....................................................... 1
-2 71393-HW .................... Hardware Kit ................................................................................ 1
-3 71303 ............................ Wear Pad; TiplMid Top ................................................................ 1
-4 71306 ............................ Wear Pad, TiplMid Bottom ........................................................... 1
-5 71259 ............................ Boom Weldment, Tip ..................................................................... 1

-2 BOW30104 ................... Bolt, .50-13UNC x 1.00 Hex ......................................................... 8
-3 BOW31329 ................... Washer, .50 Gr 5 Split Lock .......................................................... 8
-4 BOW32275 ................... Nut, 1I2-13UNC Hex Jam ............................................................. 8

MANUAL 92375"()()3
April 1998
\
FIGURE 6.9: Slave Cylinder Assembly

I I
Ref. 71565 ............................ Slave Cylinder Assembly ..... :.................................................... Ref.
-1 71565-DWG ................. Slave Cylinder Assembly Drawing ................................................ 1
-2 71565-HW .................... Hardware Kit ................................................................................ 1
-3 71565-FTG .................... FittingKit ....................................................................................... 1
-4 71146 ............................ Slave Cylinder Level Telescope .................................................... 1
-5 71444 ............................ PinWeldment,SlaveCylinderlBoom ............................................. 1
-6 71488 ............................ Cap, Slave Cylinder Pin Retainer .................................................. 1
Ref. 71565-HW .................... Hardware Kit Slave Cylinder Assembly .................................. Ref.
1 BOW30000 ................... Bolt 1/4-20 x 1/2 Hex .................................................................... 1
2 BOW30054 ................... Bolt 3/8-16 x 1 Hex ....................................................................... 2
3 BOW31325 ................... Washer .25 ID Split Lock .............................................................. 1
4 BOW31327 ................... Washer 3/8 ID Split Lock .............................................................. 2
Ref. 71565-FTG .................... FittingKitSlaveCylinder Assembly ......................................... Ref.

1 02525 ............................ Straight MJ04 M004 ..................................................................... 1
2 02236 ............................ Elbow 90 MJ04 M004 .................................................................. 1
=
1, C::}S USED TO CALL OUT PIECE PARTS FOR THE HARDWAR£ KIT,
2. [~}s USED TO CALL ouT PIECE PARTS FOR THE FITTING KIT.
f!
_.1.' ___ 1._
I
MANUAL 92375-003
April 1998
FIGURE 6.1 0: Slave Level Cylinder •
JI_ "--

Ref. 71146 ............................ Slave Level Cylinder ................................................................. Ref.
1 ...................................... Wiper ............................................................................................. 1
2 ...................................... Seal ................................................................................................ 1
3 ...................................... O-Ring ........................................................................................... 1
4 ...................................... Back-Up ........................................................................................ 1
5 ...................................... O-Ring ........................................................................................... 1
6 ...................................... O-Ring ........................................................................................... 1
7 ...................................... Seal ................................................................................................ 1
8 ...................................... WearRing ..................................................................................... 1
9 ...................................... WearRing ..................................................................................... 2
10 ...................................... SeaIKit .......................................................................................... 1
11 ...................................... Locknut .......................................................................................... 1
12 ...................................... Port Plug ........................................................................................ 4
13 ...................................... Bushing .......................................................................................... 4
14 ...................................... Counterbalance Valve ................................................................... 2
15 ...•.................................. Tube Assembly .............................................................................. 1
16 ...................................... RodAssembly ............................................................................... 1
17 ...................................... Head .............................................................................................. 1
18 ...................................... Piston ............................................................................................. 1
MANUAL 92375-003
April 1998
MANUAL 92375-003
April 1998
FIGURE 6.11 :Angle Sensor Installation •

Ref. 71627 ............................ Angle Sensor Installation .......................................................... Ref.
-1 71627-DWG ................. AngleSensorInstallationDrawing ................................................ 1
-2 71529 ............................ Angle Sensor Plate ........................................................................ 1
-3 71531 ............................ ModifiedBolt ................................................................................. 1
-4 71499 ............................ Cover, Boom Angle Sensor ........................................................... 1
-5 71728 ............................ Blade, Angle Sensor ...................................................................... 1
-6 BOW31213 ................... Nut, Hex .38-24 UNF .................................................................... 1
-7 BOW31147 ................... Screw, #10-32 UNF x 1.50 Slotted Round .................................... 2
-8 BOW31400 ................... Washer, #10 Flat ........................................................................... 2
-9 BOW93775 ................... Lockwasher #10 ............................................................................ 2
-10 71535 ............................ Angle Sensor ................................................................................. 1

MANUAL 92375-003
April 1998
• FIGURE 6. 12:SkirtInstallation
\
---
---
2PL
2PL
0 4PL
~_O~A
2PL
2PL
A~
VIEW A-A
NOTES:
1. (:;:}S USED TO CALL OUT PIECE PARTS FOR THE HARDWARE KIT.
2. [;}S USED TO CALL OUT PIECE PARTS FOR THE FITTING KIT.
~2PL
(6\
\,.
0
0
~
:::J
0
MANUAL 92375-003
Al'rill998
FIGURE 6. 12: Skirt Installation •
Ref. 71017 ............................ SkirtInstallation ...................................................... ,................. Ref.

-1 71017-DWG ................. SkirtInstallationDrawing .............................................................. 1
-2 71017-HW .................... Hardware Kit ................................................................................ 1
-3 71017-FTG .................... Fitting Kit ....................................................................................... 1
4 71439 ............................ Pin, Boom Tip ................................................................................ 1
5 71464 ............................ Pin,SlaveCylinderISkirt ................................................................ 1
6 71022 ............................ SkirtWeldment .............................................................................. 1
7 35460 ............................ Actuator ......................................................................................... 1
8 71215 ............................ Lower Skirt Bracket Weldment .................................................... 1
9 71219 ............................ Upper Skirt Bracket Weldment ..................................................... 1
10 71515 ............................ Spacer, SkirtlRotator ..................................................................... 1
11 81399 ............................ Washer, Skirt Upper ...................................................................... 1
12 71621-STD ................... Hose Kit, Skirt ............................................................................... 1
13 71554 ............................ Dual P.O. Check Valve ................................................................ 1
14 81368-36-16 .................. Gar-Max2.00"IDx2.50"ODx 1.00"L .......................................... l
15 71733 ............................ Skirt Stop Weldment LH ............................................................... 1
16 71732 ............................ Skirt Stop WeldmentRH ............................................................... 1

2 BOW39011 ................... Bolt, .25-20 UNC x2.75 Gr 8 Hex ............................................... .4
3 BOW34272 ................... Nut, .25-20 UNC Nylon Lock ....................................................... 8
4 BOW39012 ................... Bolt, 114-20 x 3.00 Gr 8 Hd Hex .................................................. .4
5 BOW39105 ................... Bolt, 112-13 x 1114 Gr 8 Hd Hex .................................................. .4
6 BOW31329 ................... Washer, .50 Gr 5 Split Lock .......................................................... 4
7 BOW39060 ................... Hex Hd Bolt 3/8-16 x 2 1/2 Gr 8 ................................................... 1
8 BOW34274 ................... Nut, .3/8-16 UNC Hex Lock ......................................................... 1
9 BOW33979 ................... Keystock, .500 x .500 ............................................................ 21LF.
10 BOW36102 ................... Screw, .50-13 UNC .750 Hex Cap .............................................. .4
11 BOE30030 .................... Bolt, 5/16-18 UNC x 1.25 Gr 5 Hex .............................................. 2
12 BOW34273 ................... Nut, 5116-18 UNC Nylon Lock ..................................................... 2
1 71017-FTG .................... FittingKit .................................................................................. Ref.

2 00456 ............................ Straight, MJ04 M006 .................................................................... 2
3 04630 ............................ Elbow, 45° MJ04 M006 ................................................................ 2
4 02236 ............................ Elbow, 90° MJ04 M004 ................................................................ 4
gf~77 - (-/e~"y C//~cL

5" h'~r-f-
Su. rv/{t1w?- p~ ~ 7fdJ rD-J- J-b3
MANUAL 92375-003
April 1998
~
~ FIGURE 6.l3:BoomlSkirtInstallation,T60/T661
Ul Ul
:2 2
0 0
0 0
IT] IT]
-,
1O
1O
l-
LL
0
S:
w
5>
~I ....J
D...
N
w
o
Ul
MANUAL 92375-003
April 1998
___
-
0IIGIIPftIII
. . DW
..
ow ,
f:lpartsl88kl88343.dwg Oec 04, 2000 08:55:41

20 88432 1.00 EA HOSE KIT, SKIRT
19 CLL01815-003 1.00 EA TBE, RND, 2.75 OD x .313W x .50L
18 66770-200 1.00 EA BEARING, THRUST, 2.00 ID
17 BOW34276 1.00 EA NUT, .50-13UNC HEX LOCK
16 BOW30111 1.00 EA BOL T, HEX, .50-13UNC x 2.75
15 88313 1.00 EA MNT PLT, CHECK VALVE
14 BOW30062 4.00 EA BOLT, 3/8-16 x 3.00 GR5 HEX
13 BOW33979 2.50 IN KEYSTOCK .50 x .50
12 BOW34274 4.00 EA NUT 3/8-16UNC NYLON LOCK
11 BOW31329 6.00 EA WASHER, 1/2 GR5 SPLIT LOCK
10 BOW30105 6.00 EA BOLT, .50-13UNC x 1.25 GR5 HEX
) 9 BOW30032 2.00 EA BOLT, HEX, .31-18 UNC x 1.75
€ 7 71549 1.00 EA VAL VE ASSY, 2STR
6 71439 1.00 EA PIN, T60/66 BOOM TIP
5 35460 1.00 EA PARKER PLATFORM ROTATOR
4 71464 1.00 EA PIN, SLAVE C-YL/SKIRT
3 88298 1.00 EA PLATFORM MNT WLDT, LOWER
2 88294 1.00 EA PLATFORM MNT WLDT, UPPER
1 88280 1.00 EA SKIRT WLDT, T-SERIES
ITEM PART NUMBER QTY UM DESCRIPTION
UNLESS OTHERWISE NOTED:
TIME CONDOR CORPORATION
TOLERANCES: DECIMALS I C=;1 0 J .'l O~ .R1 8300 IMPERIAL DRIVE
FRACTlONS:I: 1/16
ANGLES :I: l'
SURFACE FINISH 120/
.X :I: .1
.XX :I: .03
.XXX :I: .010 TITLE
~
-- WACO, TEXAS 76712
PROJECTION OF VIEWS @CJ SKIRT ASSY, T-SERIES

ALL DIMENSIONS ARE IN INCHES
DRAYIN SIZE DRAWING NO. REV.
DALE WYBLE 7/31/99
CHECKED K SNYDER 8/2/99 B 88343 B
APPROVED JB 8/3/99 ERCN NO. 13531 ISCALE 1/5 ISHEET 1 OF 1
f:\parts\88kl88343.dwg Dec 04, 2000 08:56:04

-_ ... --
6.19
)1
.56j
REF I.
1.75 L
~--~-------------------------19.25----------------------------~ J
5 81318-11-18 1.00 EA 8EAIItNG. GARMAX. 2 x 2.25 x lL

4 71217 1.00 EA PIAl£, SKIRT KICK
3 88297 2.00 EA PLT. PlAlFORII MIlT. LOlIER
8829Il 1.00 EA lust:. PLATFORM MIlT. LOlIER
1 88288 1.00 EA PLT. PLAlFORII !lNT.LOlIP
EST. WT. -7.1 l.B
---
-
ITEII PART NUMBER OTY UM D£SCRIP'I11lN
f:lparts\88kI88298.dwg Dec 04. 2000 08:58:13

_... ..."
2.938
1------1- TO CENTER OF
MACHINED HOLE
l1.31 I
1-----7.25 ----........j
1.375
TO CENTER OF
MACHINED HOLE
I
)
4.81 4------+
l~==========~:=:::::::=::==:~
jl
f:lpartS\88k\88294.dwg Dec 04, 2000 08:57:56

~
~ FIGURE 6.13 :BoomlSkirtInstallation,T60/T66J
(f) (f)
::;E ::;E
0 0
0 0
rn rn
-,
lO
lO
f-
lL.
0
:;::
w
'>
w
o
Vi
MANUAL 923 75-003

April 1998
FIGURE 6.13 :BoomlSkirtInstallation,T60/T66J •

Ref. 71016 ............................ Boom/Skirtlnstallation, T60ff66J ............................................ Ref.
1 71016-DWG ................. Boom/SkirtT60/66JInstaliation DWG .......................................... 1
2 71016-HW .................... Boom/Skirt T60/66J Hardware Kit ................................................ 1
3 71562 ............................ Main Boom AssemblyT60/66J ..................................................... 1
4 71627 ............................ AngleSensorlnstallation ............................................................... 1
5 71563 ............................ Jib/SkirtAssembly ......................................................................... 1
71017 ............................ SkirtAssembly ............................................................................... 1
6 71437 ............................ Pin, Base Boom Pivot T60/66J ...................................................... 1
7 71456 ............................ Pin, Master CylinderlBase Boom .................................................. 1
8 71438 ............................ Pin, Lift CylinderlBase Boom ........................................................ 1
9 71498 ............................ Cover, T60/66J Boom Pivot Upper ............................................... 1
10 71504 ............................ Cover, T60/66J Boom Pivot Lower ............................................... 1
11 71435 ............................ Cover, Boom Sheave Access ........................................................ 2
12 71620-T60 ..................... Hose Kit, Boom T60/66J ............................................................... 1
71620-T66J ................... Hose Kit, Boom T60/66J ............................................................... 1
13 71778-T60 ..................... Electrical Cable Assembly ............................................................. 1
71778-T66J ................... Electrical Cable Assembly ............................................................. 1
14 71528 ............................ Boom Pivot Cover ......................................................................... 1
MANUAL 92375-003
April 1998
• FIGURE 6. 14:Jib/SkirtAssembly, T66J
, i
1
.~,:,:~
~-'~C:~~,"J'Yi===:I::::~=t:~;¥
VIEW 8-8
ASSEMBLED VIEW
~
EXPLODED VIEW
B~
A
2FL
d A
2
15
,
REF
W2HOSES
SECTION ,A-A
VIEW C-C
""-=
I. C::}s USED TO CA.Ll OUT PI[e( PARTS fOR THE HI>.RDWAR£ I<1T.
2. [:}S USEO TO CALL OUT PIEC( PARTS fOR THE F'!TTlNG KIT.
MANUAL 92375-003
April 1998
REV
REF TIP JRtVrERCNNO:I DESCRIP110I
\\\f:
\
J
~]----r
+ ------------I...,
I ------------ 'J
II
VIEW 8-8
ASSEMBLED VIEW
:E~:~----~~~~~:!...-----------{Ilr_----_=t7t<;====----1n
~'---TJ'
\\JJ---r~~~~~~===fr-IJ~rT~n!r
II
I- 01HERIIISE NO'IED<
'III..f:RANCEII IIECIIIALS 11'9 n I .n"Qr
4 02236 4.00 EA ELBOW 90· M004 MJ04
3 04630 2.00 EA ELBOW 45° M006 MJ04
2 00456 2.00 EA STRAIGHT M006 MJ04
1 71563-DWG 1.00 EA JIB/SKIRT INST DWG
71563-FTG JIB/SKIRT INST FITTING KIT
01S USED TO LABEL FITTING KIT COMPONENTS.
13 BOW34276 1.00 EA NUT - .50-13UNC HEX LOCK

12 BOW30112 1.00 EA BOLT .50-13UNC X 3.00" GR5 HEX
11 BOW30063 2.00 EA BOLT, 3/8-16UNC x 3.25 GR5 HEX
10 BOW36102 4.00 EA CAPSCREW,1 /2-13x3 /4"L FLATHEAD
9 BOW33979 2.50 IN KEYSTOCK .50 x .50
7 BOW30060 10.00 EA BOLT, 3/8-16UNC x 2.50 GR5 HEX
6 BOW31329 4.00 EA WASHER. 1/2 GR5 SPLIT LOCK
5 BOW30105 4.00 EA BOLT, .50-13UNC x 1.25 GR5 HEX
4 BOW30062 6.00 EA BOL T, 3/8-16UNC x 3.00 GR5 HEX .
3 BOW23923 12.00 EA TIE, CABLE NYLON .188W x 8"L

2 BOW34273 2.00 EA NU1~5/f6-18UNC NYLON LOCK
1 71563-DWG 1.00 EA JIB/SKIRT INST DWG
71563-HW JIB/SKIRT INST HARDWARE KIT
01S USED TO LABEL HARDWARE KIT COMPONENTS. i
27 81368-05- 20
. REF EA GAR-MAX 1.251DX 1.5000 X 1.25L
~IS USED TO LABEL HARDW' -, "T COMPONENTS.
I
27 81368-05-20 REF EA GAR-MAX1.25IDX 1.5000 X 1.25L
26 34147 REF EA GARMAX 1.25 I.D.x 1.50"L
25 34145 REF EA GARMAX 1.50 1.0. x 1.50"L
24 71055-RH 1.00 EA PARALLEL 'ARM WLDMNT, 6'JIB RH
23 71621-JIB 1.00 EA HOSE KIT, JIB/SKIRT T46J/66J
22 71983 6.00 EA RUBBER PAD, 5" x 5" x 1/4"
21 71549 1.00 EA VAL VE ASSY, 2STR ®
20 71733 1.00 EA SKIRT STOP, LH
19 71732 1.00 EA SKIRT STOP, RH
18 71515 1.00 EA SPACER, SKIRT/ROTATOR
17 71586 1.00 EA PIN, JIB PLATE/JIB BOOM
16 71439 1.00 EA PIN, T60/66 BOOM TIP
15 71587 1.00 EA PIN, SLAVE CYL/JIB PLATE
14 71027 1.00 EA CYLINDER, 6' JIB LIFT
13 71215 1.00 EA LOWER BRACKET WELDMENT
12 71219 1.00 EA UPPER BRACKET WELDMENT
11 35460 1.00 EA PAR~ER PLATFORM ROTATOR
10 71149 1.00 EA SKIRT WELOMENT, T46J/66J
9 71056 1.00 EA JIB, BOOM WELDMENT, 6'
8 71055-LH 2.00 EA PARALLEL fARM WLDMNT, 6'JIB LH
7 71054 1.00 EA JIB PLATE. WLDMNT, 6' JIB TELESCOPE
6 71469 1.00 EA PIN,JIB~ BOOM/SKIRT
5 71466 2.00 EA P1N, JIB· ARM
4 71465 1.00 EA PIN, JIB B()OM/CYL
3 71563-FTG 1.00 EA FITTING KIT, 6' JIB ASSY
2 71563-HW 1.00 EA H~RD~ARE KIT, 6' JIB ASSY NOTES:
1 71563-DWG 1.00 EA ASSY DWG, JIB/SKIRT 1. TY-RAP HOSES TOGET
TY-RAP'S AROUND THI
, ITEM PART NUMBER QTY UM DESCRIPTION
I I
REV ERaf NO.1
RE\1SION
DESCRIP110N
R~O~~~
\ ----J---~~~~~~~~~=
r~==T
~J---r VIEW B-B

\ • ASSE"BLED VIEW
26) REF
REF TIP
-- ..
\\\J J: ___ r~~~~::::--~gE~~~U--~r-~~L..""'---r-;JL~
II
I~01IIER\tS£tnDi DEQIIAL.S I rc:l (] I ~ DiJj E' J

~
VIEW C-C I~ I 1~ I
~ 14092
S± ~CN
71M9 WAS 71554
'lEC
OW
6/28/99
1/5/00
SECTION A-A
~~-
A II Ii 1-"0
UNLESS OTHER\\ISE HOlED:

TOI..ERANCES: DEQMAlS
FRAC1lONS:t 1 / 1 6 . X :t.l
I ~O[J TIME CONDOR CORPORATION
8300 IMPERIAL DRIVE
ANGlES :I: 1· .XX :1:.03 WACO. lEXAS 76712
SURFACE fiNISH '~ .XXX :t .010 TIllE
PRO.JECllON OF \1EWS @ CJ
REMOVE BURRS ok SHARP EOCES JIB/SKIRT ASSY, T46J/T66J
ALL DIMENSIONS ARE IN INI:HES
FIGURE 7.l:PlatfonnInstallation •

0)'
, \, Ref. 71513 ............................ PlatfonnInstallation .................................................................. Ref.
-1 71513-DWG ................. Installation DWG, Platfonn 36 x 60 .............................................. 1
2 71513-HW .................... Hardware Kit, Platfonn Installation .............................................. 1
3 71025 ............................ Platfonn Weldment; 36 x 60 .......................................................... 1
4 66095-021 ..................... Glides, Load-Bearing 1.25 00 ..................................................... 1
Ref. 71513-HW .................... Hardware Kit, Platfonn Installation ......................................... Ref.

1 BOW39055 ................... Bolt3/8-16x 1114"HexHD ......................................................... 8
2 BOW36713-HD ........... Washer, .375 SAB ....................................................................... 16
3 BOW34274 ................... Nut, 3/8-16UNC Hex Lock ........................................................... 8
A'L13-T-
\;
MANUAL 92375-003
April 1998
FIGURE 7.2:PlatfonnElectrical Installation
SECTION A-A

Ref. 71019-002 ..................... Platform Electrical Installation .................................................. Ref.
-1 71019-DWG ................. PlatformElectricalInstallationDrawing ........................................ 1
2 71368-002 ..................... Platform Control Box Assembly .................................................... 1
3 71570 ............................ 110 Volt Platform Assembly ......................................................... 1
4 71630 ............................ FootSwitchInstallation ................................................................. 1
5 71019-HW .................... Hardware Kit ................................................................................ 1
713'f6 - ffD1 z~ J;r l'-(,&J'j7-f/6 J

--:i-.5 ~p.[
,/3(; Z - (Tb').. MANUAL 92375-003
April 1998
1- ;(J/ 7 - 'to AID" II ~
FIGURE 6. 14:Jib/SkirtAssembly, T66J •

Ref. 71563 ............................ Jib/SkirtAssembly, T66J .......................................................... Ref.
1 71563-0WG ................. Jib/SkirtAssemblyOWG .............................................................. 1
2 71563-HW .................... Hardware Kit, 6' Jib Assembly ...................................................... 1
3 71563-FTG .................... Fitting Kit, 6' Jib Assembly ........................ ,................................... 1
4 71465 ............................ Pin,JibBoomlCylinder ................................................................. 1
5 71466 ............................ Pin, Jib Arm ................................................................................... 2
6 71469 ............................ Pin,JibBoomlSkirt ........................................................................ 1
7 71054 ............................ Jib Plate Weldment, 6' Jib Telescope ............................................ 1
8 71 055 ............................ Parallel Arm Weldment, 6' Jib ....................................................... 2
9 71056 ............................ Jib, Boom Weldment,6' ................................................................. 1
10 71149 ............................ SkirtWeldment, T66J ...................................................•................ 1
11 35460 ............................ Parker Platform Rotator ................................................................ 1
12 71219 ............................ Upper Bracket Weldment ............................................................. 1
13 71215 ............................ Lower Bracket Weldment ............................................................. 1
14 71027 ............................ Cylinder,6' Jib Lift ......................................................................... 1
15 71587 ............................ Pin, Slave Cylinder/Jib Plate .......................................................... 1
16 71439 ............................ Pin, T60/66 Boom Tip .................................................................... 1
17 71586 ............................ Pin, Jib Plate/Jib Boom .................................................................. 1
18 81399 ............................ Shim, Arm Lift Cylinder 86A ........................................................ 1
19 71515 ............................ Spacer, SkirtlRortator .................................................................... 1
20 71732 ............................ SkirtStop,RH ................................................................................ 1
21 71733 ............................ SkirtStop,LH ................................................................................ 1
22 71554 ............................ Oual P.O Check Valve ................................................................. 1
23 81368-36-16 .................. Garamax 2.00 10 x 2.50 00 x 1ilL ............................................... 1
24 71621-Jib ....................... Hose Kit, Jib/Skirt T66J ................................................................. 1
Ref. 71563-HW .................... Jib.skirt Installation Hardware Kit ........................................... Ref.

1 71563-0WG ................. Jib/SkirtInstallationOwg ............................................................... 1
2 BOW39011 ................... Bolt, .25-20UNC x2.75 GR8 Hex ............................................... .4
3 BOW34272 ................... Nut, .25-20UNC Nylon Lock ....................................................... 8
4 BOW39012 ................... Bolt, .25-20UNC x 3.00 GR8 Hex ................................................4
5 BOW39105 ................... Bolt, .50-13UNC x 1.25 GR8 Hex ............................................... .4
6 BOW31329 ................... Washer, 112 GRS Split Lock ...........................'............................... 4
7 BOW39060 ................... Bolt, 3/8-16UNC x 2.50 GR8 Hex ................................................ 1
8 BOW34274 ................... Nut 3/8-16UNC Nylon Lock ......................................................... 1
9 BOW33979 ................... Keystock .50 x .50 .......................................................................21
10 BOW36 102 ................... Capscrew, 112-13 x 3/4 ilL Flat Head ............................................ 4
11 BOW30030 ................... Bolt, 5/16-18UNC x 1.25 GR5 Hex .............................................. 2
12 BOW34273 ................... Nut51l6-18UNCNylon Lock ...................................................... 2
Ref. 71563-FTG .................... Jib/SkirtInstallationFittingKit .................................................. Ref.

1 71563-0WG ................. Jib/SkirtInstallationOWG ............................................................. 1
2 00456 ............................ Straight Mo06 MJ04 ...................................................................... 2
3 04630 ............................ Elbow 45 0 M006 MJ04 ................................................................. 2
4 02236 ............................ Elbow 900 M006 MJ06 ................................................................. 4
MANUAL 92375-003
April 1998
• FIGURE 7.1 :PlatformInstallation
\
(J
n--G 2PL
j
II
3
1/
~ r---
== --=-=- - =:
=
----
= = ~
I!
I' !
!
)
~ \
" / (
L ~
~ 1"
I<J J------4 if1
0RE~ \
(o,lf'
3
2
1
BOW34274
BOW36713-HD
BOW39055
/ 8,00
16,00
8.00
EA
EA
EA
NUT, 3/8-16 UNC HEX LOCK
WASHER, .375 SAE
BOLT 3/8-16 X 1 1/4" HEX HD
71513-HN HARDWARE KIT, PLATFORM INST
MANUAL 92375-003
April 1998
FIGURE 7.4:Platform Control Box Assembly •
Ref. .71368-002 ..................... Platform Control Box

' .
Assembly ...... --&,a~() A~.,........
l.........,.,.!......... f.~/l J'~H4f.
1 71592 ............................ Upper Control Box Mach .............................................................. 1
2 ...................................... Screw ............................................................................................ 4
3 71501 ........................... , Joystick, Single Axis ...................................................................... 1
4 71502 ............................ Joystick, Single Axis wlRocker ..................................................... 1
5 71503 ............................ Joystick, Dual Axis ........................................................................ 1
6 50075 ............................ Switch (Ref PIN 67760) ................................................................ 2
7 69145 ............................ Operator, Yellow Push Button ...................................................... 1
8 51913 ............................ Operator, Red Push-Pull ................................................................ 1
9 71533 ............................ Platform Control Board ................................................................. 1
10 67760-003 ..................... Toggle Switch 2 Pos Maintain ....................................................... 1
11 67760-001 ..................... Toggle Switch 3 Pos 2 Pole Man .................................................. 1
12 67760-002 .................... Toggle Switch 3 Pos 2 Man 1 Mom .............................................. 1
13 34644 ........................... Alarm ............................................................................................. 1
14 52672 ........................... Base + 1 NO Contact .................................................................... 1
15 51914 ........................... Base + 1 NC Contact .................................................................... 1
16 54257-005 .................... Light, Red Indicator ....................................................................... 1
17 71710 ........................... 6 Pin Plug For Female Pins ............................................................ 2
18 71711 ........................... 8 Pin Plug For Female Pins ............................................................ 2
19 71712 ........................... 10 Pin Plug For Female Pins .......................................................... 2
20 71713 ........................... FemaleCrimpPinForPlugs ........................................................ 48
21 54910-104 .................... Connector Mounting Base; Ag Panel ............................................ 1
22 58257 ........................... Wire, 18 Ga White .......................................................................... .
23 71740 ........................... Seal, Switch .................................................................................... 7
40 67760-003 .................... Toggle Switch 2 Pos Maintain ....................................................... 1

41 34863 ........................... White Push Button ......................................................................... 1
42 52672 ........................... Base + 1 NO Contact .................................................................... 1
43 ..................................... Push Button .................................................................................... 1
44 ..................................... Base w/Contact ............................................................................. 1
45 69146 ........................... Green Push Button .........................: ............................................... 1
46 52672 ........................... Base + 1 NO Contact .................................................................... 1
47 ..................................... Computer Board Led Readout ....................................................... 1
48 ..................................... CableRibbon ............................................................................ :..... 1
49 67758 ........................... Toggle Switch 3 Pos Maintain ....................................................... 1
50 54257-005 .................... Light, Red Indicator ....................................................................... 1
MANUAL 92375-003
April 1998
e
-
'Tj
PIN
2
1
#
COMPUTER CABLE CONNECTOR FOR .JP1
CIRCUIT # FUNCTION
10
11
STEER RIGHT
STEER LEFT
~
©
~
-J
~
mm
-e,
3 44 LIGHT SWITCH (OPTION)
4 55 PLA TFORM lEVEL (UP) I
g
o 5
JPl
1"
Jf'2
,
IIIIIOIC.t8..£PIIOWlEII
0 ~
."i
5 54 PLATFORM l.EVEL (DOWN) AS All O'OON
6 52 PLATFORM ROTATE (CW)
i~\ 0 0
7 53 PLATFORM ROTATE (CCW)
8 5 EMERGENCY PUMP C1
~
~
-~ S
9 NOT USED
® ® ~
~ JP, g
g
.~
10 NOT USED ~
~ -
JP6 _ If) 0
# CIRCUIT # FUNCTION
:~ A~iJ~ cI)
PIN
c:;
1 MF MACHINE FUNCTION SPEED
2 4W 4 WHEEL STEER (OPTION) ~
~
i
3 3A HORN ON (OPTION)
U
IJ
4 4A ENGINE ON
g
CIl
9 l
5
6
4
51
ENGINE START
GLOW PLUG ® ® 10 o I
0"'
>~ -<
7 43 ENGINE THROTTLE
8 17A FOOT SWITCH GRN WIRE TO C1-7 ©
1F: , ,
-'"
~tl
.. ~ PIN
1
2
# CIRCUIT # FUNCTION
25B
CS
ALL .JOY STICKS GROUND
CRAB STEER PIN #
COMPUTER CABLE CONNECTOR FOR JP6
CIRCUIT # FUNCTION PIN #
C1 CONNECTOR (54940-102) PINOUT
CIRCUIT# CONNECT TO IN BOX CONNECT TO OUT OF BOX
3 TS TEMPERATURE SENSOR (OPTION) 1 36 SYSTEM POWER +12 VDC 1 3 POWER (+ 12VDC) TO ESTOP C1-02 ON GROUND BOX
4 OS LED DISPLAY PANEL LIGHT SWITCH (OPTION) 2 25 SYSTEM GROUND TO C1-8 2 _,6 ESTOP C1-01 ON GROUND BOX
5 26 .JlB UP/DOWN (.JlB UNITS ONLY) 3 NOT USED 3 36 800M EXT/RET POI\£R JJMPER FOOT SWITCH BLACK WIRE
6 6 BOOM EXTEND RETRACT 4 NOT USED 4 01 JP4-5 C1-04 ON GROUND BOX
7 B SWING LEFT/RIGHT 5 2B +12 VDC TO .JP8-1 5 02 .JP4-4 C1-03 ON GROUND BOX
8 12 BOOM UP/DOWN 6 25A GROUND 6 4B STARTER SNTCH NC SIDE OF FOOT SWITCH (WHITE)
9 14 DRIVE FORWARD/REVERSE 7 NOT USED 7 17A J'H NO SIDE Of fOOT SWITCH (GREEN)
10 2A ALL .JOY STICKS +5 VDC 8 NOT USED 8 25 .JP6-2 C1-0S ON GROUND BOX
14 B6 .JUMPER TO C1-8 RETURN FROM BEACON (OPTION)
COMPUTER CABLE CONNECTOR FOR .JP4 I COMPUTER CABLE CONNECTOR FOR JP8 I 15 85 JUMPER TO C1-16 +12V TO BEACON (OPTION)
PIN #I CIRCUIT # FUNCTION I PIN # I CIRCUIT # I FUNCTION l 16 85 .JUMPER TO C1-15 CH 7 GROUND BOX (BEACON OPTION)
1
1FUTURE LJSE 1 NOT USED
GROUND FOR FUTURE OPTIONS
JL
2
1 12B
19A
1 +12VDC TO .JP6-5
TILT ALARM +
J
2
-, NOT USED .3 20 ENGINE LIGHT +
4 D2 DATA RECEIVE 4 NOT USED
5 D1 DATA TRANSMIT 5 20A AXEL LIGHTS + (OPTION)
6 NOT USED 6 NOT LJSED
"\
FIGURE 7.3:110VPlatfonnAssembly, T-Series . ,
3
o
WHT
GRN
BLK
Ref. 71570 ............................ 11 OV Platform Assembly, T-Series .......................................... Ref.

-1 71570-DWG ................. Assembly DWG, 110V IN Platform ............................................. 1
2 40956 ............................ Box, Rain Tight Single-Gang ......................................................... 1
3 66357 ............................ Receptacle, Ground Fault .............................................................. 1
4 66358 ............................ Cover, Weatherproof ..................................................................... 1
5 66136-003 ..................... StrainRelief45°-1/2-.375 .............................................................. 2
6 67123-001 ..................... Seal,ConnectorElectronicaI1l2" .................................................. 2
7 BOW31362 ................... Washer, Split Lock # 10 10 ............................................................ 4
8 BOW23075 ................... Connector, Butt 12-10GA Wire ..................................................... 5
9 BOW31146 ................... Screw, Slot, Round #10-32UNF x 1.00 ......................................... 4
10 BOW31430 ................... Washer, Flat #10 10 .................................................................... 16
MANUAL 9237S"()()3
April 1998
FIGURE 7.4:Platfonn Control Box Assembly
SEE
NOTE 3
TURRET SWING
RIGHT/LEFT
o o
4PL
MANUAL 92375-003
April 1998
DESCRIPTION
87285-038 WAS 87295-005;
87961-001 WAS 80W23027
CONNECTOR (3 PIN)
CABLE VIRE COLOR ACTUATIR WE CII.IR
BLK BLK
GRN RED
W'HT W'HT
HIGH
2"
6" BlK 65"
BlK SPEED
2"
6·'~GRN GRN AND
6"~WHT (CABLE CUT lENGTH 65")
WHT
2"
LOW
SPEED
5 65351-010 3.00 EA CABLE SEAL; 2.80 - 2.03

4 65351-135 3.00 EA TERMINAL: FEMALE FOR 14-16 GA
3 65351-045 1.00 EA CONNECTOR: 3 CONTACT MALE
2 67295-039 5.42 LF CABLE 18GA/3COND SPEC SJO
67961-001 3.00 EA TERMINAL 6 STUD 22/18GA FORK
QTY UM DESCRIPTION
nME CONDOR CORPORATION
~~ a300 IWPERlAl DRIVE
WACO. TEXAS 7e712
HARNESS, DEUTZ PANEL/ENGINE

DRA"" B BRITIAIN 9/21/118 SIZE REV.
OIECKED A A
APPROVED SEC 10/5/98
REVISION
THIS DR'_ IS THE SOLE PROPERTY OF OE~ CC»IlROLS IHC.. 10 CC»IlROLS DRIVE. SIIElTON. CT 06484. USA. THIS DOCUII£NT CONTAiNS REVISIONS
OEW PROPRIETARY INFORWAnON. WRITIDI PERWiSSKill TO USE DR DISCLOSE ANY _AnON HER8N MUST BE OBTAINED DEW. REV ERCftI "to. OESCRIPTION DAlE
",..
f1lOIj
DESCRIPTION S£E ERCH 12/5/97
11975 SEt £RCN 9/9/98
ORIGINAL PER ECN #7741
'..0, ADO \€NI)OIit OWl; a: SER\IICE p /t-I's 8/14/00
Ports List
CONDOR PIN NO -~I;""1f I DESCRIPTION IOty
71501-100 1 HANDLE I 1
71501-101 2 PLATE
71501-102 3 PLATE R-SIDE
71501-103 4 CASTING
71501 104 5 GASKET
71501 105 6 WASHER
- ---
71501 106 7 . PINS I 4
rr AWN
CliEC1<ED
AJS DATE
5,j:31 j(00 71501-107 8 SCREW I 2
71501 108 9 SLAVE GEAR
71501-109 10 BOOT
AP\ID
ENG. T 71501 110 11 ROUND KNOB
AP\ID 71501-111 12 SCREW
DESN 71501-112 13 STANDOFF
,P\ID 71501-113 14 BOOT CLAMP
SALES
PROJECTION:
at -E:3-
@ - 1'\
.::, PART NO.
SCALE N/A
loWG NO.
lSHEET 1 OF 1
A10721 IREV
J?IZE A
A 71501 114
71501-115
71501-116
15
16
17
RETAINING CLIP
WASHER
COUPLING ASSY
71501 117 18 SLEEVE
71501 118 19 PCB ASSY
~oTHtll:.S£HOn
TOLERANCES: OEClNA.LS ~o 0 T\I,4£ CON~ COftPORATl(»l
¥RACllOtG 4= l/ft .X :l.1 8300 IWPERIAL ORIV£
AHGI.£S :I: l' .)(l{ :1:.01 . WACO. 1(XA$ 76712
SURfACE f'tI&I I~'; ,leU :t .010 TITLE .
PftQ.f:ClION OF \4£W'S @c::J
~tt4OVE BUIUtS .t SHARP EOCES JOYSTICK. SINGLE AXIS
ORA"-
Mt-.l:
K SNYDER
IN INI
I 12/0/97 I B ORA.MHO fo/O.
71501
R< •.
C
......... ERCH NO. PMR SCALE 1/1.5 SHEET l'OF 1
R£IIIS<ON
REVISIONS 11_
REV ERCN NO. OESCR1PTION BY CHKI). APPR. DATE
REV. DESCRIPTION A?PROVED I DESQtIPllON 12/5/97
A I ORIGINAL PER EeN 67741 , ....

11975 DESCRIPTION
ADD \/EHDOR DWG ok SERVICE Pjl(S
' '198
8/"'100
Ports List
CONDOR PIN NO DESCRIPTION 10ly
71502-100 1 RGI HANDLE
71501 113 2 BOOT CLAMP
-1'
71501-109 3 BOOT
71501-107 4 SCREW
71501-105 5 WASHER
71501-104 6 GASKET
~A"'AJS - 'DAlE 5/31 /00 71501 103 7 CASTING
!C"ECKu> 71501-101 8 PLATE
71501-106 9 PINS
!~t' 71501-112 10 STANDOFF
APYO 71501-118 11 PCB ASSY
DESN 71501-111 12 SCREW
APYO 71501 102 13 PLATE R-SIDE
SALES
71501-108 14 SLAVE GEAR
A10722 A
@ -E3- I"" SCALE N/A
PART NO, IOWG NO, /REV
71501 116 15 COUPLING ASSY
PROJECTION: ISHEET 1 OF 1 ISiZE A 71502-101 16 TERMINAL BRACKET
71502-102 17 TERMINAL STRIP
71502 103 18 SCREW
UHIEss O'!'HEII:wtsE"iiOTED:
T~
ntlrC1IONS:t
ANCLES *' 1/16
I'
~
l(
lO(
= 1
:I: 03
I ~o nat£'CONDORCQRf'OR"TION
~IMPERIAlDRlW:
WACO. 'TEXAS 76712
SURF'4CE F1NISIi ''tit XXI( % 010 TITLE
PftOoIECnaNr:F\I£WS @c:::J
kDllM: 8UMtS .t SIWIP iIXES JOYSTICK, SINGLE AXIS W/ROCKER
B1""'_-.0: 71502
-
MA~ K SNYOER 12/:1/97 REV.
C
""""" ERCN NO. PMR ISCALE 1/1.5 SHEET 1 OF 1
REVISION
ntS ORAtwG IS n£ SOLE PROPERTY OF 001 CONlROlS It«:;., 10 CONmoLS DRI't'E. SHEI..~, CT 1l6484, USA. TItS ooc:ut.IENT CONTAINS
,_
REVISIONS
00f PROffiIETARY INFORWA'OON. '-ITT'EH PERUISSION 10 USE OR DISClOSE 1141 IffF'ORWAlION t£REIH MUST BE (IITAIIED FROM COl. REV tltCN NO.
"""""""ON BV CHl<D. A.PPft DAll:
ORIGINAL
DESCRIPTION
PER EeN 87741
APi'RO'<Ul
",..
11975
I)[SCRIPTIOH
OESCRIPTION SEC
12/5/97
9/9/98
ADO 'tIENDOR OWG .. SERlilct PjloI'S I(NCS OWW oww 8/14/00
Ports list
CONDOR PIN NO. PART# DESCRIPTION OTY
71503-100 1 r' .- JS5 ASSEMBLY 1
71503-101 2 , BEARING GEAR 2
71503-102 .3 "E" CUP 2
71503-103 4 I SCREW 4
71503-104 5 WASHER 4
71503-105 6 GATE 1
71503-106 7 SCREW 4
~
71503-'107 POT CLAMP 2
& 71503-108 9 ADAPTER 2
71503-109 10 SOUD CAP 1
(,?) Ir,AWN IDATE
71503-110 II POT ASSEMBLY 2
71503-111 12 WIRE CLAMP 1
71503-112 13 , SHAFT 2
.PVIl
ENG. MECHANICAL ASSEMBLY & PARTS LIST 71503-113 14 I BOOT 1
APVIl
DESN 71503-114 15 I BEZEL 1
.PVIl 71503-115 16 I WASHER 4
SALES ,
PRO.(CTION @ -e DWG NO.
SHEET 1 OF 1
EV
m: A
A 71503-116
71503-117
17
18 I " ..
SCREW
PIGTAIL
4
1
UHL£$S-~ Hi:iitO:
~~ 1/16 .~:I:~ ~ ~~~~~A.T'ON
ANGlES :t l' .tIC :I::.OJ ~~ WACO, TEXAS 76712
Sl,J/tP'ACE FlHISI-I llt/ .xxx t .010 TITLE
PRQ.EC'IUlN r.6 \4£WS @ c:::J
lit""'" BURRS. "':'" EOCES JOYSTICK, DUAL AXIS
I:: K SNYDER 1 12I'/i7 1B IDRA"'~ NO 71503 R£V.
C
.......... ERCN NO. PMR SCALE 1/1.75 SHEET 1 or 1
REVlSIOO
TliS DRAWING IS Tl£ sou: PROPERTY OF 001 CONTROLS INC., 10 CONTROLS DRIVE, SHELTON, CT OM8.t., USA. THIS OOCUM(lH CQNTAft.lS REV1SIONS
OEM PROPRIETARY INFORMAT\OO. \W:ITTEN Pffil.415S1ON TO USE OR OISClOS£ ANY lNFORI.4AnOO HEREIN "'U5r BE OBTAINED FROW CJE:U. REV ! EReN No.1 D£SCR:IPTION BY I CHKD. I APPR I O,t.TE
DESCRIPTION APPROVED 11298 I DESCRIPTION 12/S/g7
ORIGINAL PER EeN #7741 11975 I DESCRlPTIe»-I SEC I 9/9/98
1*04 I ADO VENDOR DWG « SERVICE PIN'S KNCS I O'tNI I OWW I e/l~/OO
17
Parts list
NO. PART# DESCRIPTiON OW
1 GG/82 JS5 ASSEMBLY 1
2 A/40 BEARING GEAR 2
3 A/204 "E" CLIP 2
4 GG/92 SCREW 4
5 C/151 WASHER 4
6 GG/4 GATE I
7 GG/6 SCREW 4
* 8
9
GG/93
GG/91
POT CLAMP
ADAPTER
2
2
* 10 A/I 77 SOLID CAP 1
11 SAPP/212 POT ASSEMBLY 2
Parts list
12 EPEH/895 WIRE CLAMP I
CONDOR PIN NO. PART# OESCRIPTION OW
13 GG/79 SHAFT 2
71503-100 1 GG/82 JS5 ASSEMBLY 1
14 GG/127 BOOT I
71503-101 2 A/40 BEARING GEAR 2
15 GG/128 BEZEL I
71503-102 3 A/204 "E" CLIP 2
16 GG/37 WASHER 4
71503-103 4 GG/92 SCREW 4
17 GG/132 SCREW 4
71503-104 5 C/151 WASHER 4
18 PTA 1 PIGTAIL 1 71503-105 6 GG/4 GATE 1
t!QIL. 71503 106 7 GG/6 SCREW 4
* ITEMS #8 & #9 NEEDS TO BE REPLACED
TOGETHER.
71503-107 8 GG/93 POT CLAMP 2
& 71503-108 9 GG/91 ADAPTER 2
riC
"l'M/\
DAlE
a:) @3 ~ 10 Coolr~s Dri.. - Shel"" Cl 06484
Conlrol., Inc. I'IIOi< (203) 929-8lJI F".: (203)929-7~
71503-109
71503-110
71503 111
10
11
12
A/I77 SOLID CAP
SAPP/212 POT ASSEMBLY
EPEH/895 WIRE CLAMP
1
2
I
71503-112 13 GG/79 SHAFT 2
'PYO
IENG. MECHANICAL ASSEMBLY & PARTS LIST 71503-113 14 GG/127 BOOT 1
APYO
IDESN
FOR JS5DM11318 CONTROLER 71503-114 15 GG/128 BEZEL 1
'PYO 71503-115 16 GG/37 WASHER 4
SALES
A 71503-116
@ -8 OWG NO. EV 17 GG/132 SCREW 4
PROJECTION: SHEET 1 OF I SIZE A 18 PTAI PIGTAIL 1
71503-117
UNLESS OlHtRWlSENOttO;
TOlERA.NCES: DEClMJ.LS ~Oa TIU( COHOOI't CORPORATION
VENDOR OEM CONTROLS FftACTIOHS:t.
ANGlES t
lj16
I"
.X
.xx
:1:.1
:t .OJ
8300 IMPERIAL DRIVE
w,t.CQ, 1D<A$ 7671.2
VPN JS5Ml1318 SUl'lf'ACE FINIS!; 12$/ ~)(l( :to 010 n1l..E
PROJECTlOlllOF'VlEl!r.> @c:::J
REWOVE SURRS .t S*1ARP Em:£S JOYSTICK, DUAL AXIS
JS5 DUAL AXIS JOYSTICK ,IUEHSIONS ARt IN IN
ORAIWoI K SNYDER I 12/!I/91 I B DRAWING NO.
71503
'EV.
e
""'"'". ERCN NO. PMR SCALE 1/1.75 SHEET 1 OF 1
REVISION
T1"US DRAWNG IS THE SOlE PROPERN or 0E1oI COOTROlS INC . , 10 CONTRCl.S DRI\{, SHELTON, CT 06484, USA... THIS DOCUMENT CONTAINS REVISIONS
OEM PROPRIETARY INFORMAnON. \\llITlEN PERMISSION TO USE OR DISCLOSE ANY INFORMAnON HEREIN MUST BE 08TAlNED FROM OEM. REV ERCN NO. DESCRIPTION DATl:
..
DESCRIPTION 11298 SEEERCN 12/5/97
ORIGINAL PER EeN #7741 , ,.

11975 SEt ERCN
ADO \l£NDOA: owe " SERVICE P/N'S
9/9/98
8/104/00
Ports List
NO PARTH DESCRIPTION Oly
1 A/292 HANDLE 1
2 A 498 PLATE 1
3 A 327A PLATE R SIDE 1
4 A/128 CASTING 1
5 A/133 GASKET 1
6 A 97 WASHER 2
7 A 51 PINS 4
8 EPSU 947 SCREW 2
9 A/46 SLAVE GEAR 1
10 A/346 BOOT 1
11 A 177 ROUND KNOB 1
12 A 252 SCREW 6
13 A 131 STANDOFF 2
14 A/130 BOOT CLAMP 1
15 A/119 RETAINING CLIP 1
16 A 360 WASHER 1
17 MSAl COUPLING ASSY 1
18 A/lll SLEEVE 1
19 ESA143 PCB ASSY 1
Ports List
19 ) ~~"-JI 'hl'-#Ai11P1f" r CONDOR PIN ND PART# DESCRIPTION I Dty
71501 100 1 A 292 HANDLE I 1
71501 101 2 A 498 PLATE
71501-102 3 A/327A PLATE R-SIDE
71501 103 4 A 128 CASTING
71501 104 5 A 133 GASKET
71501 105 6 A/97 WASHER
- - - - - - - _.. _--
ORA\IIN
;BY
CHECKED
AJS DATE 5/3-1/00 CO:> iQ)3 ~ 10 Contr~s Drive - Sh~ton, CT 06484
Controls, Inc. f'I1"'" (103)929-8431 F",.: (203)929-7546
71501 106
71501 107
71501 108
7
8
9
A/51
EPSU/947
PINS
SCREW
SLAVE GEAR
I 4
I 2
A 46
71501 109 10 A 346 BOOT
APVC
ENG. MECHANICAL ASSEMBLY & PARTS LIST 71501-110 11 A/l77 ROUND KNOB
APVD
DESN
FOR TIME CONDOR 71501 111
71501 112
12
13
A 252
A 131
SCREW
STANDOFF
13 ) ( " \ I "'11_ ~jf<'JI -
./I' --- APVC
SALES
MS4M11320 CONTROLLER 71501 113 14 A 130 BOOT CLAMP
A10721 71501-114 15 A/119 RETAINING CLIP
@ E3- I"" SCALE N/A
PART NO. IDWG NO. IREV A 71501 115 16 WASHER
PRO&:CnON ISHEET 1 OF 1 ISIZE A Aj360
71501 116 17 MSAl COUPLING ASSY
71501 117 18 A/lll SLEEVE
71501-118 19 ESA143 PCB ASSY
UNLESS OlHtlI:YI'ISE NOTE!):
TOLERANCES: O£CII,IALS ~Da TIME CONI>ClR CORPORATION
F"RAC.TIONS i: 1/1' .x *-.\ 8.300 IMPERIAL ORI\IE
VENDOR OEM CON TROLS ANGlES t: I' )Ix :t: .Ol WACO, TE)(AS 76712
VPN MS4M11320 SURFACE ~NISI-I !~I ~l(l( :t:.Q10 mu:

Pli!O.£CTlON OF" 'A£\IIS @ c::J
".". "'''' ~~::~N"'''' JOYSTICK, SINGLE AXIS
MS4 SINGLE AXIS JOYSTICK
I:: K SNYOER I "/>I" IBI'""'"" NO 71501
REV,
C
A,PPRO\CI ERCN NO. PMR SCALE 1/1.5 SHEET 1 OF 1
REVISION
ll<S DRAWING IS THE SOlE PROP£RTY Of OEM CONTROlS INC., 10 CONTROLS MVE, SHf:LTON, CT 06484, USA. ll<S DOCUMENT CONmNS REVISIONS REV ERCN NO OESCRIPTION OAll:
OEM PROPRlETARY INfORMATION. I\flITlEN PERMIS~ON TO USE OR DiSCLOSE ANY INfORMATION HER8N MUST BE OBTAINED fROIoI OEM,
11298 OESCRIPTION 12/5/97
DESCRIPTION
ORIGINAL PER EeN #7741
'" .
11975
, ""
DESCRIPTION
ADD VENDOR: DING &: SERVICE PIN'S
9/9/98
8/14/00
Parts List
NOl PART# DESCRIPTION Oty
RG1M9704 RGI HANDLE 11
A/130 BOOT CLAMP
A 346 BOOT
4 EPSU/947 SCREW
5 A 97 WASHER 12
6 A/133 GASKET
7 A 128 CASTING
8 A 498 PLATE
9 A/51 PINS
10 A/131 STANDOFF
11 ESA143 PCB ASSY
12 A 252 SCREW
13 A/327A PLATE R-SIDE
14 A/46 SLAVE GEAR
15 MSAI COUPLING ASSY
TERMINAL BRACKET
TERMINAL STRIP
SCREW
Parts List
CONDOR P N DESCRIPTION Oty
71502-100 RGI HANDLE
71501-113 A 130 BOOT CLAMP
71501-109 3 A 346 BOOT
71501-107 4 EPSU 947 SCREW
71501-105 5 A 97 WASHER
71501-104 A 133 GASKET
~~A\\N AJS -OAft S/31/00 <:::::-0--==» ~~ 10 C""trols Dri., - Shelton, CT 06484 71501-103 7 A 128 CASTING
CHEC1<ED Controls, Inc. PIIcne: (203) 929-8431 fox,: (203)929-7546 71501-101 8 A 498 PLATE
71501-106 9 A 51 PINS 4
APVf)
ENG MECHANICAL ASSEMBLY & PART LIST 71501-112 10 A 131 STANDOFF
71501-118 11 ESA143 PCB ASSY
APVf)
DESN
FOR TIME CONDOR 71501-111 12 A 252 SCREW
APVf)
SALES
MS4M11319 CONTROLLER 71501-102 13 A 327A PLATE R-SIDE
71501-108 14 A 46 SLAVE GEAR
A10722
@ -E3- J~ SCALE N/A A
PART NO. IDWG NO. IREV
PROJECTION: 71501-116 15 MSAI COUPLING ASSY
lSHEET 1 OF 1 JsIZE A 71502-101 16 A 644 TERMINAL BRACKET
71502-102 17 BB 66 TERMINAL STRIP
71502-103 18 V/2:1 SCREW
UltLESS OTHERWISE NOTED·
TOLtR~:
FRAC1IONS!:
A/fGlES .t:
1/16
)"
DECIMALS.
.x
.)lX
i:: 1
r.OJ
I ~D0 TI~E CONOOR CORPORAnON
8300 IMPERIAL DRIVE
WACO, TEXAS 76712
Si...!l'WACE FINISH \2$/ xxx ± .010 TITLE
VENDOR OEM CONTROLS PRo.£cnON OF IIlEWS @ c:J

R(I;I(JYE BURRS .t: SHARP EOC£S JOYSTICK, SINGLE AXIS W/ROCKER
VPN MS4M11319 :tf$lONS ARE IN ~CHtS
DRA"fIN K SN YDER REV.
MS4 SINGLE AXIS JOYSTICK WI ROCKER CHEc!<;EO 71502 C

J..PPItO~ SCALE 1/1.5 SHEET 1 OF 1
\ r- PLATFORM PLATFORM 4-WHEEL
©1Ji-~U;SC
'--_/ ROTA TE LEVEL STEER
r~ ~I l-'--rJ2 SJ)J 5 ----~~.~ ~

.16 "lU
.---J
~I 'l ~
J6--------1
@ @
ill .. 5 2
o
r+---'~----''1I:::~L:::::1F
r-.t-4 4 1 4A CHECK ('.nNTROUIR BOo\RO CHECK COlTROIl[R BOARD
H~ 5.1K OHM RESISTORS FOR 5.11( 0... RESISTORS
R[FIR 10 owe 71726 RErERTOO'«<;7172S
'l
ill I
>~
11:
-'" d~
8J ~
'l
0 o
:8tl
.~ ENGINE
RPM
~~:~ II
"Tj
i
11111011
~
~
oj
!Q
j---J
5 CH[O( r.QNlR(ll(R BOMD -...J

i
E~~ff -,~ III ~lllWJ] "is ~
FOR 5.1K tJit.t RESlST(J!S
116
.~ I~
REfER TO owe 71726
111111 !1l
::!2
~ 5
,.. ~
~
u
~
~
~ BUtT
~ ~
z §
j "' ::~'
o
~
:z: E-
e
~
'rr-rf"f,?I;I
1'1 ................. 1
N
J, ~
N N .- .-
J. .!. ~ ~
01
Q
tg '" .. ij
H~~ ~ 9;:~::u~
'fJ: 9; 9; &!;;!Js
~
,J,~
~
::
-~
0,'
~ 0;0,
E E
01;
~o
E QS' ~ 81-l-1- ....
NI'1NIfl..,.
~ I-
to
f2
~ ~
~ 8 ~ 8 8
o
nITn! II r i
~~
t1 :;j?~.:!1~ ~ ~~
:<l ~'l ~~
I i 1111 I II II II II
g.~
-<
o
OJ FIGURE 7.5.:FootSwitchInstallation
GREEN
I,,'HITE
FULL GUARD BLACK
#522-\v'16-1
wIRING DIAGRAM
~ CDRDSET ff534-J4-3
BASEPAD #522-P1J-J
Ref. 71630 ............................ Foot Switch Installation ............................................................ Ref.

-1 66751 ............................ Foot Switch w/Guard + Cable ....................................................... 1
-2 34667 ............................ Retainer, Foot Switch 77/8 ........................................................... 1
MANUAL 92375-003
April 1998
FIGURE 8.1:ChassisCoverAssembly •
6PL~
~-"'-+-iJ--+----+- I 4
NOTES:
1. (;)s USED TO CALL OUT PIECE PARTS FOR THE HARDWARE KIT.
Ref. 71451 ............................ Chassis Cover Assembly ........................................................... Ref

-1 71451-DWG ................. Chassis Covers Drawing ............................................................... 1
2 71451-HW .................... Hardware Kit, Chassis Covers ...................................................... 1
3 71340 ............................ Cover, Chassis Side ....................................................................... 2
4 71338 ............................ Cover, Chassis Rear ...................................................................... 1
5 71337 ............................ Cover, Chassis Front ..................................................................... 1
71451-HW .................... Hardware Kit, Chassis Covers ....................................................... .

1 71451-DWG ................. Dwg, Chassis Covers .................................................................... 1
2 BOW91666 ................... Nut, .25-20 Zinc PLT Acorn ....................................................... 20
MANUAL 92375-003
April 1998
\
FIGURE 9.1:FiberglassDoorAssembly
16
:3
SECTION A-A

Ref. 71392 ............................ Fiberglass Door Assembly ........................................................ Ref.
-1 71392-DWG ................. Fiberglass Door Assembly Drawing .............................................. 1
-2 71392-HW .................... Hardware Kit ................................................................................ 1
3 71198-1 ......................... Turret Cover, Left Side ................................................................. 1
4 71198-2 ......................... Turret Cover, Right Side ................................................................ 1
5 71773 ............................ Weldment, Turret Cover Mount Lower RH .................................. 1
6 71772 ............................ Weldment, Turret Cover Mount Lower LH .................................. 1
7 71771 ............................ Weldment, Turret Cover Mount Upper RH .................................. 1
8 71770 ............................ Weldment, Turret Cover Mount Upper LH .................................. 1
9 71275 ............................ Gas Shock Assembly, Cover ......................................................... 4
10 71741 ............................ Hinge,CoverDrilled ...................................................................... 4
11 71039 ............................ Turret TraylDoor Latch Plate ....................................................... 1
12 71774 ............................ Latch Bracket, Engine Side ........................................................... 1
13 71750 ............................ Bracket, Cover Mount RH ............................................................ 1
14 71742 ............................ Bracket, Cover Mount LH ............................................................ 1
15 71580 ............................ BoltPlate, Hinge ............................................................................ 4
16 71581 ............................ Gasket, Bolt Plate .......................................................................... 4
17 71756 ............................ Guard, TurretRH .......................................................................... 1
18 71757 ............................ Guard, TurretLH .......................................................................... 1
-19 71779 ............................ Cup Latch, Mod ............................................................................. 1
MANUAL 92375-003
April 1998
FIGURE 9.2:GasCoverShockAssembly •
Ref. 71275 .•.......................... Gas Cover Shock Assembly .........................................•........... Ref..
-1 71275-DWG ... :............. Gas Shock Assembly Drawing, Cover .......................................... 1
-2 71275-001 ..................... Gas Shock, 200LBS wlMale Ends ................................................ 1
-3 71275-002 ..................... End Fittings, Female Attachment ................................................... 2
MANUAL 92375-003
April 1998
• FIGURE 10.1 :ManualInstallation
1 0 01
I 1
1 1
1 1
I 1
I 1
MANUAL 92375-003
April 1998
FIGURE 1O.1:ManualInstallation •
Ref. 71519 ............................ Manual Installation .................................................................... Ref.

-1 71519-DWG ................. ManuaIInstallationDrawing .......................................................... 1
2 71519-HW .................... Hardware Kit ................................................................................ 1
3 54699 ............................ Container, Manual Storage ............................................................ 1
4
5 92375-001 ..................... Operator's Manual ......................................................................... 1
6 A630-T60-0 1 ................ Manual, M-T60-0 1 OplMaintlParts ............................................... 1
MANUAL 9237S'()()3
April 1998
• FIGURE 11.1 :Decal Kit, T60-0 1
1 i
MANUAA': 92375-003
pnll998
FIGURE 11.1:Decal Kit, T60-01 •

. .
Ref.' 71491 ............................ Decal Kit, T60-01 ...................................................................... Ref
-*1 71491-100 ..................... DecaIKit,M-T60-01 Essential ...................................................... 1
-*2 71491-DWG ................. InstallationDWG,DecaIM-T60-01 .............................................. 1
*3 67938-080 ..................... Decal, 80 PSI Tire Pressure ......................................................... .4
67938-075 ..................... Decal, 75 PSI ................................................................................ 4
*4 54984-004 ..................... Decal, Lift And Tie Down ............................................................. 4
*5 56023 ............................ Decal, 7.00" High Arrow ............................................................... 2
*6 56024 ............................ Decal, 2.50" High" Forward" ....................................................... 2
*7 21882-001 ..................... Decal, EI Hazard Keep Clear ........................................................ 2
*8 21849 ............................ Decal, Unleaded Gas Only ............................................................ 1
15376-012 ..................... Decal, Diesel ................................................................................. 1
*9 71799 ............................ Decal,HydraulicFluid ................................................................... 1
*10 71618 ............................ Decal, Lower Caution Boom ......................................................... 2
*11 54984-006 ..................... Decal, 110 Volt EXT To Platform ................................................. 1
*12 21079 ............................ Decal, Lube Fitting ........................................................................ 1
-* 13 71795 ............................ Decal, T60 Transportation ............................................................. 1
*14 71614 ............................ Decal, Boom Upper Caution ......................................................... 1
*15 37958-500 ..................... Decal, 500 LB Rated Work Load ................................................. 2
*16 56034-500 ..................... Decal, 500LBS Rated Work Load ................................................ 1
*17 71826 ............................ Decal, Boom Down ....................................................................... 1
*18 38550 ............................ Decal, Platform Fall Arrest ........................................................... 2
*19 71369 ............................ Decal, Platform Control Box ......................................................... 1
*20 71370 ............................ Decal, Lower Control Box ............................................................ 1
. *21 71589 ............................ Decal, Error Code Turret .............................................................. 1
*22 71617 ............................ Decal, Ground Board Lights .......................................................... 1
*23 56033 ............................ Decal, 3.5" High Twin Stripes ........................................... 12.23LF
24 71765 ............................ Decal, T60 Gry .............................................................................. 2
71765-1 ......................... Decal, T60Blk ............................................................................... 2
25 55941-017 ..................... Decal, 17x2.5" Condor Bird ........................................................ 1
26 55940-060 ..................... Decal, Condor 9 x 60 Gray ............................................................ 1
*27 71768 ............................ Decal, Boom Ext........................................................................... 1
*28 71767 ............................ Decal, Boom Raised Fully ............................................................. 1
29 71785 ............................ Decal,)totation Stop ...................................................................... 2
*30 71856 ............................ Caution Decal, Hi to Low Speed ................................................... 1
-50 15843 ............................ Nameplate, Boom Identification .................................................... 1

51 56022 ............................ Decal, 4 x 4 ................................................................................... 2

*Indicates Items In Essential Decals
MANUAL 92375-003
April 1998
FIGURE 11.1 :Decal Kit, T60-0 1
14
16
21 22
\
)
MANUAL 92375-003
April 1998

,-
Ref. 71491 ............................ Decal Kit, T60':'01 ...................................................................... Ref
-*1 71491-100 ..................... Decal Kit, M-T60-0 1 Essential ...................................................... 1
-*2 71491-DWG ................. InstallationDWG,DecaIM-T60-0l .............................................. 1
*3 67938-080 ..................... Decal, 80 PSI Tire Pressure .....................................................'..... 4
67938-075 ..................... Decal, 75 PSI ................................................................................ 4
*5 56023 ............................ Decal, 7.00" High Arrow ............................................................... 2
15376-012 ..................... Decal, Diesel ................................................................................. 1
*10 71618 ............................ Decal, Lower Caution Boom ......................................................... 2
*11 54984-006 ..................... Decal, 110 Volt EXT To Platform ................................................. 1
*12 21079 ............................ Decal,LubeFitting ........................................................................ 1
-*13 71795 ............................ Decal, T60 Transportation ............................................................. 1
*17 71826 ............................ Decal, Boom Down .............\, .......................... :.............................. 1
*18 38550 ...........•................ Decal, Platform Fall Arrest ........................................................... 2
*19 71369 ............................ Decal, Platform Control Box ......... ~............................................... 1
*21 71589 ............................ Decal, Error Code Turret .............................................................. 1
24 71765 ............................ Decal, T60Gry .............................................................................. 2
71765-1 ......................... Decal, T60BIJ<;: ............................................................................... 2
25 55941-017 ..................... Decal, 17x2.5" Condor Bird ........................................................ 1
*27 71768 ............................ Decal, Boom Ext. .......................................................................... 1
*28 71767 ............................ Decal, Boom Raised Fully ........................... ,................................. 1
29 71785 ............................ Decal, Rotation Stop ...................................................................... 2
*30 71$56 ............................ Caution Decal, Hi to Low Speed ................................................... 1
-50 15843 ............................ Nameplate,BoomIdentification .................................................... 1

51 56022 ............................ Decal, 4 x 4 ................................................................................... 2

MANUAL 92375-003
April 1998
• FIGURE 11.1:Decal Kit, T60-01
l ~
[]g[[J[I[JLJ2JQ .
-~
•
v-------
-- ~
@
~ "--
MANUAL 92375-003
April 1998

Ref. 71491 ............................ DecaIKit, T60-01 ...................................................................... Ref
-*1 71491-100 ..................... Decal Kit, M-T60-01 Essential ...................................................... 1
-*2 71491-DWG ................. InstallationDWG,DecaIM-T60-01 .............................................. 1
*3 67938-080 ..................... Decal, 80 PSI Tire Pressure .......................................................... 4
67938-075 ..................... Decal, 75 PSI ................................................................................ 4
*5 56023 ............................ Decal, 7.00" High Arrow ............................................................... 2
15376-012 ..................... Decal, Diesel ................................................................................. 1
*10 71618 ............................ Decal, LowerCautionBoom ......................................................... 2
*11 54984-006 ..................... Decal, 110VoltEXTToPlatform ................................................. 1
*12 21079 ............................ Decal, Lube Fitting ........................................................................ 1
-*13 71795 ............................ Decal, T60Transportation ............................................................. 1
*17 71826 ............................ Decal, Boom Down ....................................................................... 1
*18 38550 ............................ Decal, Platform Fall Arrest ........................................................... 2
* 19 71369 .................... ;....... Decal, Platform Control Box ......................................................... 1
*21 71589 ............................ Decal, Error Code Turret .............................................................. 1
24 71765 ............................ Decal, T60Gry .............................................................................. 2
71765-1 ......................... Decal, T60 Blk ............................................................................... 2
25 55941-017 ..................... Decal, 17 x 2.5" Condor Bird ........................................................ 1
*27 71768 ............................ Decal, Boom Ext. .......................................................................... 1
*28 71767 ............................ Decal, Boom Raised Fully ............................................................. 1
29 71785 ............................ Decal, Rotation Stop ...................................................................... 2
*30 71856 ............................ Caution Decal, Hi to Low Speed ................................................... 1
-50 15843 ............................ Nameplate,BoomIdentification .................................................... 1

51 56022 ............................ Decal, 4 x 4 ................................................................................... 2

MANUAL 92375-003
April 1998
• FIGURE 12.1:A506NissanLP/GasDuaIFuel(Liquid)
REF STANDARD AIR

CLEANER
INTAKE HOSE
TO CARBURATOR
FUEL LINE
TO CARBURA TOR
2 PL
SEE NOTE 2
SEE NOTE 2
2 PL
TO PLATFORM
CONTROL BOX
53
21
SEE NOTE 4 2 Pl
...____-1+--- WA TER PUMP

WA TER JACKET
63
TO PLATFORM
CONTROL BOX
31A
TO OIL i?71
PRESSURE SWITCH 31 6
TO ENGINE
CONTROL BOX ENGINE FRONT VIEW
61
LP (LIQUID) TANK
NOTES:
1. ITEMS 4 & 5 ARE LOCATED IN PLTFRM CNTL BOX.
2. CONNECT A GROUND WIRE FROM EACH OF THE
GROUND SCREvVS ON ITEM 1 (FIL TERLOCK BODY)
AND ITEM 2 (SHUTOFF VALVE BODY) TO AN
ACCEPTABLE GROUND SPOT ON ENGINE.
3. REF DWG 38356.
4. SPLICE "T" CONNECTOR IN EXISTING CARBURETOR/
DISTRIBUTOR VACUUM HOSE.
5. ITEMS 51 THRU 61 ARE PARTS OF ITEM 33 AND
ARE FOR REF ONLY.
MANUAL 92375-003
April 1998
FIGURE 12.1:A506NissanLP/GasDualFuel(Liquid) •

Ref. 71729 ............................ A506 Nissan LP/Gas Dual Fuel (Liquid) ................................... Ref
1 51630 ............................ FilterLock FL-218 LP-Gas ............................................................ 1
2 68097 ............................ Valve, Gasoline Shut Off ............................................................... 1
-3 71725 ............................ Installation Dwg, Tank Assembly, LP Liquid ................................ 1
4 52029 ............................ Base + 2 NO Contacts .................................................................. 1
5 52670 .... :....................... Operator, 3 Pos Rot. ...................................................................... 1
6 71526 ............................ HHFC Installation, A506Nissan ................................................... 1
-7 71729-DWG ................. lnstallationDrawing,A506-TNSSN-l ........................................... 1
8 02453 ............................ Tee, FP6 FP6 FP6 ......................................................................... 1
9 BOWI1101-X ............... Elbow, Street 900 Brass 3/8 NPT ................................................. 3
10 04727 ............................ Straight, MS06MP04 .................................................................... 2
11 02795 ............................ Connector, Male 114 NPT x 3/8 HC ............................................. 1
12 BOW24110 ................... Clamp, Hose 5116-7/8 Dia '" .......................................................... 8
13 BOW36001 ................... Bolt, Hex .25-20 UNC x %/8 Lg ................................................... 2
14 BOW31201 ................... Nut, Hex .25-20 UNC ................................................................... 2
15 BOW36725 ................... Washer, Split Lock .251D .............................................................. 2
16 BOWI1099-2 ................ Nipple, .125 NPT x 2.00 Brass ...................................................... 1
17 37084 ............................ Bracket Weldment, LPlFuel Tanks ............................................... 1
18 BOW31144 ................... Screw, Socket Rd #10-32 UNF x .50 ........................................... 1
19 BOW13350 ................... Bushing, 3/8 x 1/4 .......................................................................... 1
20 BOW00282 ................... Connector, T 25 x .18 x .18 ........................................................... 1
21 BOW09757 ................... Tubing, Vacuum .25 ID Low Pressure ................................... lLF.
22 BOW11573 ................... Hose Barb, 114 NPT x 1/4 ID ....................................................... 1
23 BOWIII00 ................... Street Elbow, 114 NPT .................................................................. 1
24 02458 ............................ Tee, MP04 FP04 FP04 .................................................................. 1
25 BOWI0838 ................... Elbow, 45 0 • 125NPT Street Brass ................................................. 1
26 BOW13348 ................... Bushing, 1/4 x 1/8 M ...................................................................... 1
27 67957 ............................ Filter, Fuel Inline Bubble ................................................................ 1
28 02699 ............................ Straight, MP06-MP06 .................................................................... 1
29 38501-076.00 ................ Hose Assembly, #06 04167 LPG .................................................. 1
30 66818 ............................ Hose, Bulk #10 LPG .......................................................... 2.33LF.
31 66833 ............................ LP Kit, Nissan HIS ....................................................................... 1
32 38708 ............................ Clamp, Loom 1.. 50 Dia .5 Hole ..................................................... 1
33 67280 ............................ Bosch Relay .................................................................................. 1
34 BOW31233 ................... Nut, Keps #10-32 UNF ................................................................. 1
51 66833-026 ..................... Switch, Vacuum Dual Fuel ....................................................... Ref.

52 66833-0 I 0 ..................... Vaporizer Regulator Liquid ...................................................... Ref.
53 66833-029 ..................... Hose Barb, #06 x Male 114-19 HS ........................................... Ref.
54 66833-013 ..................... Clamp, Hose 3/4 to 1 3/4 Dia ................................................... Ref.
55 66833-005 ..................... Hose, 3/8 ID Fuel Line ............................................................. Ref.
56 66833-005 ..................... Hose, 3/8 ID Fuel Line ............................................................. Ref.
57 66833-023 ..................... Carburator Adapter, LPG ......................................................... Ref.
58 66833-012 ..................... Clamp, Hose 2 ID to 2.25 ID ................................................... Ref.
59 66833-007 ..................... Hose Barb, #10 x 3/8 NPT ...................................................... Ref.
60 66833-027 ..................... Elbow, Male 1/4 NPT x 3/8 HC ............................................... Ref.
61 66833-030 ..................... Hose Barb, #06 x Male MI0-1.25 HS ..................................... Ref.
MANUAL 92375-003
April 1998
• FIGURE 12.2:4WDManifoldInstallation
4 5 2PL
- -- -
II
I
I
I
I
lr
II
I I
/ I I
--~
I I
I I
I I
_______u_______ _I I
NOTES
1. D IS LJSED TO CALL OUT PIECE PARTS FOR THE FITTING KIT.
e::> IS USED TO CALL OUT PIECE PARTS FOR THE HARDWARE KIT.
MANUAL 92375-003
April 1998
FIGURE 12.2:4WDManifoldlnstallation •

Ref. 71455 ............................ 4WDManifoldlnstallation ........................................................ Ref.
-1 71455-DWG ................. AssemblyDrawing, Drive Manifold .............................................. 1
-2 71455-FTG .................... FittingKit ....................................................................................... 1
-3 71455-HW .................... Hardware Kit ................................................................................ 1
4 71424 ............................ Drive Manifold BracketWeldment ............................................... 1
5 71048 ............................ DriveManifold,4WD .................................................................... 1

-1 71455-DWG ................. 4WDManifoldInstallationDrawing .............................................. 1
2 BOW39 106 ................... Bolt, 1I2-13UNCx 1.50"L ............................................................. 4
3 BOW34284 ................... Nut, 1I2-13UNC Stop Elastic ........................................................ 4
4 BOW30053 ................... Bolt, 3/8-16UNC x 7/8"L ............................................................... 2
5 BOW31327 ................... Washer, 3/8"ID Split Lock ............................................................. 2

-I 71455-DWG ................. 4WDManifoldlnstallationDrawing .............................................. 1
2 04051 ............................ Straight, MJI0M012 .................................................................... 4
3 00267 ............................ Straight,MJI2MOI2 .................................................................... 4
4 02579 ............................ Straight, MJ16M016 .................................................................... 2
5 00456 ............................ Straight, MJ04 M006 .................................................................... 2
6 00344 ............................ Tee, MJ04 FJ04 MJ04 ................................................................... 3

fliPot/-T6D-/
MANUAL 9237S"()()3
April 1998
e
>~
'2:F:
.
--0
:Eel
...,
---' ~ --~ _.-

--_.... I
I:HOSIlii_
~ 1M~1XIII"tIU._
~:1 ~ =."=~=
_. (] 0
=:-: :t-
___ ." ...... 1_lIU
Almi),' I'IIO.E~IF_ 8c::J T-ELECTRICAL SCHEMATIC

UR. o.~~7tJIQ. ~/M C 71675 IItA
.,
i:;; 0 !
••
~,.
,Iii II III
I I
I I
;!;
!I!!
lAIIIl llJH,~ i 111MllldO
MANUAL 92375-003
April 1998
NOTES:
1, VENDOR SHALL TAG ACH HOSE ASSY AT BOTH ENDS WITH A LABEL STATING
e
~'<
\~c, \"'0,~ \"'0,,<
KIT PIN - OWG REV - ITEM NUMBER
EXAMPLE: 71015-A-l0 WOULD MEAN FROM
~4'> ~4'> ",4'> HOSE KIT: "71015"
DWG REV: "A"
",,0, ",,0, ",,0, ITEM #: "10"
A~
-:f'.t. tJI' ~." ~~
2, LENGTHS ON ITEMS 26-31 ON THE A653-1 OPTION TO BE PROTOTYPED,
~.t.... ~~.
CO'" <}- coO ,,'v ",<:> ,,'v
,'?' ,p ,'?' ~O ,0, ~O
."'12 66712-XXX 1,00 EA HOSE ASSY, #06 66645 J37 ST -90' 4 STEER VALVE ROTARY COUPLING
,il 66712-XXX 1,00 EA HOSE ASSY, H06 6664.'1 J."U ST-9O' 4 STEER VALVE ROTARY COUPLING
,iO 66712-XXX 1.00 ; EA HOSE ASSY, #06 66645 J,17 SI-90' 4 STEER VALVE END STEER CYL
29 66712-XXX 1.00 ; EA HOSE ASSY, #06 66645 J37 51-90' 4 STEER VALVE END STEER CYL
HOSE ASSY, #06 66645 J37 ST -90' RIGHT STEER CYL RIGHT STEER CYL
~ ~~12-XXX 1.00 EA
:~ioo
27 66712-XXX 1.00 EA HOSE ASSY. #06 66645 J37 ST -90' LEFT STEER CYL RIGHT STEER CYL
26 66696-156,00 1.00 EA HOSE ASSY, #04 66646 J37 ST-ST RIGHT FRONT DRIVE MOTOR BRAKE DRIVE MANIFOLD BRAKE
25 65,"\68-162,00 1.00 1.00 EA HOSE ASSY, #10 66743 ,137 STM-90' RIGHT FRONT DRIVE MOTOR BOTTOM 90 DRIVE MANIFOLD M,l 90
24 65,i68-153,00 1.00 1.00 EA HOSE ASSY, #10 66743 ,137 STM-90' RIGHT FRONT DRIVE MOTOR TOP 90 DRIVE MANIFOLD M4 90
CASE #3 RIGHT
23 66700-143,00 1,00 1.00 EA HOSE ASSY. #06 66645 J37 ST -ST,I RIGHT FRONT DRIVE ROTARY COUPLING ST,I
DRAIN INSIDE TEE
CASE g,; RIGHT
22 66700-1.)2,50 1.00 1,00 EA HOSE ASSY, #06 66645 J37 ST-ST,I LEFT FRONT DRIVE MOTOR ROTARY COUPLING ST,I
DRAIN INSIDE TEE
21 66696-147,00 1,00 , 1,00 EA HOSE ASSY, #04 66646 J37 ST-ST LEFT FRONT DRIVE MOTOR BRAKE DRIVE MANIFOLD BRAKE
20 65368-141.00 1,00 1.00 EA HOSE ASSY, #10 66743 ,l.i7 STM-90' LEFT FRONT DRIVE MOTOR BOTTOM 90 DRIVE MANIFOLD M5
>~ 19 65368-133,00 1.00 1.00 EA HOSE ASSY, #10 6674,; ,137 STM-90' LEFT FRONT DRIVE MOTOR TOP 90 DRIVE MANIFOLD M6
18 65369-036,75 1,00 1.00 1.00 EA HOSE ASSY, #16 65366 ,137 ST-90' DRIVE MANIFOLD A 90 ROTARY COUPLING #1
'2:F: 17 71687 1,00 1.00 1,00 REF HARDLlNE#16. MANIFOLD/ROTARY DRIVE MANIFOLD B ROTARY COUPLING #2
-'"
:8tl 16 66712-058,00 1.00 I 1.00 1.00 EA HOSE ASSY, #06 66645 J37 ST 90' DRIVE MANIFOLD T 90 ROTARY COUPLING #4 90
...... 15 66696-058,00 1.00 1,00 1.00 EA HOSE ASSY, #04 66646 J37 ST -ST RIGHT REAR DRIVE MOTOR BRAKE 90 DRIVE MANIFOLD BRAKE
~ 14
1.1
65368-043,50
65368-035,50
1.00
1,00
;
i
1.00
1.00
1,00
1.00
EA
EA
HOSE ASSY, #10 66743 J37 STM 90' RIGHT REAR DRIVE MOTOR
HOSE ASSY, #10 66743 J37 STM-90' RIGHT REAR DRIVE MOTOR
BOTTOM
TOP
90
90
DRIVE MANIFOLD
DRIVE MANIFOLD
MR2
M2
90
90
CASE #3 RIGHT
12 66700-087,00 1.00 1,00 1.00 EA HOSE ASSY, #06 66645 J37 ST -ST,I RIGHT REAR DRIVE MOTOR ROTARY COUPLING 5T
DRAIN OUTSIDE
CASE #3 LEFT
11 66700-087,00 1.00 ! 1,00 1.00 EA HOSE ASSY, H06 66645 J37 ST-STJ LEFT REAR DRIVE MOTOR
DRAIN
ROTARY COUPLING
OUTSIDE
STJ
10 66696-05B,00 1,00 1.00 1.00 EA HOSE ASSY, #04 66646 J37 5T-ST LEFT REAR DRIVE MOTOR BRAKE DRIVE MANIFOLD BRAKE
9 65.168-034,50 1,00 1.00 1,00 EA HOSE ASSY, #10 66743 ,137 STM 90' LEFT REAR DRIVE MOTOR BOTTOM 90 DRIVE MANIFOLD MRl 90
8 65368-035.50 1.00 1,00 1.00 EA HOSE ASSY, #10 66743 J37 STM-90' LEFT REAR DRIVE MOTOR TOP 90 DRIVE MANIFOLD Ml 90
7 66712-054,50 1.00 1.00 1.00 EA HOSE ASSY, H06 66645 J37 ST -90' 2 STEER VALVE Vl 90 ROTARY COUPLING #5
6 66712-062,75 1.00 1.00 1,00 EA HOSE ASSY, #06 66645 J37 ST-90' 2 STEER VALVE V2 90 ROTARY COUPLING #6
5 66712-028,50 1.00 1,00 1,00 EA HOSE ASSY, H06 66645 J.l7 ST -90' 2 STEER VALVE C2 90 END STEER CYL CAP
4 66712-028,50 1.00 I 1.00 HOSE ASSY, H06 66645 J37 ST -90' 2 STEER VALVE 90 END STEER CYL CAP
1.00 EA Cl
3 66712-030,50 1.00 I 1.00 1.00 EA HOSE ASSY, #06 66645 J.l7 ST-90' RIGH T STEER CYL ROD 90 RIGHT SIEER CYL CAP
2 66712-030.50 1.00 I 1.00 1,00 EA HOSE ASSY, #06 66645 J,17 ST -90' LEFT STEER CYL ROD 90 RIGHT STEER CYL CAP
1 71015-DWG 1.00 ! 1,00 1.00 EA HOSE KIT OWG, CHASSIS
LOCATION A PORT HOSE END LOCATION B PORT HOSE END
ITEM PART NUMBER OTY i OTY QTY UM DESCRIPTION
UNLESS O'J'H£R'MS£ NOTED'
OIV'StOH OF Tl~E IIIFG. CO.
TOLERANCES:
FRACT!OHSi:
ANGlES
1/16
'* '" .XI(
..,
OEClIIIAlS
,X
:i .o.~
~ 8300 lIdPERII\l DRIVE
WACO. TEXAS 76712
!
xxx", .01 OnTlE
SURrAtt FlNISH ."/
PROJEcnCIN OF VIEWS @ CJ HOSE KIT INST DWe, CHASSIS
A 11851 ALL OtIolENSIONS ARt ""INCHES
l TIt
-
D.C.N. NO.
'1629
DATE
4/16/911
APPR
,IHB
DR""
CHECKED
K SNYDER
J
1/8/'7
SrMNGNO 71015 rEA i
LTR. O.R.N. NO.
0'" APPR. APPROVED JH8 I 4/115/9" SCALE 1/1 ISHEET 1 OF 1 I
7
4
~~O=',18
I '
i
NOTES:
1. VENDOR SHALL TAG EACH HOSE ASSY AT BOTH ENDS WITH A LABEL STATING
KIT PIN - owe REV - ITEM NUMBER
EXAMPLE: 71619-STD-A-l0 WOULD MEAN FROM
HOSE KIT: "71619-5TO"
DWG REV: "A"
ITEM #: "10"
'O'O~ <;) 5 00 6 :
'O~\ Q\'O " 00: 4 I
A.,.'fJi. "I>i 1 -zl '
f?;-'<t- f?;-'<t-
I'~ ~".
'
<." /4'-Q ~~.<."
'
~
BULKHEAD ON TURRET
''',,~ ," ,,«..
'1,'0 0x:- '1,'0 X:-0
HOSE AS5Y, H04 66646 ,137 5T-ST BULKHEAD ON TURRET (B) JI8 RET 87
HOSE ASSY, #04 66646 ,1.,7 5T-ST (7) JI8 EXT A7
f-:~t':-:=::-=:-::c:-+--:'=-+---: '::::--t7:-+H:,::O:,::S::-E_A:-:S:,::S::-:Y,-,-':#::-04:-'-;6"'6::-64::-:6:----:'I.::-,7:-'-;S:::T_-::-:4":-'-1 TURRE TROT AliON MOTOR A6
28
27
HOSE A55Y, H04 66646 J37 5T-45
H05E A5SY, H06 66645 J37 ST -5T
HOSE ASSY, H06 66645 ,1.17 5T -5T
LIFT CYL I RET
EXT
IS<a 28
27
1S<2:I
86
AS
85
26 66698-121.50 1.00 1.00 EA HOSE ASSY, H06 66645 J37 ST-ST RET:>< 26 > < B4
I 25 66697-120,50 1.00 1.00 EA HOSE AS5Y, H08 66675 J37 ST-5T EXT CYL EXT >< 25 A4>< l LOWER CONTROL VALVE
I 24 66696-086,00 1.00 1.00 EA HOSE A55Y, H04 66646 ,1,,7 ST -5T (6) ROTATE CCW >< 24 >< A3
I 23 66696-086,00 1.00 1.00 EA H05E A55Y, H04 66646 J37 ST-ST BULKHEAD ON TURRET (5) ROTATE CW >< 23 83 ><
22 66696-086,00 1.00 1,00 EA HOSE ASSY, H04 66646 J37 5T-5T (4) CYL RET @ TEE >< 22 B2 ><
>~
21 66696-086,00 1.00 1,00 EA H05E A55Y, 604 66646 J.,7 5T-5T (3) CYL EXT «I TEE ~ 21 ~ A2
20 66698-036,00 1.00 1.00 EA H05E A55Y, H06 66645 J37 ST-5T 7 ~ 20 X -::><:::
2:~ 19 6669B-032,75 1.00 1.00 EA HOSE A5SY, H06 66645 J,l7 ST-ST 6 >< 19 AI ><
--0 I lB 6669B-036,00 1.00 1.00 EA HOSE AS5Y, H06 66645 J.17 ST-ST 5 >< 18 >< Bl
~~
I ~~ ::~~~-~:::~~ ~:~~ ~:~~~: :~~~ :~~~: :~: ::;~~ ~;; ~;=:~ ~ ~~ ~I~;~:N
~
ROTARY COUPLING HYO TANK
15 65369 049,00 1.00 1,00 EA HOSE AS5Y, #16 65366 J37 5T-90 2 15 8
14 65369 046,00 1.00 1.00 EA HOSE ASSY, #16 65366 ,137 ST-90 1 14 A
13 166718-086,00 1.00 1.00 EA HOSE ASSY, H'2 6670B ,137 ST-90 I FiLTER 13 ICASE DRAIN I
12 65369 068,00 1.00 1.00 EA HOSE ASSY, #16 65366 ,137 ST-90 HYO TANK SUCTION 12 IN MAIN ENGINE PUMP
II 165403-014,50 1.00 1,00 EA H05E A55Y, #1066706 ,137 ST-45 HI PRESSURE FILTER I'N 11 lOUT
10 66711-014,00 1,00 1.00 EA HOSE AS5Y, H'~ 66706 ,}37 ST-90 OUT 10 RETURN
9 166766-017.50 1.00 1,00 lEA IHOSE ASSY, HOB 66675 ,137 ST-45 IEMERGENCY PUMP IOtn I 9 I Ip
8 HOSE ASSY, HID 66706 ,137 ST-90 PIGGY BACK PUMP OUT P LOWER CONTROL VALVE
HOSE ASSY, H08 66675 J37 5T-90 HYD TANK FILTER
6 166718-062,00 I 1.00 I 1.00 lEA IHOSE AS5Y, #12 66708 J37 5T-90 IplGGY BACK PUMP liN I 6 I I SUCTION
HOSE ASSY, HOB 66675 J.17 ST-ST EMERGENCY PUMP IN SUCTION HYO TANK
f---=-t~:::__:;:::~=___+---C:::::-+--:.::=----j7:'-+H.::O~S:::E-A::S=S:,:Y:'-,-l!#:::0::4-,6::=6:::6::460-:J:::3::-7-:S:;T,..-=9::-D_ CASE DRAIN FILTER
f--=--t~:::__:;:::~=___+---C:::::-+-"':':':=----j7:'-+H.::D~S:::E-A::S=S:,:Y:,-'-l!,:::0:;.4-,6::=6:::6::
460-:,I=3::-7-:S:;T,..-=9::-0_ MASTER LEVELING CYL RET (2) CYL RET@TEEBULKHEADONTURRET
HOSE ASSY, 604 66646 ,1.17 ST-90 EXT (1) CYL EXT @ TEE
1
ITEM
1.00~_J--',00
QTY-r<JTY
EA
UM
HOSE KIT OWG, TURRET
DESCRIPTION
LOCATION A PORT I HOSE liTEM
END N
I HOSE I
END
PORT LOCATION B
UNlESS OTHERWISE NOrtO:
DIVISION OF" TIME .... e, co.
·~I~
TOt.ERAHCES: 8300 IMPERI.t.l DRIVE
*' .010rniiiru:£-----===:::::..-~~~~~--J
.1OI:i.Ol~~
ntACTloe.Sz 1/111 WAt':n lI'XAS 16112
.;
MlGLES :t. ,.
.IOOC
B 11851 =~ ~ IIil c::J HOSE KI T OWG, TURRET

A I 11809 I 5/5/98 JHB AU. OIIH:NSIONS AIlE IN INQo£li
lm B/".. '.0 NO 71619 T'B

LTR.I O.R.N. NO.1 DATE APPR.IAPf'ROVEO JHB I "/28/18 !SCALE 1/1 SHEET 1 Of 1
i
e
~~
llill.E:S;.
1. VENDOR 5HALL TAG EACH H05E A55Y AT BOTH ENDS WJTH A LABEL STATING
KIT PIN - DWG REV - ITEM NUMBER
a:F:
-><> EXAMPLE: 71620- T60-A-l0 WOULD MEAN FROM
:Btl H05E KIT: "71620- T60"
.. ~ {d
ro~
<,'00
DWG REV: "A"
ITEM N: "10"
O~ O~
<00 <00
~ -t-' *,<"
'0'0 f>4.. '00 f>'v
/~ ¥:-O /A..:. V:-0
9 66044-674.00 1.00 EA HOSE A55Y, H04 67685 ,137 5T - ST JIB EXT 5T 9 5T ,liB EXT
BULKHEAD Qll TIP BOOM BULKHEAD @ TURRET
8 66044-674.00 1.00 EA HOSE ASSY, #04 67685 J37 ST -5T JIB RET 5T 8 5T JIB RET
7 66044-024.00 1.00 1.00 EA HOSE A55Y, H04 67685 J37 5T -5T 5LAVE EXT 5T 7 5T EXT
IN TOP OF TIP BOOM 5LAVE CYL
6 66001-024,00 1.00 1.00 EA H05E A5SY, #04 67685 J37 5T-90' 5LAVE RET 5T 6 9O' RET
5 66044-724.00 1.00 1.00 EA HOSE ASSY, N04 67685 ,137 5T-5T SLAVE EXT ST 5 5T SLAVE EXT
ON TOP OF TIP BOOM
4 66044-724.00 1.00 1.00 EA HOSE A5SY, N04 67685 J37 5T ST 5LAVE RET 5T 4 ST 5LAVE RET
BULKHEAD @ TURRET
.1 66044-672.00 1.00 1.00 EA HOSE A55Y, H04 67685 J37 5T 5T ROTATE ST 3 ST ROTATE
BULKHEAD Qll TIP BOOM
2 66044-672.00 1.00 1.00 EA HOSE A55Y, H04 67685 J37 ST 5T ROTATE ST 2 ST ROTATE
1 71620-DWe 1.00 1.00 EA INST DWe, HOSE KIT, BOOM HOSE 1 HOSE
LOCATION A PORT PORT LOCATION B
ITEM PART NUMBER OTY QTY UM DESCRIPTION END ITEM END
UfirllESS OlH£RWlSE NOTED:
TQ.ERANC£S:
rltACTIOHs±
ANQ.£S :i:
1/16
I"
,
10(
..,
OEOtMl!'l
:t.0l
.XXX:t.010 met
~
OIVlSION OF TIME MFO. CO.
8300 IIolP£RIAL DRIVE
'NACO, TEXAS 76112
,- ....
SURfACEFtN1SH '~
PROLCTION ()( VIEWS @ C] HOSE KIT, BOOM T60/66,)
A 11886 AU OIMENStOMS ARE IN INCHES
CT. D.C.N. NO.
11700
.,"
4/11/96 ,JHB
"'
CHECKED
K SNYDER _/17/98
B 000
1 ....
c ... 71620 I"A
em D.R.N. NO. .Alt APPR. APPfl:CM:D JHe 4/11/98 SCALE 1/1 SHEE:1 1 OF 1
il.....
->0
:8t;l ~
VENDOR SHALL TAG EACH HOSE ASSY AT BOTH ENDS WITH A LABEL STATING
1.
~ KIT PiN - DWG REV - ITEM NUMBER
EXAMPLE: 71621-STD-A-l0 WOULD MEAN FROM
.p-t- HOSE KIT: "71621-STD"
~\"
DWG REV: "A"
.p-t- ITEM #: "10"
f> ¢-.3 C}'" ¢-."
..../ of: ,/ ..f
",'j. f7'" ",'j. f7'"
,\" ~O ,\" ~O
X
7 66001-061.00 1.00 EA HOSE ASSY. 604 67685 J37 ST -90' JIB CYL EXT 90' 7 ST BULKHEAD ON TIP BOOM
6 66001-062.00 1.00 EA' HOSE ASSY. #04 67685 .1~7 ST-90' JIB CYL RET 90' 6 ST BULKHEAD ON TIP BOOM
66001-152.00 1.00 EA HOSE ASSY. 604 67685 .137 ST-90'
5 DUAL P.O. CHECK VALVE 90' 5 ST BULKHEAD ON TIP BOOM
66001-037.00 >< 1.00 EA HOSE ASSY. #04 67685 .137 ST -90'
4
66001-152.00 1.00 ::::><: EA HOSE ASSY. #04 67685 .137 ST -90'
DUAL P.O. CHECK VALVE 90' 4 ST BULKHEAD ON TIP BOOM
66001-037.00 >< 1.00 EA HOSE ASSY. #04 67685 J37 ST -90'
3 66001-016.00 1.00 1.00 EA HOSE ASSY. #04 67685 .137 ST-90' DUAL P.O. CHECK VALVE ST 3 90' LETT ACTUATOR
2 66001-016.00 1.00 1.00 EA HOSE ASSY. #04 67685 J37 ST-90' DUAL P.O. CHECK VALVE ST 2 90' RIGHT ACTUATOR
1 71621-DWG 1.00 1.00 EA HOSE KIT OWG, SKIRT T-SERIES HOSE ITEM HOSE
LOCATION A PORT END END PORT LOCATiON B
ITEM PART NUMBER QTY QTY UM DESCRIPTiON #
UM..ESS OTHERWISE HOttO:
DI""SlOH or TIME 111m. co,
TOLERANCES:
FRACTIONS: 1/18
AHQ.ES :t I'
D£ClWALS
.X
,Xl(
:t.l
:t.0l
~ 1I:ro<l IMPERIAL DRIVE
WACO, TEXAS 1ti712
.ICXK;I;,OtO TITLE
llUltf'M::£ I'NSH ''V
PfIIo.I:CTIDN OF \'OS @ c:J INST DWG. JIB/SKIRT HOSE KIT
A 11809 AU. DIUEH!IOHS ARE IN IMOtES
lIR. O.CoN. NO,
11712
OAT(
_/28/98
APPR. ORA ...
JH8 """'ED
K SNYDER 1/"/91
BI MA
....
NO
71621 IREA
------------_ ... _ - - - - - - - - - - -
lm O.R.N. NO. 0'" ""'R. .,..""" JH8 4/211/98 ~~_~l~ __ - - _.. - _[s~~~~___ 1 OF 1

Operation, Service Parts Models T60 T66J: AND Manual

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Operation, Service Parts Models T60 T66J: AND Manual

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TIME CONDOR Corporation

MODELS T60 & T66J

SHIPPING ADDRESS MAILING ADDRESS

MODELS T60 & T66J

SHIPPING ADDRESS MAILING ADDRESS

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

DO NOT ALTER OR MODIFY THIS UNIT WITHOUT PRIOR WRITTEN

SERVICE & MAINTENANCE

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

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

A. Primary Machine Components ................................................................................................ 13

III. MOVING FROM JOB SITE TO JOB SITE ....................................................................................... 40

IV. EMERGENCY PROCEDURES ....................................................................................................... 43

V. MACHINE SPECIFICATIONS ........................................................................................................ 48

ANSIISIA 92.5-1992 MANUAL OF RESPONSIBILITIES

This Page Intentionally Left Blank

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

• The "UNPOWERED EMERGENCY MOVEMENT" procedure (described later in

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

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

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

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

21882-001 - Decal, Electrocution Danger

• DO NOT OPERATE THIS MACHINE UNTIL YOU

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

.. • DO NOT USE THIS MACHINE IF IT IS DAMAGED

• RAISE PLATFORM ONLY WHEN ON FIRM, LEVEL

• AL·NA YS LOOK IN THE DIRECTION IN WHICH THE

, • THiS MACHINE is NOT ELECTRICALLY INSULA TED.

• DO NOT MAKE ANY MACHINE MODIFICATIONS

• DO NOT FORCE THE BOOM, PLATFORM, OR

• IN CASE OF EMERGENCY, PUSH RED

71618 - Decal, Lower Boom Caution

• BEFORE OPERATI~G, ALL PERSONS IN

• THIS MACHINE IS NOT ELECTRICALLY

• RAISE PLATFORM ONLY WHEN MACHINE IS

• ALWAYS LOOK IN THE DIRECTION IN WHICH

• NORMAL TRAVEL POSITION IS WITH BOOM

• DO NOT DRIVE ON A SLOPE UNLESS BOOM

• IF SLOPE ALARM SOUNDS, THE MACHINE IS

• DO NOT FORCE THE BOOM, PLATFORM OR

• IN CASE OF EMERGENCY, PUSH RED

71614 - Decal, Upper Boom Caution

RATED \.JORK LOAD

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

Right Hand Side

ITEM PART NUMBER DESCRIPTION QTY

- Indicates Items Not Shown

LEFT HAND SIDE

AUTDMA TIC RETRACT

Item Control Location Description

Glow plug button for some Diesels. Press and hold

Turn key left (counterclockwise) one position to

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

NOTE: Main power key switch must be in

7. Volt Meter On Ground Indicates electrical system voltage.

Item Control Location Description

8. Engine Oil On Ground

Item Control Location Description

1. Emergency Stop On Platform Used to stop all functions in an emergency. Push

When the button is reset, the engine distress light

2. Off/On/Start On Platform Three position toggle switch. Up is "OFF". Move