Condor 38AG OMP No. 92323

BOOM-SUPPORTED
ELEVATING WORK PLATFORM
MODEL 38AG
ARTICULATING
OPERATION, PARTS & MAINTENANCE MANUAL
THIS MANUAL APPLIES ONLY TO CONDOR® MODEL 38AG

GASOLINE AND DIESEL ENGINES
BEGINNING WITH SERIAL NUMBER 1563
CALAVAR CORPORATION
8300 IMPERIAL DRIVE
WACO, TEXAS 76712
(817) 666-4545
MANUAL 92323
SEPTEMBER 1994
INTRODUCTION
•
The primary purpose of this manual is to provide the user with a thorough under-
standing of the proper operating procedures necessary to comply with the intended use
of the CONDOR®, and to provide the information necessary to maintain and service the
CONDOR®.
THE OPERATOR'S MANUAL MUST BE RETAINED ON THE UNIT 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 your-
self 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 at-
tached to this machine also contain vital safety and operational instruc-
tions. Read the decals before operating this machine.
It is YOUR RESPONIBILITY 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, ai id local

regulations regarding the safe operation and use of aerial work platforms. A copy of
the ANSI/SIA 92.5-1992 Manual of Responsibilities is attached for your use
Calavar 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 CALA VAR CORPOR4770N
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 Cala-
var Corporation in order to ensure the original integrity of the fieoduct. Repairs and
adjustments should only be made by trained and qualified personne:. 'lease refer to the
maintenance and parts sections of the Calavar Operation, Maintenance, & Parts Manual
for information on service and maintenance of the CONDOR®.
NOTE: Please refer to the Calavar Parts section of the Operation, Maritenance, &
Parts Manual for information pertaining to your machine.
MANUAL 92323
SEPTEMBER 1994
LAWAR
CALAVAR CORPORATION
Condor® Self-Propelled Aerial Work Platforms

WARRANTY
Calavar Corporation ("Calavar") warrants to the purchaser that each new aerial work platform
made by Calavar 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 Calavar's plant; and in
the case of all other parts, for a period of one (1) year after the aerial work platform is placed
in service or two (2) years after the original shipment of the aerial work platform from Calavar's
plant, whichever comes first.
The obligation and liability under this Warranty is expressly limited to repairing or, at Calavar's
option, replacing free of charge at its factory or at an authorized repair facility designated by
Calavar, the defective part. In no event shall Calavar or its suppliers be liable to the purchaser
or any, other person for transportation charges or for any incidental, collateral, special, or
consequential damages, including without limitation damages for loss 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 Calavar, its suppliers, or its representatives have
been advised of the possibility of such damages.
Parts cla,tos be defective and for which repair or replacement is desired shall be returned
transportation prepaid to Calavar's 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, substitution upon it of parts not approved by Calavar or alteration or repair of the
equipment by any person not authorized by Calavar shall, at Calavar's option, void this
Warranty. Calavar shall have no liability or responsibility for damages resulting from accident
or the malfunction of equipment and components not supplied by Calavar.
No agent, employee, distributor, dealer, or other representative of Calavar 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 Calavar and
should not lit relied upon as limited warranties of Calavar, and no attempt, effort, or promise
to repair equipment by Calavar 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 Calavar. This
Warranty covers only new and unused aerial work platforms manufactured by Calavar.
Products or parts manufactured by others are covered only by such warranties as are extended
to the parchas;ar by Calavar's suppliers.
This Warranty is of all other warranties, expressed or implied, including but not limited
to warrantips of merchantibility and fitness for a particular purpose. Any applicable implied
warranty shalla be limited in duration to the warranty period.
8300 Imperial Drive, P.O. Box 21447, Waco, Texas 76702-1447

817-666-4545, FAX 817-666-4544
Printed in
MANUAL 92323
SEPTEMBER 1994
CALAVAR CORPORATION
BOOM-SUPPORTED
MODELS 38AG, 47AG, AND 47AE

ARTICULATING
OPERATOR'S MANUAL
CALAVAR CORPORATION
8300 IMPERIAL DRIVE
WACO, TEXAS 76712
(817) 666-4545
MANUAL 92265-001
SEPTEMBER 1994
INTRODUCTION
CONDOR®.
Do not attempt to operate or service the CONDOR® until you have read
and understood all information provided in this manual. Familiarize your-
self 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 at-
tached to this machine also contain vital safety and operational instruc-
tions. Read the decals before operating this machine.

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 92.5-1992 Manual of Responsibilities is attached for your use.
changes.

FROM THE MANAGEMENT OF CALA VAR CORPORATION
var 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
NOTE: Please refer to the Calavar Parts section of the Operation, Maintenance, &
Parts Manual for information pertaining to your machine.
MANUAL 92265-001
SEPTEMBER 1994
TABLE OF CONTENTS
INTRODUCTION
TABLE OF CONTENTS ii
I. PREPARATION, INSPECTION, AND MAINTENANCE 1
A. Overall Machine Condition 1

B. Lower Control Station 1
C. Platform and Upper Control Station 2
D. Hydraulic System 2
E. Multi-Axis Slope Sensor 2
F. Batteries/Charger 2
II. MACHINE OPERATION 2
A. Rated Work Load 2

B. Upper Controls, Gas & Diesel Power 3
C. Lower Controls, Gas & Diesel Power 3
D. Upper Controls, Electric Power 5
E. Lower Controls, Electric Power 5
F. Travel 7
III. OPTIONAL EQUIPMENT 7
IV. AUXILIARY LOWERING 7
V. MOVING FROM JOB SITE TO JOB SITE 8
A. TOWING 8
B. TRANSPORTING 8
VI. EMERGENCY STOPPING 8
APPENDIX: DECALS ILLUSTRATION 9
INSPECTION REPORT
ANSI/SIA 92.5-1992 MANUAL OF RESPONSIBILITIES
MANUAL 92265-001
SEPTEMBER 1994
IMPORTANT: A COPY OF THE ANSI/SIA 92.5-1992 MANUAL OF RESPONSIBILITIES IS
ATTACHED TO THIS OPERATOR'S MANUAL. IT CONTAINS IMPORTANT OPERATING
INFORMATION FOR THIS MACHINE. READ BEFORE OPERATING THIS MACHINE.
I. PREPARATION, INSPECTION, STEERING:

AND MAINTENANCE
Check tie rod ends and steering
The condition of this unit is very impor-
El cylinder for proper and secure
tant, as it directly affects the operator's mounting.
safety as well as the safety of others.
The operator must perform a thorough
walk-around inspection each day prior to SWING BEARING:
operating the machine. Any damage or
faulty operation should be reported imme- Check that all mounting bolts are
diately. A DO NOT OPERATE tag outlin- securely in place.
ing the problem should be attached to the
lower control station and any discrepan-
cies should be corrected before operating DECALS:
the CONDOR®.
Check that all decals and warning
KNOW THE UNIT AND ITS CAPABILITIES. signs are in place and are clearly
REPORT ANY UNUSUAL OPERATION, legible.
SUCH AS ERRATIC SWAY OR MOTION
OF THE BOOM, ARM, OR PLATFORM.
CAUTION: Defective components,
Some major areas to check daily are: structural damage, missing
parts, and equipment mal-
A. OVERALL MACHINE CONDITION function jeopardize the
safety of the operator and
TIRES AND WHEELS: other personnel and may
cause excessive damage to
Check for proper tire pressure, the unit. A poorly main-
cracks, tears, cuts, or missing or tained machine could be-
loose lug nuts (a rust line running come the greatest opera-
down the rim from the lug nut tional hazard you may
indicates a loose lug nut). encounter.
MISSING, BROKEN, OR DAMAGED B. LOWER CONTROL STATION

PARTS:
Check electrical installations for
Check cylinder mounting pins, loose, broken, or frayed wires and
pivot pins, retainers/fasteners, cables.
bearing pads, bolts, and nuts.
Check that all functions operate
properly, and that all controls
STRUCTURAL: return freely to center (neutral).
Check for damaged or cracked

welds on structural components--
boom, arm, platform, skirt, chas-
sis, and turret.
MANUAL 92265-001
1 SEPTEMBER 1994
C. PLATFORM AND UPPER The slope sensor is located adjacent to
CONTROL STATION the lower controls (see illustration).
Check electrical installations for

loose, broken, or frayed wires and
Ei Check the general condition of the
slope sensor, inspect for loose or
cables. Re-check the structural damaged wires, and ensure that
condition of the platform, pivot mounting is secure and that hous-
points, pins, railings, and floor. ing is not cracked or broken.
Check to see that slide bar is in

place and moves freely at access F. BATTERIES/CHARGER
opening. See that footswitch
operates properly, and that guard
is secured and in its proper place LI Check electrolyte level and ensure
that all caps are present and
on the platform floor. installed properly. Cable connec-
tions should be tight and clean.
LII Check the red EMERGENCY STOP

button; this button disconnects
power to the controls and stops all LI (Electric models) Ensure that
charger is operating properly, and
powered functions. inspect charger, plug, and meter
for damage.
El Check the operation of the auxil-

iary lowering pump.
G. MOTORS/ENGINE
D. HYDRAULIC SYSTEM
El Check the hydraulic tank fluid level LI Check to see that power units are
operating properly. Inspect for
with the arms lowered and the loose cables or fasteners.
boom lowered and retracted.
Maintain fluid level at the full mark
on the sight glass. Add only Shell LI levels—oil,
(Gas/diesel models) Check all fluid
fuel, and coolant.
Tellus T-32 Hydraulic Oil (or Inspect air cleaner and muffler
equivalent) to the system. Ensure operation and mounting, and
that the breather cap is clean and perform routine maintenance as
in place on the tank. recommended in engine manual.
LI Check for hydraulic oil leaks at all

fittings, valves, and controls, and II. MACHINE OPERATION
check hydraulic hoses and tubes
for damage and kinks. A. RATED WORK LOAD
LI Ensure that hydraulic lines are

routed properly to avoid pinch The CONDOR® Models 38A and 47A have
points. an rated work load of 500 lbs. (226.8 kg),
or two occupants. This means that the
platform will support a 500-1b. combined
E. MULTI -AXIS SLOPE SENSOR weight (including personnel and their tools
and equipment) throughout the working
The CONDOR® is equipped with a slope envelope of the machine.
sensor to warn the operator of an out-of-
level operating condition.
MANUAL 92265-001
SEPTEMBER 1994
2
Models 38AG, 47AG —Gas & Diesel Power
UPPER CONTROLS
DRIVE/STEER
BOOM LIFT
EMERGENCY STOP
ENGINE START
TURRET ROTATE
LP/GAS (OPTION)
PLATFORM TILT
CHOKE/GLOWPLUGS
BOOM EXTEND
DRIVE SPEED SELECTOR
AUX. LOWERING ARM LIFT

(OPTION)
LOWER CONTROLS
ENGINE START
EMERGENCY STOP
CHOKE/GLOWPLUGS
AUX. LOWERING (OPTION) ARM LIFT
THROTTLE
BOOM EXTEND
KEY SWITCH
& UPPER/LOWER TURRET ROTATE
CONTROL STATION
SELECTOR
BOOM LIFT
MANUAL 92265-001
3 SEPTEMBER 1994
B. UPPER CONTROLS, GAS & C. LOWER CONTROLS, GAS &
DIESEL POWER DIESEL POWER
The upper control station provides for The lower control station is located on the
complete operation of the machine. As a turret of the machine. The DRIVE/STEER
safety precaution, the footswitch functions are not operable from the lower
mounted on the platform floor must be controls; all other functions may be
depressed and held during all functions. operated from the lower control station.
The upper control console is equipped
with a red EMERGENCY STOP switch that The main key switch is located on the
will cease all movement and (on gas and lower control console. With the key in
diesel models) stop the engine. the center (OFF) position, power is disen-
gaged. With the key in the left (LOWER)
On engine-powered units, the upper position, the lower controls are energized
control console will contain an engine for operation. With the key in the right
START switch and either a CHOKE (gas (UPPER) position, the upper controls are
engines) or GLOWPLUGS switch (diesel energized for operation.
engines). If the CONDOR® is equipped
with an optional dual fuel system, the The THROTTLE switch must be depressed
console will also contain an LP/GAS continuously in order to operate the
switch for selecting the mode of fuel functions from the lower control station.
consumption.
On engine-powered units, the control
The upper control console also contains a console contains an engine START switch
drive speed selector switch, which allows and either a CHOKE (gas engines) or
the operator to select either FAST or GLOWPLUGS (diesel engines) switch to
SLOW speed, and a DRIVE/STEER control- assist in starting the engine.
ler. The steering control is a spring-loaded,
return-to-center rocker switch located on top Also located on the lower control console
of the drive control handle. With the coun- is the optional auxiliary lowering switch.
terweight over the steer wheels, the steering This switch is used to energize the auxil-
control moves the unit in the direction in iary pump and motor, which may be used
which the rocker switch is actuated. to lower the platform in the case of
primary power failure.
Directly in front of the control console are
five (5) handles that control the following Adjacent to the lower control console are
functions: ARM LIFT, BOOM EXTEND, four (4) handles that control the following
PLATFORM TILT, TURRET ROTATION, functions: ARM LIFT, BOOM EXTEND,
and BOOM LIFT. The aerial functions TURRET ROTATION, and BOOM LIFT.
correspond directly to the movement of
the control levers in the directions indi- The lift functions correspond directly to
cated on the control valve decal. the movement of the control levers in the
directions indicated on the control valve
When set properly, the platform on Mod- decal.
els 38A and 47A will remain level
throughout the operational envelope of NOTE: The CONDOR® is not equipped
the machine. with continuous turret rotation. With the
counterweight over the drive wheels, the
The CONDOR® is also equipped with a turret may be rotated 179° in either
hand-operated rotating platform. To direction until the stop is reached.
rotate the platform, turn the handle
located on the right side of the skirt, just
below the control station.
MANUAL 92265-001
SEPTEMBER 1994
4
Model 47AE —Electric Power
UPPER CONTROLS
DRIVE/STEER
POWER ON/OFF
TURRET ROTATE
BATTERY
CONDITION
INDICATOR
BOOM LIFT
DRIVE SPEED
SELECTOR
BOOM EXTEND
PLATFORM TILT
ARM LIFT
LOWER CONTROLS
PUMP
ARM LIFT
KEY SWITCH
& UPPER/LOWER
CONTROL STATION
SELECTOR BOOM EXTEND
HOUR METER
TURRET ROTATE
BOOM LIFT
MANUAL 92265-001
5 SEPTEMBER 1994
B. UPPER CONTROLS, C. LOWER CONTROLS,
ELECTRIC POWER ELECTRIC POWER
The upper control station provides for The lower control station is located on the
complete operation of the machine. As a turret of the machine. The DRIVE/STEER
safety precaution, the footswitch functions are not operable from the lower
mounted on the platform floor must be controls; all other functions may be
depressed and held during all functions. operated from the lower control station.
The upper control console is equipped
with a red POWER switch that will cease The key switch is located on the lower
all movement and disengage the power control console. With the key in the
unit. center (OFF) position, power is disen-
gaged. With the key in the left
The upper control console contains a (GROUND) position, the lower controls
drive SPEED selector switch, which are energized for operation. With the key
allows the operator to select either FAST in the right (PLATFORM) position, the
or SLOW speed, and a DRIVE/STEER upper controls are energized for operation.
controller. The steering control is a spring-
loaded, return-to-center rocker switch The PUMP switch must be depressed
located on top of the drive control handle. continuously in order to operate the
With the counterweight over the steer functions from the lower control station.
wheels, the steering control moves the unit
in the direction in which the rocker switch is Also located on the lower control console
actuated. is the optional auxiliary lowering switch.
This switch is used to energize the op-
The console also contains five (5) handles tional auxiliary pump and motor, which
that control the following functions: ARM may be used to lower the platform in the
LIFT, BOOM EXTEND, PLATFORM TILT, case of primary power failure.
TURRET ROTATION, and BOOM LIFT.
The aerial functions correspond directly to The lower control console contains four
the movement of the control handles; the (4) handles that control the following
direction of operation for each function is functions: ARM LIFT, BOOM EXTEND,
indicated on the upper control console TURRET ROTATION, and BOOM LIFT.
decal.
The lift functions correspond directly to
When set properly, the platform on Mod- the movement of the control handles in
els 38A and 47A will remain level the directions indicated on the control
throughout the operational envelope of console.
the machine.
All models are equipped with an hour
The CONDOR® is also equipped with a meter at the lower control station.
hand-operated rotating platform. To
rotate the platform, turn the handle NOTE: The CONDOR® is not equipped
located on the right side of the skirt, just with continuous turret rotation. With the
below the control station. counterweight over the drive wheels, the
turret may be rotated 179° in either
Electric models may be equipped with an direction until the stop is reached.
optional battery condition indicator at the
upper control station.
MANUAL 92265-001
SEPTEMBER 1994
6
D. TRAVEL Avoid erratic movement of the controller
by moving smoothly into and out of
Driving the machine may only be accom- travel. Come to a complete stop before
plished from the upper control station, changing directions.
with the boom in raised or lowered
(stowed) position. Even thought the The brakes on the unit are spring-applied
gradeability of the unit is 14° (25%), and hydraulically released. The brakes
such a grade should only be negotiated are automatically released when the drive
with the boom in the fully lowered controller is returned to the neutral posi-
(stowed) position and in SLOW drive tion.
speed. The CONDOR® is designed to
travel with the platform elevated only The upper control console is equipped
when on firm, level ground. with a maintained two-position toggle
switch to select either FAST or SLOW
The CONDOR® is designed to be driven travel speed. However, when the boom
with the counterweight positioned over or arms are raised sufficiently to open the
the drive wheels. In this configuration, boom limit switch (approximately horizon-
the direction of travel corresponds directly tal), both drive speeds are automatically
to the direction of movement of the drive reduced by one half.
controller. Moving the controller away
from the operator drives the unit forward; III. OPTIONAL EQUIPMENT
moving the controller toward the operator
moves the unit in reverse. The following options are available on the
CONDOR® Models 38A and 47A:
The steering control is a spring-loaded
return-to-center rocker switch located on • 110-Volt Line to Platform
top of the drive controller handle. With • Foam-Filled Tires
the counterweight over the drive wheels, • Motion/Travel Warning Horn
the steering direction corresponds directly • Low Voltage Warning (electric models)
to the direction in which the rocker • Strobe Light/Rotating Beacon
switch is activated. Pushing the rocker • Larger Platform
switch to the left turns the unit to the • Air Line to Platform
left, and pushing the rocker switch to the • Platform Work Lights
right moves the unit to the right. When • Diesel Engine
the rocker switch is released and returns • Dual Fuel (liquid, vapor)
to center, the sterring wheels remain in
the last directed line of travel and do not IV. AUXILIARY LOWERING
return to a straight line of travel; steering
is not self-centering. Provisions are made to return the operator
to the ground in the event of primary
When the machine is driven with the power loss.
counterweight in a position other than as
described above, the relationship of the The boom and arm lift cylinders on elec-
drive and steer functions to the move- tric units are equipped with (manual)
ment of the controller will change. The gravity lowering cartridges on the holding
operator should move the unit slowly until valves. To lower the boom or arm manu-
familiar with this change in movement. ally, depress the red button and turn
counter-clockwise. The lowering process
Always look in the direction of travel and may be halted at any time by depressing
maintain a clear field of view, paying the red button and turning clockwise.
particular attention to overhead obstruc-
tions.
7 MANUAL 92265-001
SEPTEMBER 1994
making sure that the controls return to
On electric models, the turret may be center smoothly when released. Move
rotated manually by placing the ROTA- the CONDOR® slowly back and forth to
TION TOOL provided (located directly ensure that the brakes apply each time
below the rotation gearbox) over the hex the drive controller is released.
head shaft of the rotation gearbox.
It may be necessary to elevate the boom
Optional on engine-powered units is an or lift the arms to clear the ramp during
auxiliary power unit which is operated loading. The unit is equipped with a slope
from both control stations. This option sensor that will warn the operator of an
allows the lift functions to be operated in out-of-level condition of 5° or greater.
case of engine or main pump failure. Move the unit up or down the ramp
Push and hold the AUXILIARY LOWERING slowly, allowing time for steering correc-
switch while operating the desired functions to be made, and keep the unit in
tion. alignment with the ramp and carrier
during loading and unloading operations.
V. MOVING FROM JOB SITE
TO JOB SITE The. CONDOR® may be transported easily
and safely to and from the work site by
A. TOWING completing the following procedures:
block all wheels to prevent forward and
The brakes on the CONDOR® are auto- reverse movement during transportation;
matically applied when the drive controller tie down the CONDOR® using chains,
is returned to neutral. However, for straps, or cables of sufficient strength;
towing purposes the drive hubs may be set the platform on wooden pallets and tie
disengaged by removing the two (2) bolts the boom down near the skirt; turn off the
(.25" - 20UNC x .75" long) that secure power at the key switch and remove the
the disconnect cap, removing the discon- key. [See diagram below]
nect cap and reinstalling with the nipple FACTORY RECOMMENDED
facing inward, and resecuring the cap • TRANSPORTATION DIAGRAM
using the two bolts.
B. TRANSPORTING
The CONDOR® Model 47A weighs ap-

proximately 12,500 lbs.; Model 38A
weighs approximately 11,500 lbs. The
means of loading or unloading must be of
sufficient strength to withstand the
weight of these machines.
[Decal located on chassis—both sides]
When using a ramp, it should be set at an
angle no greater than 14° or 25% (30" VI. EMERGENCY STOPPING
rise in 10 feet).
As stated previously, the EMERGENCY
Remember that the normal driving posi- STOP button may be used in an emer-
tion of the CONDOR® is with the counter- gency to stop movement from both the
weight over the drive wheels, and that upper and lower control stations. How-
any other position will change the opera- ever, the foot may be taken off of the
tion of the drive and steer functions. footswitch to 'panic stop' any function,
Before driving the unit onto the ramp, test including drive and steer.
each of the controls and the brakes,
MANUAL 92265-001
SEPTEMBER 1994
8
APPENDIX: DECALS ILLUSTRATION
[Model 47AG Shown]
21
15
19
1
7 110.MAINIJICIRI
0 0
26
35
9 MANUAL 92265-001
SEPTEMBER 1994

APPENDIX: DECALS ILLUSTRATION
47AG 47AD 47A 38AG 38AD

ITEM PART NUMBER DESCRIPTION QTY QTY QTY QTY QTY
1 34271 Decal, 47A 2 2 2 N/A N/A

37290 Decal, 38A N/A N/A N/A 2 2
2 50172 Decal, CONDOR® 2 2 2 2 2
3 35366 Decal, Gen. Op. Instructions 1 1 1 1 1
4 21882-001 Decal, Electrocution Hazard 2 2 2 2 2
5 21882-002 Decal, This Unit Not Insulated 2 2 2 2 2
6 21882-003 Decal, Danger: Qual. Operator 1 1 2 1 1
7 52759 Decal, Stand Clear/Operating 2 2 2 2 2
8 37348 Decal, Lower Valves (see NOTE 1) 1 1 1 1 1
9 34270 Decal, Upper Valves 1 1 1 1 1
10 21850 Decal, Hydraulic Fluid 1 1 2 2 2
11 50070 Decal, Battery Service 1 1 2 1 1
12 37354 Decal, Aux. Lwrg. (see NOTE 2) 1 1 N/A 1 1
67880 Decal, Emergency Lowering (47A) N/A N/A 1 N/A N/A
13 35042 Decal, Forward (Arrow) 1 1 1 1 1
14 35043 Decal, Forward 1 1 1 1 1
15 67938-100 Decal, Tire Press. 100 PSI (47AG) 4 4 N/A N/A N/A
34523 Decal, Tire Pr. 60 PSI (38AG/47A) N/A N/A 4 4 4
16 21849 Decal, Gas 1 N/A N/A 1 N/A
15376-012 Decal, Diesel 1 1 N/A N/A 1
17 21971-002 Decal, Do Not Lift Wheels w/Boom 2 2 2 2 2
18 37784 Decal, Transportation Diagram 2 2 2 2 2
19 35656 Decal, Made in U S A —6 00" 1 1 1 1 1
20 68859 Decal, Oil Dipstick Inside 1 1 N/A 1 1
21 81417 Decal, Rated Work Load 1 1 1 1 1
22 36885 Decal, 500 LBS 1 1 1 1 1
23 54416 Decal, Caution: Tie-Down Ring 3 3 3 3 3
24 37419 Decal, Panic Stop/Ramping Control 1 1 1 1 1
25 58419 Tape, Orange/Red 5.00" (linear ft.) 39 39 39 39 39
26 38176 Decal, Manual Lowering Procedure 2 2 N/A 2 2
27 32200 Decal, Warning Power Lines 1 1 1 1 1
28 37958-500 Decal, Rated Work Load 500 LBS 1 1 1 1 1
29 Nameplate, Booms Identification 1 1 1 1 1
30 38072 Decal, Lower Control Console 1 N/A N/A 1 N/A
37365 Decal, Lower Control Console N/A 1 N/A N/A 1
37024 Decal, Pump (electric models) 1 N/A 1 N/A N/A
31 37969 Decal, Key Switch—Upper/Lower 1 1 N/A 1 1
37025 Decal, Key Switch—Ground/Plat. N/A N/A 1 N/A N/A
32 38144 Decal, Upper Control Console 1 1 N/A 1 1
37080 Decal, Upper Control Console N/A N/A 1 N/A N/A
33 67812 Decal, Glowplugs (diesel models) N/A 2 N/A N/A 2
34 52735 Decal, 110 Volts option .. option ...option .. option . option
35 15376-024 Decal, 110V Power To Platform option .. option ...option .. option . option
36 67881 Decal, Rotation Tool Inside 1 1 1 1 1
37 34767 Decal, Aux. Lowering (plat. cntrl.) .... option .. option ...option .. option . option
(see NOTE 2)
- Indicates Items Not Shown
NOTE: 1. Decal #37348, showing lower control valve operation, replaces decal #34502.
2. Decal #34767 is used to indicate the pushbutton control for Auxiliary Lowering on units
equipped with an optional auxiliary power unit. Decal #37354 contains the instructions
for auxiliary lowering on units equipped with the optional power unit.
MANUAL 92265-001
SEPTEMBER 1994
10
NOTES
MANUAL 92265-001
SEPTEMBER 1994
CA la R.VA R
CALAVAR CORPORATION

WARRANTY
the case of all other parts, for a period of one (1 ) year after the aerial work platform is placed
or any other person for transportation charges or for any incidental, collateral, special, or
Parts claimed to be defective and for which repair or replacement is desired shall be returned

should not be relied upon as limited warranties of Calavar, and no attempt, effort, or promise
to the purchaser by Calavar'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.

817-666-4545, FAX 817-666-4544
Printed in U.S.A.
MANUAL 92265-001
SEPTEMBER 1994
NOTES
MANUAL 92265-001
SEPTEMBER 1994
CALAVAR CORPORATION
BOOM-SUPPORTED
MODEL 38AG
ARTICULATING
MAINTENANCE MANUAL

CALAVAR CORPORATION
8300 IMPERIAL DRIVE
WACO, TEXAS 76712
(817) 666-4545
MANUAL 92323-002
SEPTEMBER 1994
INTRODUCTION
CONDOR®.
Do not attempt to operate or service the CONDOR® until you have read and understood
all information provided in this manual. Familiarize yourself with the functions and
operations of the upper and lower controls. A good understanding of the controls, their
limitations, and their capabilities will maximize operating efficiency and safety. The
various decals attached to this machine also contain vital safety and operational instruc-
tions. Read the decals before operating this machine. The parts and maintenance
sections of this manual will serve as a tool to be used in servicing the machine and in
ordering parts. When referring to this manual, please note the publication date and any
Serial Number information pertaining to this manual and its corresponding model(s).

used in carrying out a variety of jobs. Therefore, it is YOUR RESPONSIBILITY to con-
sider 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. The
ANSI/SIA Manual of Responsibilities pertaining to this model is attached for your use.
changes.

Parts Manal for information pertaining to optional parts.
MANUAL 92323-002
SEPTEMBER 1994
CONDOR® MODEL 38AG
MAINTENANCE MANUAL
TABLE OF CONTENTS
CONDOR® SERVICE INFORMATION
CHECK-OUT INSTRUCTION 1
WARRANTY PROGRAM 3
A. WARRANTY PERIOD 5
B. PRE-DELIVERY INSPECTION SHEET (P.D.I.) 6
C. ITEMS NOT COVERED 6
D. PROCESSING OF CLAIM 7
E. RETURN AUTHORIZATION 7
SERIAL NUMBER LOCATION 9
MANUAL 92323-002
SEPTEMBER 1994
CA IL. INVII 14
CALAVAR CORPORATION
CONDOR® SERVICE INFORMATION
1. If you need assistance or have any service or maintenance questions, Calavar service
and parts personnel are always available by phone or fax. The telephone numbers are:
(817) 666-4545 Telephone

(817) 666-5125 Voice Mail
(800) 443-5803 FAX
2. There are numerous written Maintenance Procedures available for this machine. These
procedures are available through the Calavar Service Department to anyone who
requests them.
3. Service and maintenance are not a substitute for trained, qualified service technicians.
Calavar conducts service schools on a continuing basis. Call any of our service or sales
persons for a schedule. Remember, training of mechanics is the responsibility of their
employer, but Calavar Service Schools help you provide this training.
4. Calavar Service School Training Manuals are available for purchase through the parts
department. The part numbers for these manuals are: #92333 for self-propelled mod-
els; and #92334 for truck-mounted models.
CALAVAR CORPORATION
8300 IMPERIAL DRIVE, P.O. Box 21447, WACO, TEXAS 76702-1447 • 817-666-4545, 817-666-4544 FAX
MANUAL 92323-002
SEPTEMBER 1994
CHECK-OUT INSTRUCTION
The following instructions are a step-by step procedure for checking out the self-
propelled CONDOR®, as well as for acquainting operating personnel with the unit's
operation. This procedure will not take more than one hour and is time well-spent,
as it will give both operating and maintenance personnel preliminary experience and
a better understanding of the operation of the self-propelled CONDOR®.
Prior to placing the unit into service, a full check-out of the unit should be made and
the Installation Inspection Report should be completed and returned to Calavar.
Each unit has undergone a thorough Quality Control Inspection, and each unit leaves
Calavar in first-class condition. Unfortunately, some units may be damaged in
transportation; all such damage should be recorded on the consignee copy of the
freight bill. Calaver Corporation is not responsible for damage to units in transit.
1. Visually inspect all exposed components. Check for loose nuts and bolts,
damaged hydraulic lines, broken wires, and structural damage.
2. IMPORTANT: Check tire pressure. Tires must be properly inflated before

operating the unit. Do not over-inflate. Proper P.S.I. rating appears on
decals applied to both sides of the carriage.
3. Check hydraulic oil level and add Shell Tellus T-32 hydraulic oil, if required.
4. Fill fuel tank using unleaded gasoline or diesel fuel.
5. Check battery with an hydrometer. Battery must have a full charge.
6. Inspect all hydraulic valves located in the front carriage compartment before
putting the unit into service.
7. Turn on the key switch at the lower control station; IF D1ESEL-POWERED,

first activate glowplugs and allow 30 seconds before starting engine. De-
press the start button and allow engine to warm up at idle. After the unit
has warmed up, and with the UPPER/LOWER control station selector switch
in the LOWER position, the unit may be operated by activating the control
handles on the lower control valve. While wheel drive is not available from
the lower control station, the engine may be started and stopped from both
control stations.
8. With the key switch ON, switch to the UPPER control station. Position the
unit in an area that is free from any overhead obstruction. At the upper
control station, engage the footswitch and activate a control lever while
maintaining pressure on the footswitch. Ensure that when released, the
control levers return to center. Learn to operate the controller slowly to
obtain the smoothest possible operation.
MANUAL 92323-002
SEPTEMBER 1994
1
9. The CONDOR® has been designed to drive with the counterweight over the
drive wheels. This configuration will provide the best traction and a familiar
driving position.
10. A series/parallel drive valve is located in the front carriage compartment

between the drive wheels. This valve performs the necessary functions of
dividing the hydraulic oil for slow speed travel with adjustable differential
action to round corners, and diverting the oil flow for high speed travel. The
counterbalance valve softens the brake release and application efficiently
without an accumulator.
1 1 . The wheel drive has the following features:
A. There is a FAST/SLOW speed selector (toggle switch) on the upper

control box.
B. FAST speed is only available in stowed position.
C. In FAST speed mode, no aerial functions may be operated, even if the

controllers are activated. When the boom is elevated off of the turret,
HIGH speed is not available and boom functions become operable.
D. A CREEP speed mode is automatically engaged when the lift arm is

raised or the boom is elevated out of its stowed position.
1 2. Operate the boom at a horizontal position until you are familiar with the
operation and feel of the controls. The unit will respond more smoothly to
the controls when they are activated properly.
1 2. Gradually operate the unit up to its maximum elevation and extension.
13. All CONDOR® models are equipped with a slope-sensing device which senses
a 5° out-of-level condition. This safety system is operational when the
ignition circuit is on and the boom is above horizontal. When the unit is
subjected to an out-of-plumb condition of 5° or more, the system will sound
an audible alarm at both control stations. The operator should correct the
condition by reversing the drive direction or by selecting an alternate path,
observing normal safety precautions when operating the equipment. The
slope-sensing device is a safety system and must not be disconnected.
Should the system be found inoperable, the unit must be taken out of service
and must not be used until the system has been repaired.
2 MANUAL 92323-002
SEPTEMBER 1994
CA EWA 14
CALAVAR CORPORATION

WARRANTY
the case of all other parts, for a period of one (1) year after the aerial work platform is placed
or any other person for transportation charges or for any incidental, collateral, special, or
Parts claimed to be defective and for which repair or replacement is desired shall be returned

should not be relied upon as limited warranties of Calavar, and no attempt, effort, or promise
to the purchaser by Calavar'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.

817-666-4545, FAX 817-666-4544
Printed in U.S.A.
MANUAL 92323-002
SEPTEMBER 1994 3
NOTES
4 MANUAL 92323-002
SEPTEMB E R 1994
Effective January 1, 1993
WARRANTY PROGRAM
Warranty is a function of a manufacturing company to back up the product it manufactures.

It is a guarantee against defects in design and workmanship of components utilized in the
product, and is offered for a fixed period of time following the purchase of the product by
a customer.
Calavar Warranty states, in general, that Calavar 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 Calavar. These will be
outlined in subsequent paragraphs.
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 Calavar,
whichever comes first. In the case of major weldments (chassis, turret, and
booms), the Warranty Period is five (5) years following shipment from
Calavar.
2. The Truck-Mounted unit Warranty Period is one (1 ) year from shipment of the
unit from Calavar's plant.
3. For parts sold through the Parts Department, the Warranty Period is six (6)
months from utilizing the component or placing it in service, or twelve (1 2)
months following shipment from Calavar, whichever comes first, unless the
part is furnished to correct a defective part on the original shipment still under
Warranty.
4. Replacement parts provided under the terms of the Warranty are for the
Warranty Period applicable to the unit in which they were installed as if such
parts were original components of the aerial work platform.
5. During the Warranty Period, in addition to covering the parts replaced under
Warranty, Calavar 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 unit
is first used for any purpose. An example: The dealer may have purchased
a unit to have in stock, but may not use it. After three months, the unit is
sold or the dealer decides to put the unit into its rental fleet. In this situation,
the Warranty Period begins the day the dealer puts the unit into the fleet or
when the unit is delivered to the end user.
The submittal of a warranty claim against a stock machine constitutes it as

being "in service," initiating the warranty period.
MANUAL 92323-002
SEPTEMBER 1994
5
B. PRE-DELIVERY INSPECTION SHEET (P.D.I.)
1 . Each Self-Propelled Boom or Scissor unit shipped from Calavar'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 of the unit from Calavar,
whether it will be the dealer or the end user, to complete this form and return
it to Calavar's facility within 45 days from the date of receipt to set up the
Warranty Account.
3. Failure to complete the P.D.I. sheet and return it to Calavar within the time
frame given will result in voiding the Warranty on the unit.

NOTE: The form must be filled out completely, giving the name of the dealer,
address, model number, serial number, person inspecting the units, signa-
ture, and date of inspection. (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 Calavar.
However, these are warranted by the component manufacturer. Some of these 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. Calavar can advise you who the dealer is if unknown to you.
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.
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 Calavar by its suppliers.
5. Freight and Charges: The warranty does not include any transportation, other
charges, or the cost of installation or any liability for direct, indirect, or
consequential damages or delay resulting from the defect.
6. Travel Time I Mileage: Travel time and the mileage to and from dealer facilities
to machine location are not covered or reimbursable.
7. Troubleshooting: Troubleshooting is not covered or reimbursable. However,

Calavar Warranty will cover reasonable labor charges for the removal and
replacement of defective components.
6 MANUAL 92323-002
SEPTEMBER 1994
D. PROCESSING OF CLAIM
During the Warranty Period, should a component failure be encountered within the
guidelines of the Calavar Warranty Policy, the following procedure is to be followed:
1. Upon identifying the defective component, the replacement can be obtained

by:
a. Issuing an order to our Parts Department through normal channels,

which entails your being invoiced.
b. You may have previously purchased the part from Calavar for your
stock and will utilize it for this replacement.
The above two methods will enable you to indicate on the claim the Calavar
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 of the purchase order or receipt MUST
accompany the claim. Calavar has the option to ship a replacement
part at no charge if the local cost would be greater, in lieu of issing
credit for locally purchased parts.
d. When parts are puchased from Calavar, 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 Calavar to
thoroughly evaluate the claim and process it in the shortest amount of time
possible.
NOTE: CLAIMS NOT RECEIVED BY CALAVAR 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 Calavar Service Department and ask
to be issued a Return Authorization (R/A) number. You will be asked for a
Dealer Claim Number. As noted in Section 2, Item A, of the 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 unit. The R/A
number issued must be logged in the appropriate section of the claim form,
and the gold copy (R/A) of the form must be returned with the parts being
returned.
MANUAL 92323-002
SEPTEMBER 1994
7
NOTE: DO NOT SHIP ANY RETURN PARTS WITHOUT
A RETURN AUTHORIZATION (R/A) NUMBER
Doing so may result in parts getting lost in the system and may delay
processing the claim, or may cause denial dut to the time element of the
claim.
3. All R/A parts must be received at Calavar within 45 days from the date the
R/A 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

Calavar FREIGHT PREPAID. No freight collect shipments will be accepted.
8 MANUAL 92323-002
SEPTEMBER 1994
CONDOR® Model 38AG Serial Number Location

STAMP ON TURRET PLATE STAMP ON STEER AXLE
STAMP ON DATA PLATE
The CONDOR® Model 38AG Serial Number is stamped in three locations on the machine.
1. The first place to find the serial number stamp is on the data plate affixed to
the chassis, as indicated on the illustration above.
2. Another serial number stamp is located on the steer axle, as shown above.
3. The third serial number stamp is located on the turret plate, near the lower
control console, as shown above.
MANUAL 92323-002
SEPTEMBER 1994
9
NOTES
10 MANUAL 92323-002
AUGUST 1994

OEM Drive Controller Adjustment Procedure
CAUTION: Have another person in the platform to assure safe driving during this procedure.
1. Turn 'RAMP RATE' all the down counterclockwise.
2. Threshold Adjustment:
• Put arm and boom all the way down.
• Switch to fast drive speed.
• Move handle slowly off center until LED comes on and hold it there.
• Adjust 'THRESHOLD' until unit will just start to creep with control handle moved 1" to
2" after LED has come on. Also, unit should slow and stop just prior to LED turning
off.
NOTE: Move handle slowly to allow system to respond.
3. High Range Adjustment:

• Turn 'HIGH RANGE' all the way down counterclockwise.
• Push handle all the way to drive forward and hold it in maximum position.
• Turn 'HIGH RANGE' up clockwise and 1/2-turn at a time. Each time you will feel unit
accelerate. After several turns, there will be no further acceleration. Stop adjustment
and driving at this point.
• While driving forward at maximum, move control handle slowly toward neutral a few
degrees. There should be a definite sensation of slowing. If not, then HIGH RANGE
is set too high and needs to be slowed by turning counterclockwise about 1/4-turn to
1/2-turn.
4. Low Range Adjustment (see NOTE at 'Fine Tune" below):

• Lift boom off limit switch. (This will de-energize terminal 'R' on the controller.)
• Switch to slow drive speed.
• Adjust 'LO RANGE' to a speed of .75 mph. (This is 80 sec in 88 feet.)
5. Ramp Rate Adjustment:

• Put arm and boom all the way down.
• Switch to FAST drive speed.
• Turn 'RAMP RATE all the way up clockwise.
• Turn 'RAMP RATE' down counterclockwise 6 turns.
• Check ramp rate performance. While driving at maximum speed, pull handle rapidly
and fully in opposite direction. Unit should stop and reverse its direction in approxi-
mately 3 feet. If stopping distance is excessive, turn ramp rate down, counterclock-
wise, one to two turns, and recheck.
6. Fine Tune:
• Repeat Threshold Adjustment.
• Check High Range setting.
NOTE: Low Range may not be functional on units shipped prior to August 1991.
If not, then skip this step.
MANUAL 92323-002
AUGUST 1994
NOTES
MANUAL 92323-002
12 SEPTEMBER 1994

•
BC
rRENOTH ( T I
SIZE BASIC
STRESS
AREA
OF LOAD IN
GRADE (195,) GRADE 5
MAJOR Mal28 ■ 33E1v3LY TORQUE
LOAD
01A 1)5- c00 DRY R 150 LUB 1831 R-.200 DRY
4-40 1120 . 006 12 151‘4 1150M 11201 8 1N/L83 6 1N/L83 540
4 - 48 ..20 0064 120h4 85h4;150M112011/1 IN/L83 7 IN/LBS
6-32 HI380 00909 120M1f — 1150M1120M u 1 0 IN/L133 12 IN/LBS
®4 .1380 ® 01015 120M1 50M1120Mi 4 s 13 IN/1_83 920 Z5 IN/L83 19 IN/LBS

8-32 I 1640 rtthnIA 30 IN/LBS 22 IN/L133
1111111111111111IL
1260 41 IN/1.33 31 IN/LBS
zUMIJMI 944.t 31 IN/LEIS 23 !NABS 120 43 IN/LBS 32 IN/LBS

19 0 I ZO M 150,A 120M 1120 43 IN/L83 32 IN/L83 1580 80 IN/LBS 45 IN/LBS
1900 02000 12mAl 01.41120M! 1265 49 IN/LBS 38 IN/LBS 1800 88 INIUM 51 IN/LBS
1/4-20 2500 $. 0316C OM I1ZOMI 2020 8 FT/LBS 75 IN/LBS Z880 12 FT/L113 9 FT/LBS
1/4-28 2.500 1. 038 I OM11ZOMI 20 10 FT/LBS 88 IN/LBS 3280 14 FT/LBS 10 FT/LBS
5/18 i8
- 2125 I.Q5Z )5M 1150/41120W, 33 ,-.0 17 FT/LBS 13 FT /LBS 4720 5 FT/L153 16 FT/LBS
5/16-24 .3125 r.-6.7100 tI4V1641 d5M 1150L411201 19 FT/LBS 14 FT/LBS 5220 ZO FT/LBS
3/8-16 . 2750 .0775011ZOM1 85M 1150M1120M t 40 30 FT/LBS Z3 FT/LBS 7000 43 T/L133 35 FT /LBS -
3/8-2-1 .3750 .08780 120M 85M 1150M11ZOM 5800 35 FT/LBS I 25 FT 7900 50 FT/1153 35 FT/LBS
7/17-14 1 .4375 10630 120M 85M 1150M1120M1 6800 50 FT/LBS 35 FT/LBS 9550 70 FT/LBS 55 FT/LBS
7/18-20 I .4375 11870 120M 85M 1150M1120M1 7550 55 FT/LBS 40 FT/LBS 0700 80 FT/LBS 60 FT /LBS
1/Z-13 .5000 120M$851.4 1150141120M 9050 75 FT/L83 2750 110 FT/LBS
1 / Z- 2 0 . 5000 15990 85M 1150).41120M 10700 90 FT/LBS 65 FT/LBS 4400 120 FT/LBS 90 FT/LBS
85M 15014 120M 1 11800 110 FT/LBS 80 FT/LBS 8400 150 FT/LBS 110 FT/LBS
9/ 1111- 18 . 56z5 .z0300 120M 85k4 150M 120M 12950 120 FT/LBS 90 FT /L8S 8250 170 FT/LBS 130 FT/LBS
U 8-11 IIMNUEZ 4 85M 150/441120M 14400 150 FT/LBS 110 FT/LBS 20350 220 FT/LBS 170 FT/1.83
.6250 . 25800 MEM 85M 1501441120M1 16950 180 FT/LBS 130 FT/LBS 180 FT/LBS
280 FT/L83 ZOO FT/LBS 0100 380 FT/ILM 280 FT /LBS
220 FT/LBS 33600 1420 FT/LBS 320 FT/LBS
390 FT/LBS 41800 ' ZS 460 FT/LBS
430 FT/LBS 45800 I 860 I
580 FT/LBS 54500 1 900 FT/L153 880 FT/LBS
630 FT/LBS 1 59700 11000 FT/LBS 740 FT/LBS
600 FT/LBS 66700 280 FT/LBS 960 FT/LBS
1/8 - 12 11.1250 1 851500 105M 1 74M 115nu Ii7oh4 47500 880 FT/LBS 680 FT/LBS 770001 440 FT/LBS 1080 FT/LBS
1/4-7.25001 969001105M1 74M 115 1 120 FT/LB 87200 1820 FT/L83 1350 FT/LBS
-.
1/4 - 1211 . 2500I 0730 t105M 74h4 t1501411ZOM m 11248 FT/L83 420 FT/LBS 96800 2000 FT/LBS 1500 FT/LBS
Jim •A 11.3 7 " v . ,j474)4 i15014i1ZOM nri 468 FT/LBS 100 1 FT/LBS 104000 2380 FT/LB.,
105M 74M 115 - 1ZOM UUU Jew FT/L83 1250 FT/LBS 118400 !ZO FT/L113 2040 FT/LBS
1 / 2-6 .A , 150 105M 74M 115 1120M 000 1 940 FT/LBS 460 FT/LBS 126500 3160 FT/LBS 2360 FT/LBS
Ii. 5%Mn 1105M 1 74M 115- 4120k41 &In T &BS 142200 3560 FT/LBS 2660 FT/LBS
OTES:
1 . THIS CHART SHOWS STANDARD BnLT TORQUES
TO E3 'F LIED UNLESS OTHER' IE SPECIFIED
a. CLAMP LOAD = 7h X PROOF X STkESS AR_
3 . TORQUE (FL) = R 0 T
R = . ZOO FOR DRY CONDITIONS
R = . 130 FOR LUB CONDITIONS
LUB CONDITIONS a NCLUDES LUBRICANTS, LUBRIZING,
PLATING AND H/V.L.)ENEE) WASHERS .
D = NOMINAL 2IAMETEER IN INCHES
T DESIRED CLAMP LOAD IN pouNo
APPENDIX E
IAILSO/011111
CALAVAR CORPORATION
T( RC
I C7 3
, Suggested assembly torques in 7eat-. ounci.

(* Values in Inch-Pounds)
The tai_r_ ri
for an
Property Class 8.8 Property Class 9.8 PropAy Class 10.C..' .-)roperty C ass 12.9
DIAMETER Dry Lubricated Dry Lubricated Dry Lubricated Dry Lubricated

Threads Threads Threads Threads Threads Threads Threads Threads
M4 38.5k 24* 53* 32.5
M6 180* 109*
M8 `L 37 22
M10
i4:12 92 55 127 76
L.; 116 69 146 89 203 122
16 18u 08 230 38 316 190
35L-, 167 617 370
M24 562 .237 609 38f 775 465 `.06 '40
M30 1111 1210 726 1E0 1271

=IL
CALAVAR CORPORATION
BOOM-SUPPORTED
MODEL 38AG
ARTICULATING
VENDOR INFORMATION

CALAVAR CORPORATION
8300 IMPERIAL DRIVE
WACO, TEXAS 76712
(817) 666-4545
MANUAL 92323-004
SEPTEMBER 1994
NOTES
MANUAL 92323-004
SEPTEMBER 1994
This catalog covers:
FD620D-[1S03
PARTS CATALOG
4-STROKE AIR-COOLED ENGINE
FE)62013
PRODUCT CODE NOTE
FD620D-AS03
111-1C Kawasaki Motors Corp., US A

ENGINE DIVISION
P.O. BOX 388285
P/N 99910-2831 GRAND RAPIDS, MI 49588-8285 Printed in U.S.A. 900APC-4/92
GRI D NO.
This catalog covers: This grid covers:
FD620D LI S03 NUivi ERI CAL PARTS Ii4DE; ,',
Parts No. Grid No. Parts Jo. Grid No. Ptr ts No. G- d No.
Firts No. Grid No. Parts No. Grid N o.
11004-2107.. ....... B-03 130G0845 8-08 180B0616 B-10 49078-2063 B-05 92033-2081.........13-14
11008-2087.. ....... B-03 130G0860.. .. .... ..8-03 18080635.... . .....8-10 49085-2052.. ..... 8-07 92036-021..........8-04
11008-6015.. ....... B-03 130G0865 B-03 21039-2059 B-14 49103-2123 8-10 92037-2209.........8-10
11009-2546.. ....... 8-03 130G0870 B-08 21040-2052 B-14 49110-2073 B-10 92037-2210.........8-07
11009-2566.. ....... B-06 130H0665...........13-08 21066-2070.........13-09 49113-2102.. .... 8-10 92042-014..........13-06
11009-2766.. ....... B-09 13001-2136.........8-04 21080-2054 ..... .... B-14 49118-2082.. . ..
......... 8-05 92043-1037.........8-03
11009-3028... ...... B-03 13002-1013.... ..... B-04 21119-2120 8-09 49119-2130 B-04 92043-2196... ...... 8-11
11011-222.. ...... B-12 13008-6025.........8-04 21121-2064 B-09 49120-6059 B-03 92045-2191.........8-07
11011-2239.. ....... B-12 13024-6004.........8-04 21130-2060.. ... ...B-09 49120-6075 B-03 92049-2097 ......... B-03
11013-2114.. ....... B-12 13025-6007.........8-04 21163-2101 B-14 510A5100 B-09 92049-2109.........8-05
11013-2139 ...... ...B-12 13025-6008 B-04 21169-2055. ........ B-09 52005-2108.........8-06 920.9-2110.. ...... .B-03
11022-2056.........8-03 13027-2064... 8-04 21169-2055.... ..... B-13 551A0314 B-08 920-39-2111.........8-07
11022-2063 ..... ....8-03 13029-2108... . ..B-04 21188-2006 ...... ...B-11 55140408 B-04 92055-2086 ......... B-06
11029-2005.........8-12 13029-2109 8-04 21193-2115 B-09 55140416.... ....... B-08 92055-2175.........B-11
110'.7-2036-9H......B - 09 13045-2051 B-06 21480512 B-06 56032-6060 C-03 92063-2241.........B-11
11047-2056-9H......B - 07 13070-2093 B-07 225B0414 B-09 59011-2056 B-07 92064-2093.... ..... B-11
1107-2057-9H......B-12 13081-2108.. ..B-14 23480525 . ..... .. ..B-12 59026-2054 B-09 92066-2099.........B-06
1107-2111-9H......B - 12 13091-2068 B-14 241B0406 B-09 59031-2096.. .. . ... B-09 92070 - 2072.........B-09
11047-2112-9H......B - 07 13107-2097.. . ..... B-07 242 8 0516 8-12 59041-2063 B-07 92093-2092.........B-11
11047-2113-9H......B-07 13107-2099.. ....B-06 26030-2073 . ..... . .. B-09 59051-2112 . .... .. B-04 92093-2093.........8-11
11047-2114-9H......B - 07 13107-2246... ...... B-07 26030-2081 ...... ...B-09 59051-2113 B-07 92141-2110.........B-03
11047-2115-9H......B - 07 13116-2057 ...... ...B-05 27010-2122.........B-14 59051-2114 B-06 92143-2010.........B-03
11060-2072 B-11 13168-2131 B-14 27010-2170 ......... B-09 59076-2056 B-11 92143-2178.........B-12
11060-2073.........B - 11 13183-2120... ...... B-03 27010-2182 B-09 59091-2052-9H B-07 92143-2187.........B-06
11060-2079.........B - 12 13183-2419 B-06 31180600 B-10 59091-2053-9H.. ...B-07 92143-2189.........B-12
11060-2080.........B - 03 13251-6022.........B - 04 311G0600 B-12 59221-2099 B-09 92143-2191.........B-11
11060-2081. ...... ..B-07 13251-6026... ...... B-04 311509-3595-00 B-10 59221-2156.. . ..8-13 92143-2192 ...... ...B-11
11060-2082.........B - 07 13304-6005.. ..... ..B-07 314401-5121B ..... B-10 59256-2051 B-07 9214 .-2052.........B-10
11060-2084.
11060-2084 ... ..... B-07
......... 14024-2113.........B-06 315B1000 B-08 59336-2052 B-07 92144-2053.........B-06
11060-2087.........8 - 11 14024-2205 B-14 315601-32454........B-04 600A1300 B-06 9214 , ;-2287.........6-10
11060-2088.........B - 11 14024-2292 B-03 316644-8577A B-09 670B1507 . ..... . ..B-08 92144-2306... ... ..B-11
11060-2089..
11060-2089 ....... B - 03
......... 14024-2293 B-07 316691-8577A B-09 670B2010 B-03 92144-2307 B-11
11060-2090.........B - 11 14037-2128.. ....... B-07 317B0800 B-14 670B2011 .. .. . ... B-06 92150-2182.........B-10
12004-2094.........B-05 14083-2051.. ....... B-09 317472-5332A B-10 92002-220.. . .. ...B-12 92150-2230.........B-07
12005-2083... ..... .8-05 15003-2243... ...... B-11 32085-2066 B-14 92002-2263 B-04 92150-2231 ...... ...B-07
12009-2061.........B - 05 16004-2051.. ....... B-11 32085-2089 B-11 92002-2269 ..... ....B-10 92150-2254.........B-03
12016-2056... ..... .B-05 16014-2066.... ..... B-11 32150-2076-9H B-03 92002-2277 B-14 92150-2255.........B-02
12020-2059.........B-05 16025-2163 B-11 352101-1349A B-07 92009-1109. ..... ..B-05 92160-2034.........B-03
12032-2064.. ....... B-05 16030-2085'. ..... ...B-11 39003-2064... . B-10 92009-2273 ..... ....B-09 92170-2002.........B-03
130B0520...........B - 09 16031-2071.........B - 11 39061-2056 B-07 92009-2308 B-03 92170-2056. ...... ..B-09
1308061 ,4 .. ..... ...B-06 16035-2073 ..... ....B-11 39062-2051... ...... B-07 92009-2330 B-11 92170-2075.........B-12
130B0614...........B - 09 16035-2074 B-11 39062-2062 B-07 92009-2331 B-11 92180-2013
92180-2013... ...... B-08
.........
130B0616...........B-08 16041-2218.........B-11 39062-2063... ...... B-07 92009-2332...... B-11 92180-2014.........B-08

130B0616 .. ... ... ...B-09 16041-2219... ...... B-11 39108-2057 B-05 92009-2333...... ..B-11 92190-2064.........B-12
130B0620...........B - 11 16060-2173.........B - 12 39129-2043 B-10 92009-2334.........B-11 92190-2086.........B-03
130B0625...........B - 03 16073-2098 B-14 410B0800.. ...... ...B-03 92015-1014...... ..B-07 92200-2036.........B-10
130B0635.. ...... ...B-08 16115-2090 B-0-6 41081000....'.......8-08 92015-1137 ..... . ..8-05 92200-2044 B-08
13080645.. ..... ....B-11 16126-2146.........8-03 41180600...........13-10 92015-1143 8-07 92200-2059-9H......8-12
13080816.. ...... ... B-03 16126-2185 B-11 461F0600 B-12 92015-1143 B-11
13080816...........8-12 16142-2066.........8-07 461F0800..... ...... B-14 92015-2146 . .... . 8-14
13080820... . . ...... B-06 16146-2186.. . . ..8-14 480J1200...........8-05 92015-2147 B-14

13080820... . . ...... B-08 16146-2187 B-14 481J2800 B-08 92015-2167 B-09
130n0825... .. ..... B-08 16154-2053.. . . ..8-06 49015-6130.........8-03 92022-1517 B-09
13080830... . . ...... 8-08 16154-2054.. . . . ..8-06 49040-2065 ...... ...8-13 92022-2194 8-04
13080830... ...... B-14 16169-2092 B-10 49044-2055 B-07 92022-2218 B-14
130808.".0. . . . ...... B-08 16171-2065.........8-10 49054-2054.........8-07 92022-2245.. . . . . 8-09
13000812.. . ...... B-03 171G0818...-........8-08 49063-2056.........8-07 92026-2311.. . B-07
130G0645 B-08 171G0880 B-11 49065-2071 8-06 92027-1568.. . . ...B-09
130G0-675.. ......... B-08 172G0616.. ....... ..8-03 49065-2072...... B-06 92027-2096.. .. ...B-09
130G0845.. .. ...... . 8-03 172G0618...........8-03 49070-2593-9Y 8-12 92027-271... . .. ..8-07

GR I L
This catalog covers: This grid cover s:
FD620D- fl so3
PART NAME INDEX

AIR—FILTER ... . .......
. 0 019 2 SIDS ..... ... B-12 PISTON ........ ..
...... .
. 80. . . .. B-04
08..0. a
CAMSHAFT ..... . ..
. BOOBOO S.S.19.1.6 0.80 a •• B-05 STARTER ......... ....
.... . ..... .. .
. . . .. B-14
CARBURETOR . .. . . . . . . .0 0 0 0 88 2.88 0.0 a .... B-11 VALVE ................................. B-05
CONTROL—EQUIPMENT.. . .....a
... a .00....8 B-10
COOLING—EQUIPMENT ... 0 BO a 0 a 0. .0 8 802. 08. B-07
COOLING—EQUIPMENT..... .. . ............
. B-08
CRANKCASE ....... .. 000.8. .0.0.008.0M B-03
CRANKSHAFT ... 88.09 0 00 0.0.8.... a .8. OS. B-04
CYLINDER ........ 8.0 0 9.8... 00.0..0 •• B-03
ELECTRIC—EQUIPMENT .... 9 0000.0.0 200018 B-09
FUEL—TANK . .. 0.. ........ 0 0 0 9 8.020 IS B-13
. ..
FUEL—VALVE ... .0. . . . . 00 8.008.... B-13
LABEL ....... . 8.8 8 .8 0 0 0 0 0.0800 • . C-03
LUBRICATION—EQUIPMENT .... a 9 0.208.9 ... B-06
MUFFLER .... ......... ... ......... B-12

3R1 D NO.
This catalog covers:
_'D620D- 11 S03 I B Thi s grid covers:
CYLINDER/CRANKCASE
EOM) -2291A -C Ref. Quantity

ND. Parts No. Description
A
130
92143 11004 11004-2107 GASKET-HEAD 2
11022 11008 11008-2087 HEAD-001:.?-CYLINDER 1
11009 130
11008A 11008-6015 HEAD-COMP-CYLINDER I
9243 11009 11009-2546 GASKET,ROCKER CASE 2
11009A 11009-3028 GASKET 2
11022A
11009 11022 11022-2056 CASE - ROCKER 1

92150 11022A 11022-2063 CASE-ROCKER 1
410
cee 11060 11060-2080 GASKET,CRANKCASE COVER 1
92190 11060A 11060-2089 GASKET 1
13183 13183-2120 PLATE 1
130E
4 ---92170
92150
130E
1402',
16126
32150
14024-2292
16126-2146
32150-2076-9H
COVER
VALVE
PIPE
1
1
1
92009 130A 49015 49015-6130 COVER-CRANKCASE 1
13183 49120 49120-6059 CRANKCASE-COMP 1
1,024
3126 11060A
( - FD620-001309)
49120A 49120-6075 CRANKCASE-COMP 1
IT 172A ( FD620-001310 - )
92009 92009-2308 SCREW 1
11000 92043 92043-1037 PIN 6
92043 92049 92049-2097 SEAL-OIL 1

11004 92049A 92029-2110 SEAL-OIL 2
92141 92141-2110 BEARING-PLANE 1
L—'1 11008A 92143 92143-2010 COLLAR 8
130E
9204:3 92150 92150-2254 BOLT 2
92170 92170-2002 CLAMP 1

92190 92190-2086 TUBE 1
130 130B0625 BOLT-FLANGED
11004 92049A 8
49015 130A 13060816 BOLT-FLANGED 4
92141 130B 13000812 BOLT-FLANGED 2
11308
11009A 130C 13000845 BOLT-FLANGED 6
130D 13000860 BOLT-FLANGED 2
49120.A 130E 13000L65 BOLT-FLANGED 8
q!) (,.‘>
0\ ,
00
C;) 92043 172 17200616 BOLT-STUD
172A 172G0618 BOLT-STUD
2
2
11060 ' 410 410B0800 W - PLAIN - S 2

92049A 32150 670 670B2010 0 RING 1
13C -
130D
670
GRID
This catalog covers: Thi s grid covers:
SO3 PISTON/CRANKSF:AF
E0120-2223A-C Ref. Quantity

No. arts No. Description
A
13001 13001-2136 PISTON-ENGINE 2
13002 13002-1013 PIN-PISTON 2
13008 13008-6025 RING-SET-PISTON 2
13024 13024-6004 RING-SET - PISTON LL,0.75 AR
92036 13025 13025-6007 RING-SET-PISTON L,0.25 AR
13025A 13025-6008 RING-SET-PISTON L,0.50 AR

13002
13027 13027-2064 PISTON-ENGINE LL,0.75 AR
r2036 13029 13029-2108 PISTON-ENGINE L,0.25 AR
13029A 13029-2109 PISTON-ENGINE L,0.50 AR
13008 13251 13251-6022 ROD-ASSY-CONNECTING 2
13024
13025•A C) 13251A 13251-6026 ROD-ASSY-CONNECTING,U/S=0.50 AR
13251.A 13251.A 49119 49119-2130 CRANKSHAFT-ASSY 1
13001 59051 59051-2112 GEAR-SPUR 1
13027 92002 315601-3245A BOLT 4
13029.A
92002A 92002-2263 BOLT,10X28 1
92002
92036 92002 92022 92022-2194 WASHER 1
13008 92036 92036-021 RING-SNAP 4
13001 13024 551 55140408 PIN-DOWEL 1
13027 13025.A
13029.A
13002
92036
551
to'
59051
92022 49119
92002A

(iR1 U NU.
Thi s catalog covers: This grid covers:
:D620D- LI S03 , B-05 VALVE/CAMSHAFT
E0130-2081A-C Ref. Quanti ty

No. Par ts No. Descr iption
A
12004 12004-2094 VALVE-INTAKE 2
12005 12005-2083 VALVE-EXHAUST 2
12009 12009-2061 RETAINER-VALVE SPRING 4
12016 12016-2056 ARM-ROCKER 4
12020 12020-2059 SHAFT-ROCKER 2
13116
12032 12032-2064 TAPPET 4
13116 13116 13116-2057 ROD-PUSH 4
39108 39108-2057 RETAINER-SPRING 4
49078 49078-2063 SPRING-ENGINE VALVE 4
49118 49118 - 2082 CAMSHAFT - COMP 1
92009 92009-1109 SCREW 4
13116
92015 92015-1137 NUT 4
12032 92049 92049-2109 SEAL - OIL 4
12032 480 480J1200 CIRCLIP 4
480
12016
92009 480
92015 12016
12009 92015
92015 92009
92009 \N 49078 12020 12016
39108 480 *---92015
92049 92009
12016 N 12004
0-12009
12020 12009
49078
480 49078 12009 --CD 1-61
—39 108
39108 49078
39108
rn92049
-
92049
92049
12005
12005
12004
GRID
Thi s catalog covers: Thi s grid covers:
FD620D- Q 203 LUBRICATION -EQUIPMENT
E0140-2146A Ref. Quant i ty
No. Parts No. Description
49065 11009 11009-2566 GASKET,DRAIN PLUG

13045 13045-2051 RECEIVER - OIL
13107 13107-2099 SHAFT
luso, 16115 13183 13183-2419 PLATE
14024 14024-2113 COVER
16115 16115-2090 CAP-OIL FILLER

16154 16154-2053 ROTOR-PUMP,IN
16154A 16154-2054 ROTOR-PUMP,OUT
49065 49065-2071 FILTER-OIL
49065A 49065 - 2072 FILTER-OIL
52005 52005 52005 - 2108 GAUGE,OIL 1

59051 59051-2114 GEAR-SPUR 1
92042 92042-014 PIN 2
130 92055 92055-2086 RING-0 1
92066 92066-2099 PLUG,DRAIN 1
92055
92042 92143 92143-2187 COLLAR,8.2X10X10 2
92144 92144 - 2053 SPRING 1
670 92042 130 130B0614 BOLT-FLANGED 3
92144 130A 130B0820 BOLT-FLANGED 2
600 214 214B0512 SCREW-PAN+ - 2
59051 13045 600 60041300 BALL - STEEL 1

670 670B2011 0 RING 1
14024
13107
16154
214
13183
11009
92066
49065A 130A
GRI D NO.
Thi s catalog covers: Thi s gri d covers:
FD620D- [11 S03 B-07 COOLING-EQUIPMENT
E0150-2374A-C Ref. Quant i ty

No. ?art s No. Descr i pt i on
39061 A
11047 11047-2056-9H BRACKET
49085 11047A 11047-2112-9H BRACKET
14037
11047C 92150B 11047B 11047-2113-9H BRACKET
130C 11047C 11047-2114-9H BRACKET
13070 11047D 11047-2115-9H BRACKET
92015 92027
11060 11060-2081 GASKET,PUPE COVER
11047A 4
130D 11060A 11060-2082 GASKET,PUPE CASE
110608 11060-2084 GASKET, THERMOSTAT COVER
13070 13070-2093 GUIDE
13304 13107 13107-2097 SHAFT,IMPELLER
92160
1
- 1 92045
13107A
13304
13107-2246
13304-6005
SHAFT,PULLEY
HOUSING-ASSY
92026 14024 14024-2293 COVER, THERMOSTAT
481 14037 14037-2128 SCREEN
92045 16142 16142-2066 COVER-PUMP
39061 39061-2056 RADIATOR-ASSY

130 39062 39062-2051 HOSE-COOLING
59041 39062A 39062-2062 HOSE-COOLING
92037A 39062B 39062-2063 HOSE-COOLING
410
49044 49044-2055 PUMP-WATER
13107A 39062A
130A 110470 49054 49054-2054 THERMOSTAT
49063 49063-2056 SEAL-MECHANICAL
92015 49085 49085-2052 CAP-ASSY-PRESSURE
59011 59011-2056 BELT,FAN
92037A
59041 59041-2063 FAN
5905i 92150
130E 92200
92150A 59051 59051-2113 GEAR-SPUR
92180.A 59336
920A9 59091 59091-2052-9H PULLEY
14024 59091A 59091-2053-9H PULLEY
59091A 13 07
551A 110608 59256 59256-2051 IMPELLER
92037A 551 49054 59336 59336-2052 CASE-PUMP
130J )70
39062B 490U3 92015 92015-1014 NUT 2
5925T I 92015A 92015-1143 NUT 3
92026 92026-2311 SPACER,12X18X1.4 1
92027 92027-271 COLLAR 4
11060A 92037 352101-1349A CLAMP 2
39062 130F
92037A 92037-2210 CLAMP 4
92037 92045 92045-2191 BEARING-BALL,6001DDUC3 2
11047 92049 92049-2111 SEAL-OIL 1
92037A
92150 92150-2230 BOLT,6X40 1
130G liC20 92150A 92150-2231 BOLT,6X20 1
1301 16142
130F
GRI D Nu.
F0620D- LI S03 COOLING-EQUIPMENT

ro. Parts No. Description
39061 A
92150B 92150-2255 BOLT 1
49085 92160 92160-2034 DAMPER 4
14037
110470 92180 92180 - 2013 SHIM,T=0.6 AR
92180A 92180 - 2014 SHIM,T=1.2 AR
92200 92200-2044 WASHER 1
92015
130 130B0616 BOLT-FLANGED 4
11047A .04
130A 130B0635 BOLT-FLANGED 2
130B 130B0820 BOLT - FLANGED 1
130C 130B0825 BOLT-FLANGED 4
130D 130B0830 BOLT-FLANGED 1
13304
130E 130B0840 BOLT - FLANGED 1
130F 130G0645 BOLT-FLANGED 3
130G 130G0675 BOLT-FLANGED 1
130H 130G0845 BOLT-FLANGED 1
92045 1301 130G0870 BOLT-FLANGED 1
130J 130H0665 BOLT-FLANGED 1

171 171G0818 BOLT-STUD 3
(56 315 315B1000 NUT-HEX-FINE 1
410 410B1000 W-PLAIN-S 1
410
481 481J2800 CIRCLIP 1
315
551 551A0314 PIN - DOWEL 1
551A 551A0416 PIN-DOWEL 1
670 670B1507 0 RING 1
92037A
59051 A45---92150
92200
59336 AP---92150A
92049 14024
59091A 107
11060B
92037A 49054
130J
390628
11060A
39062 130F
92037
11047
92037A
130G 11060
1301 16142
130F
GRI D NO.
This catalog covers: Thi s gr i d covers:
FDG2OD - LI S03 B-09 ELECTRIC -EQUIPMENT
E0160-2734A-C Ref. Quant i t y

No. Par t s No. Descr i pt i on
21130 21130 A
27010A 11009 11009-2766 GASKET
11009 11047 11047 - 2036 - 9H BRACKET
14083 14083-2051 COVER-FLYWHEEL
21066 21066-2070 REGULATOR-VOLTAGE
21119 21119-2120 IGNITER
21121 21121-2064 COIL-IGNITION 2

21130 21130 - 2060 CAP - SPARK PLUG 2
59026
21169 21169-2055 TERMINAL 6
21193 21193 - 2115 FLYWHEEL-ASSY 1
26030 26030 - 2073 HARNESS 1
26030A 26030-2081 HARNESS

27010 27010-2170 SWITCH
92027 27010A 27010 - 2182 SWITCH
21121 225 59026 59026 - 2054 COIL-PULSING
59031 59031-2096 COIL-CHARGING
14083
92170 59221 59221 - 2099 CONNECTOR-CORD 1
130 225 92009 92009 - 2273 SCREW 4
21066 920 5 92015 92015-2167 NUT 1
92022 92022-1517 WASHER 2
92022A 1308 92022A 92022 - 2245 WASHER 1
92027 92027-1568 COLLAR 2

92027A 92027 - 2096 COLLAR,6.2X7.8X5 2
92070 92070-2072 PLUG-SPARK,BMR4A(NGK) 2
27010 92072 316644-8577A BAND 2
92022 92072A 316691-8577A BAND 2
92027:
92072 92170 92170 - 2056 CLAMP 1
26030 130 130B0520 BOLT-FLANGED 4
130A 13080614 BOLT-FLANGED 4
130B 130B0616 BOLT-FLANGED 2
225 225B0414 SCREW-PAN-WSP-CROS 4
59031 241 241B0406 SCREW-PAN-WP+-

510 51045100 KEY-WOODRUFF
26030A
92072A
59221
21169
21119 130A
GRI D nu.
FD620D- 11 SO3 B-10 COrTEOL-7ECWIPMEN'T
E0170-2301B Ref. Quantity
180 No. PEr t s No. Description
A
92022
16169 16169-2092 LINK-CHOKE
160A 16171 16171-2065 LINK
92150 39003 39003-2064 ARM-PIVOT
92022
49113 39129 39129-2043 SPRING-GOVERNOR
-92037 42036 314401-5121B SLEEVE
16169
49103 49103-2123 ARM-GOVERNOR 1
16171 49110 49110-2073 GOVERNOR-ASSY 1
49113 49113-2102 PANEL-COMP-CONTROL 1
92027 92002 92002-2269 BOLT 1
92144:. 92022 311509-3595-00 WASHER 2
92144
92027 317472-5332A COLLAR 1
92037 92037-2209 CLAMP 2
92144 92144-2052 SPRING 1
92144A 92144-2287 SPRING 1
49103 92150 92150-2182 BOLT,5X18 2
311 92200 92200-2036 WASHER

411 180 180B0616 BOLT-UPSET-WS
180A 180B0635 BOLT - UPSET-WS
39129 311 311B0600 NUT-HEX
411 411B0600 WASHER-PLAIN
92002 V.
39003
42036
GKl D NU.
Thi s' catalog covers: Thi s gri d covers:
FD620D [1] S03 CARBURETOR
E0180-2A05A Ref. Quantity
No. Par t s No. Description
92009 16126 16041

92055 11060 11060-2072 GASKET
16035A-1 11060A 11060-2073 GASKET
92093A 11060B 11060-2087 GASKET,INTAKE MANIFOLD
920098 \ 11060C 11060-2088 GASKET,INTAKE MANIFOLD
92143A
92143 11060D 11060-2090 GASKET, CARBURETOR
15003 15003-2243 CARBURETOR-ASSY.

16004 16004-2051 CAP-CHAMBER
16014 16014-2066 SCREW-PILOT AIR
16025 16025-2163 VALVE-THROTTLE
16030 16030-2085 VALVE-FLOAT
16031
16031 16031-2071 FLOAT
11060 16035 16035 - 2073 JET-AIR,#1.8
16035A 16035-2074 JET-AIR,#0.9
1E003 92009A 16041 16041-2218 SHAFT-CARBURETOR, CHOKE
32085 16041A 16041-2219 SHAFT-CARBURETOR, THROTTLE
X92064 16126 16126-2185 VALVE,CHOKE 1
92093 21188 21188-2006 SOLENOID 1
16041A 32085 32085-2089 STOPPER 1
X12015 59076 59076-2056 MANIFOLD-INTAKE 1
92009 92009-2330 SCREW 3
92063 92009C
11060A 92009A 92009-2331 SCREW 1
92009B 92009-2332 SCREW 4
21188 16014 92009C 92009-2333 SCREW 1
92009D 92009D 92009-2334 SCREW 1
16025_7 92144A
92009 92015 92015-1143 NUT 2
92043 92043 - 2196 PIN

171 92055 92055-2175 RING-0
92063 92063-2241 JET-MAIN,#112
92064 92064-2093 JET-PILOT,#58
110600 92093 92093-2092 SEAL
130A
92093A 92093-2093 SEAL 1
92143 92143-2191 COLLAR 1
92143A 92143-2192 COLLAR 1
92144 92144-2306 SPRING 2
92144A 92144-2307 SPRING 1
11060C
11060B 59076 130 130B0620 BOLT-FLANGED 5
130A 130B0645 BOLT-FLANGED 3
171 171G0880 BOLT-STUD 2
GRI D Nu.
FD62OD jIJSO IL_ B AIR-FILTER/MUFFLER
E0190-2i96A-C Ref. Quantity

A
11011 11011-2224 CASE-AIR FILTER
16060 11011.4 11011-2239 CASE-AIR FILTER
11013- 11013-2114 ELELENT-AIR FILTER
110134 11013-2139 ELEMENT-AIR FILTER
11029• 11029-2005 ELEMENT-ASSY-AIR FILTER
92170 11047 11047-2057-9H BRACKET 1

11047A 11047-2111-9H BRACKET 1
11060 11060-2079 GASKET,MUFFLRT 2
16060 16060-2173 PIPE-INTAKE 1
49070 49070-2593-9Y MUFFLER-COMP 1
92002 92002-2230 BOLT 2
92143 92143-2178 COLLAr1,5.1X6.3X1/1 3
92143A 92143-2189 COLLAR,6.2X7.8X7.5 4
--11013A 92170 92170-2075 CLAMP 1
92190 92190-2064 TUBE 1
11013
92200 92200-2059-9H WASHER 2
242 234 234B0525 SCREW-PAN-WSP+- 3
242 242B0516 SCREW-PAN-WSP+- 4
92143A 311 311G0600 NUT-HEX 4
461 461F0600 WASHER-SPRING 4
130 11047
61
311
GRI D NO.
FD620D- LI S03 FUEL -TANK/FUEL -VALVE

No. Part s No. Description
59221 A
21169 21169-2055 TERMINAL 2
21169 1
49040 49040-2065 PUMP-FUEL
59221 59221-2156 CONNECTOR-CORD 1
49040
GRI D NO.
This catalog covers: Thi s grid covers:
FD620D Eli S03 14 STARTER
EQ210-21126 Ref. Quantity
No. rar t s No. Description
A
13081 13081-2108 CLUTCH-ASSY
13091 13091-2068 HOLDER,BRUSH
13168 • 13168-2131 LEVER,SHIFT
14024 14024-2205 COVER
16073 16073-2098 INSULATOR
16146 16146-2186 COVER-ASSY 1

16146A 16146-2187 COVER-ASSY 1
21039 21039-2059 BRUSH 4
21040 21040-2052 SPRING - BRUSH 1
21080 21080-2054 ARMATURE 1
21163 21163-2101 STARTER-ELECTRIC 1

27010 27010-2122 SWITCH 1
32085 32085-2066 STOPPER 2
92002 92002-2277 BOLT 2
92015 92015-2146 NUT 2
92015A 92015-2147 NUT 1

92022 92022-2218 WASHER 1
92033 92033-2081 RING-SNAP 1
317 317B0800 NUT-HEX-SMALL 2
461 461F0800 WASHER-SPRING 2
21163
130
461
317
14024
GRI D NO.
FD620D- Eli S03 C-03 LABEL
F0290-2809A Ref. Quantity
A
56032 56032-6060 LABEL - SET 1
56032
DUAL ELEMENT AIR

CLEANER MAINTENANCE
FOAM ELEMENT:CLEAN EVERY
26 HRS.
AWASH IN DETERGENT ANO
BEFORE STARTING WATER. AND ORY THOROUGHLY.
FILL CIANICASE VITN OIL 2.OATURATE IN ENGINE OIL
USE CLASS . SO.SE.SE/CC.IF . ANO 1000000 OUT EXCESS.
PAPER ELEMENT CLEAN EVERY
1111:1111IIMIEZ:111111 100 HRS.
01:11131110111311311 S. IF PAPER ELEMENT IS DIRTY.
TAP GENTLY ON YCUR HAND
E=130111111X111 ED REMOVE OUST.
*CONSULT OPERATOR'S MANUAL 2. IF PAPER ELEMENT
EXTREMELY DIRTY.
INSTTALL NEW
ELEMENT.
OPERATING IN DUETY
CONDITIONS MAY
REQUIRE DAILY
MAINTENANCE.
LIQUID COOLED V-TWIN
13
CALAVAR CORPORATION
BOOM-SUPPORTED
MODEL 38AG
ARTICULATING
ILLSTRATED PARTS MANUAL

CALAVAR CORPORATION
8300 IMPERIAL DRIVE
WACO, TEXAS 76712
(817) 666-4545
MANUAL 92323-003
SEPTEMBER 1994
INTRODUCTION
CONDOR®.
Do not attempt to operate or service the CONDOR® until you have read and understood
all information provided in this manual. Familiarize yourself with the functions and
operations of the upper and lower controls. A good understanding of the controls, their
limitations, and their capabilities will maximize operating efficiency and safety. The
various decals attached to this machine also contain vital safety and operational instruc-
tions. Read the decals before operating this machine. The parts and maintenance
sections of this manual will serve as a tool to be used in servicing the machine and in
ordering parts. When referring to this manual, please note the publication date and any
Serial Number information pertaining to this manual and its corresponding model(s).

used in carrying out a variety of jobs. Therefore, it is YOUR RESPONSIBILITY to con-
sider 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. The
ANSI/SIA Manual of Responsibilities pertaining to this model is attached for your use.
changes.

Parts Manal for information pertaining to optional parts.
CONDOR® MODEL 38AG—Serial Number 1563 and Following
ILLUSTRATED PARTS MANUAL
TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE
GENERAL INFORMATION
A Serial Number Location 3

B Recommended Spare Parts List 4
C How to Order Parts 6
D Parts Groups Breakdown 8
FINAL INSTALLATION
1.1 Final Assembly 9

1.2 Decals Installation 10
1.3 Cover Installation 12
CARRIAGE INSTALLATION
2.1 Carriage Assembly 14

2.2 Steering Installation 16
2.3 Drive Installation (Two-Wheel Drive) 18
2.3A Torque Hub Assembly 20
2.3B Drive Motor Assembly 22
2.3C Brake Assembly 23
2.4 Wheels Installation 24
2.5 Fuel Tank & Battery Installation 25
2.6 Carriage Hydraulic Installation 26
2.7 Hydraulic Tank Assembly 28
2.8 Lift/Steer Manifold Assembly 29
2.9 Series/Parallel Drive Valve Assembly 30
2.10 Proportional Drive Valve Assembly 31
2.11 Speed Control (2-Position/3-Way) Valve Assembly 32
2.12 Kawasaki Gasoline Engine Assembly 34
TURRET INSTALLATION
3.1 Turret Installation 36

3.2 Rotation Installation 38
3.3 Rotation Gearbox Assembly 40
3.4 Rotation Motor Assembly 41
3.5 Turret Hydraulic Installation 42
3.6 Turret Electrical Installation 46
3.7 Lower Control Box Assembly 48
3.8 Electrical Box Assembly, Kawasaki Engine 50
LIFT INSTALLATION
4.1 Lift Installation 52

4.2 Arm Lift Cylinder Assembly 53
(Continued Next Page)
MANUAL 92323-003
SEPTEMBER 1994
1
TABLE OF CONTENTS (Continued)
FIGURE DESCRIPTION
BOOM INSTALLATION
5.1 Boom Installation 55

5.2 Aluminum Boom Assembly 56
5.3 Boom Extension Cylinder Assembly 58
5.4 Boom Extension Cylinder Parts Breakdown 60
5.5 Master Leveling Cylinder Parts Breakdown 62
5.6 Slave Leveling Cylinder Assembly 64
5.7 Slave Leveling Cylinder Parts Breakdown 66
5.8 Holding Valve Assembly 68
5.9 Boom Hydraulic Installation 70
5.10 Hose Installation Diagram 72
5.11 Track Assembly 74
PLATFORM/SKIRT INSTALLATION
6.1 Platform Installation 76

6.2 Platform Assembly 78
6.3 Platform Wiring 81
6.4 Platform Hydraulic Installation 83
OPTIONS INSTALLATION
7.1 Kubota Diesel Engine Installation (Option) ........ ........ .... ...... ...84
7.1A Diesel Engine Electrical Installation 86
7.1B Kubota D850-B2 Diesel Engine 87
7.1C Radiator Installation, Diesel Engine 88
7.1D Electrical Box Assembly, Diesel Engine 89
7.2 Auxiliary Lowering Power Unit Assembly (Option) 91
7.3 Strobe Light Assembly (Option) 92
7.4 Dual Fuel Carburetor Assembly-Liquid (Option) 93
7.5 Dual Fuel Tank Assembly-Liquid (Option) 94
7.6 Dual Fuel Carburetor Assembly-Vapor (Option) 95
7.7 Dual Fuel Tank Assembly-Vapor (Option) 96
7.8 Travel Alarm Assembly (Option)' 97
7.9 Motion Alarm Assembly (Option) 98
7.10 Air Line to Platform Assembly (Option) 99
7.11 110-Volt Line to Platform Assembly (Option) 100
7.12 Foam-Filled Tires Assembly (Option) 101
7.13 Self-Closing Platform Gate Assembly (Option) 102
7.14 Five-Foot Wide Platform Assembly (Option) 103
7.15 Platform-Mounted Work Light (Option) 104
SCHEMATICS & DIAGRAMS
8.0 List of Schematics/Diagrams Appearing in This Section 105
MANUAL 92323-003
2 SEPTEMBER 1994
FIGURE A—Serial Number Location

STAMP ON TURRET PLATE STAMP ON STEER AXLE
STAMP ON DATA PLATE
The CONDOR® Model 38AG Serial Number is stamped in three locations on the machine.
1. The first place to find the serial number stamp is on the data plate affixed to
the chassis, as indicated on the illustration above.
2. Find another serial number stamp on the steer axle, as indicated on the
illustration above.
3. The third serial number stamp is located on the turret plate, near the lower
control console.
MANUAL 92323-003
° SEPTEMBER 1994
3
FIGURE B—Recommended Spare Parts List
CONDOR® MODEL 38AG (1 UNIT-1 YEAR OPERATION)


QTY PART NUMBER DESCRIPTION
1 58079 2-Position/3-Way (Solenoid) Valve

1 36841 Shuttle Valve
1 58425 Torque Hub Vent, 5 PSI
1 36287 NC Logic Cartridge
1 36285 NO Logic Cartridge
1 36286 Counterbalance Cartridge
1 67401 Cartridge, Flow Divider Combiner
1 50316 Hydraulic Filter Cap
4 67408 Element, Hydraulic Filter
1 80377 Relay
1 67947-010 Circuit Breaker, 10 AMP Auto-Reset
2 67280 Relay
2 BVQ01004 Dust Cover, Steering
1 34890 Control Handle Kit, Lower Controls
1 34818 Control Handle Kit, Upper Controls
2 34464 Contact Block, NO/NC
1 36878 Key Switch
2 51914 Contact Block, NC
1 67593 Relay
1 51036 Body, Limit Switch
1 51037 Offset Head, Limit Switch
1 51039 Adjustable Arm, Limit Switch
1 32002 Slope Sensor, 2-Axis 5°
1 34369 Logic Cartridge, NO
1 35033 Cartridge, Counterbalance Valve
1 32586 Cartridge, Relief
6 67865 Repair Link, Hose/Cable Track
1 37809 Mounting Bracket Set, Hose/Cable Track
1 34644 Alarm
1 34836 Operator, Pushbutton—White
1 34383 Contact Block, NO
1 80305 Toggle Switch
1 50077 Toggle Switch
2 40880 Guard, Toggle Switch
1 37165 Controller, Drive/Steer
1 36083 Footswitch
1 36083-100 Service Kit, Footswitch (includes internal switch, fasteners)
4 36847-024 Pin, Grooved
4 92265-001 Operator's Manual, Models 38/47AG (including diesel), 47AE
1 34354 Holder, Operator's Manual
2 34527 Latch
1 32111 Solenoid, Throttle (Kawasaki gasoline engine)
1 38100 Solenoid Assembly, Choke (Kawasaki gasoline engine)
1 67280 Relay (Kawasaki gasoline engine)
NOTE: For ordering replacement decals, please refer to Decals Installation in your Operator's
Manual or in the Illustrated Parts section of your CONDOR® Operation, Parts,
& Maintenance Manual.
MANUAL 92323-003
4 SEPTEMBER 1994
FIGURE B—Recommended Spare Parts List
CONDOR® MODEL 38AG (1 UNIT-1 YEAR OPERATION)

Units Equipped with Kubota D850 Diesel Engine (Option)

QTY PART NUMBER DESCRIPTION
1 34999 Solenoid Module

2 80303 Motor Mount
1 37395 Solenoid, Shut-Off
1 40808 Solenoid, Throttle
1 NNV01008 Throttle Rod End
1 67947-010 Circuit Breaker, 10 AMP Auto-Reset
1 67280 Relay
MANUAL 92323-003
SEPTEMBER 1994
5
FIGURE C—How to Order Parts
1. When ordering parts for your CONDOR®, ensure that you are able to give the
model and serial numbers of all units for which parts are needed.. The serial
number(s) will assist the Calavar Parts Department in providing the correct parts
for your machine(s). Please refer to FIGURE A for Serial Number Location on
this model.
2. If known, please specify the Calavar 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 tele-
phone. A sample parts order (with fax number) follows this page.
4. Parts needed for a warranty repair must be purchased through the Calavar Parts
Department. Credit will be authorized through the Service Department after a
Warranty Claim has been submitted to Calavar. A Warranty Claim is to be filed
for any part received as "defective".
5. Calavar will ship parts as per our customers' request at the time of the order-
i.e., UPS, Federal Express, or preferred truck line. When shipping Federal Ex-
press, your customer account must be given at the time of the order.
6. Calavar 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.

-
Stock Order to be shipped within 2 weeks.
7. Calavar has a $25.00 Net Minimum Billing charge per order.
8. All price quotations will be valid for 30 days.
9. Parts shown as shipped on the Calavar 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 adjust-
ments will be made accordingly.
MANUAL 92323-003
6 SEPTEMBER 1994
FIGURE C—How to Order Parts
CALAVAR PARTS DEPARTMENT

Fax Order Fax No. 800-443-5803
iL3iccount # 'Purchaser I Sales Order #
I Name Name
I C NI S
'U
! ( 1 Address H T Address
7 0
10 M I
1m A City State Zip City State Zip
IE T P
iR
OlPhone Fax Phone Fax
Cust.Purchase Order No Order Date Request Date Special Marks & Numbers
Shipping Instructions

PART NUMBER QTY. DESCRIPTION . NOTES
FOR ORDER STATUS PLEASE CHECK

APPROPRIATE BOX BELOW
EMERGENCY
ROUTINE
STOCK
7
MANUAL 92320-003
AUGUST 1994
CONDOR® MODEL 38AG —Serial Number 1563 and Following
PARTS GROUPS BREAKDOWN
ITEM PART NUMBER DESCRIPTION QTY
1 38229 Carriage Installation (see Fig. 2.1) 1

2 38230 Turret Installation (see Fig. 3 1) 1
3 37314 Lift Installation (see Fig. 4.1) 1
4 37316 Boom Installation (see Fig. 5.1) 1
5 34046 Platform Installation (see Fig. 6 1) 1
8 MANUAL 92323-003
SEPTEMBER 1994
FIGURE 1.1—Final Assembly
7
6
5
4
3
2

1 34354 Holder, Operator's Manual 1

2 67793 Clamp, 2.75" 2
3 BOW30029 Bolt, Hex .3125" - 18UNC x 1.00" long 2
4 BOW31432 Washer, Flat .3125" ID x 6875" OD 2
5 BOW36726 Washer, Split Lock .3125" ID 2
6 BOW31202 Nut, Hex .3125" - 18UNC 2
7 92265-001 Operator's Manual-38AG, 47AG, 47AE 1
-8 66126 Service Manual, Kawasaki FD620D V-Twin Engine 1
MANUAL 92323-003
SEPTEMBER 1994
9
FIGURE 1.2—Decals Installation
21
15
19
2

: INGO CIIR
I U. =I 38A
00
26
35
NOTE: Model 47AG Shown
MANUAL 92323-003
10 SEPTEMBER 1994

FIGURE 1.2—Decals Installation
Ref. 37564 Decal Kit, 38AG (does not include * items) 1

1 37290 Decal, 38A 2
2 50172 Decal, CONDOR® 2
3 35366 Decal, Self-Propelled CONDOR® Operating Instructions 1
4 21882-001 Decal, Danger: Electrocution Hazard 2
5 21882-002 Decal, Danger: This Unit Not Insulated 2
6 21882-003 Decal, Danger: Training/Safe Operation 1
7 52759 Decal, Stand Clear While Operating 2
8 37348 Decal, Lower Control Valves (see NOTE 1) 1
9 34270 Decal, Upper Control Valves 1
10 21850 Decal, Hydraulic Fluid 2
11 50070 Decal, Battery Service 1
12 37354 Decal, Aux. Lowering Instructions (Option; see NOTE 2) 1
67880 Decal, Emergency Lowering (47A) 1
13 35042 Decal, Forward (Arrow) 1
14 35043 Decal, Forward 1
15 34523 Decal, Tire Pressure-60 PSI 4
16 21849 Decal, Gas 1
15376-012* Decal, Diesel (option) 1
17 21971-002 Decal, Do Not Lift Wheels w/Boom 2
18 37784 Decal, Transportation Diagram 2
19 35656 Decal, Made in U S A —6 00" 1
20 68859 Decal, Oil Dipstick Inside 1
21 81417 Decal, Rated Work Load 1
22 36885 Decal, 500 LBS 1
23 54416 Decal, Caution: Tie-Down Ring 3
24 37419 Decal, Panic Stop/Ramping Control 1
25 58419 Tape, Orange/Red 5.00" 39L.F.
26 38176 Decal, Manual Lowering Procedure 2
27 32200 Decal, Warning Power Lines 1
28 37958-500 Decal, Rated Work Load 500 LBS 1
29 * Nameplate, Booms Identification 1
30 38072* Decal, Lower Control Console (gas units) 1
37365* Decal, Lower Control Console (diesel units) 1
31 37969* Decal, Key Switch—Upper/Lower 1
32 38144* Decal, Upper Control Console 1
33 67812* Decal, Glowplugs (diesel models) 2
34 52735* Decal, 110 Volts (option) 1
35 15376-024* Decal, 110V Power To Platform (option) 1
36 67881 Decal, Rotation Tool Inside 1
37 34767* Decal, Auxiliary Lowering—Platform Control (see NOTE 2) 1
NOTE: 1 . Decal #37348, showing lower control valve operation, replaces decal #34502.
2. Decal #34767 is used to indicate the pushbutton control for Auxiliary Lowering
on units equipped with an optional auxiliary power unit. Decal #37354 contains
the instructions for auxiliary lowering on units equipped with the optional power
unit.
MANUAL 92323-003
SEPTEMBER 1994
11
FIGURE 1.3—Cover Installation
3 REF
MANUAL 92323-003
12 SEPTEMBER 1994

FIGURE 1.3—Cover Installation

20 21
19
Ref. 37355 Cover Installation 1

1 Ref. Carriage Weldment 1
2 37113 Wear Pad, Sliding Cover 2
3 37115 Cover, Engine Compartment—Top 1
4 37116 Cover, Engine Compartment 1
5 37118 Door, Side (right-hand) 1
6 37126 Cover, Front 1
7 LBL00210 Latch, Vertical Mounting 2
8 LBL00256 Bracket 2
9 BOW30000 Bolt, Hex .25" - 20UNC x .50" long 16
10 BOW30002 Bolt, Hex .25" - 20UNC x 75" long 8
14 BOW31444 Washer, Flat .25" ID x 625" OD 24
15 BOW34272 Nut, Hex Lock 25" - 20UNC 12
16 37117 Door, Side (left-hand) 1
17 34527 Spring Latch 2
18 38164 Cover, Pump/Engine 1
19 37351 Cover, Lower Control Valves (top plate only) 1
20 34394 Cover, Boom 1
21 34454 Cover, Boom 1
-22 BOW36726 Washer, Split Lock .3125" ID 5
-23 BOW30200 Bolt, Hex .3125" - 24UNF x .50" long 5
-24 BOW31412 Washer, Flat .3125" ID 5
MANUAL 92323-003
SEPTEMBER 1994
13
FIGURE 2.1 —Carriage Assembly
5
7 (INSIDE COVER)
8
1
NOTE: Model 47AG Shown
MANUAL 92323-003
14 SEPTEMBER 1994

FIGURE 2.1—Carriage Assembly
Ref. 38229 Carriage Assembly 1

1 38159 Carriage Weldment 1
2 34213 Steering Installation (see Fig. 2.2) 1
3 38086 Drive Installation (see Fig. 2.3) 1
-4 38081 Hydraulic Installation (see Fig. 2.6 1
5 34388 Fuel Tank & Battery Installation (see Fig. 2.5) 1
6 37573 Wheel Installation (see Fig. 2.4) 1
7 38079 Engine Installation (see Fig. 2.12) 1
8 38205 Tube, Fuel 1
MANUAL 92323-003
SEPTEMBER 1994
15
11.1.1141
CD REF. CARRIAGE WELDMENT .
20
.
12
FIGURE 2 .2 —Steeri n g I nstall ati on

19
12
13

FIGURE 2.2—Steering Installation
Ref. 34213 Steering Installation 1

1 34877 Knuckle, Left-Hand 1
2 34876 Knuckle, Right-Hand 1
3 34350 Tie Rod, 43.50" 1
4 51170 Cylinder, Steering (Hy Power; Seal Kit #91109) 1
4A 51170-100 Clevis, Threaded (see item 20 for pin) 1
5 37009 Pin Weldment, Steering 2
6 34145 Bushing, Self-Lube 4
7 34336 Bearing, Thrust 2
9 34341 Rod End, Male 2
10 36924 Washer, Flat 2
11 BOW36475 Bolt, Hex .75" - 16UNF x 2.75" long 2
13 36847-073 Pin, Grooved .25" x 2.50" 2
14 BOW32288 Nut, Jam .75" - 16UNF 4
15 BOW34274 Nut, Hex Lock .375" - 16UNC 2
16 BOW36720 Washer, Flat 1 00" ID 1
17 02793 Straight, MJ04 MPO6 2
18 BOW34288-1 Nut, Hex Lock (Flex) .75" - 16UNF 2
19 BOW34991 Pin, Spiro! .25" x 2.00" 2
20 51170-101 Pin, Clevis for Steering Cylinder #51170 2
MANUAL 92323-003
SEPTEMBER 1994
17
FIGURE 2.3—Drive Installation (Two-Wheel Drive)
MANUAL 92323-003
18 SEPTEMBER 1994

FIGURE 2.3—Drive Installation (Two-Wheel Drive)

Ref. 38086 Drive Installation (Two-Wheel Drive) 1

1 35317 Torque Hub, 18.25:1 Ratio (see Fig. 2.3A) 2
2 58425 Vent, 5 PSI .25" NPT Relief (used on torque hubs) 2
3 34460 Brake, B-Mount Modular (see Fig. 2.3C) 2
4 34883 0-Ring 2
5 38085 Motor, Hydraulic 5.4 cu. in. (see Fig. 2.3B) 1
8 BOW36729 Washer, Split Lock 50" ID 4
9 BOW33675 Bolt, Socket Head .50" - 13UNC x 4.50" long 4
10 BOW31413 Washer, Flat .375" ID x 1.00" OD 4
13 00560 Straight, MJO8 M010 4
14 02236 Elbow, 90° MJ04 M004 (used only on left side) 2
MANUAL 92323-003
SEPTEMBER 1994
19
FIGURE 2.3A—Torque Hub Assembly
25
32
33
21 33
45
20 MANUAL 92323-003
SEPTEMBER 1994
FIGURE 2.3A—Torque Hub Assembly
-1 35317 Torque Hub, 18.25:1 Ratio 2

2 EQE01037 Coupling 1
-3 EQE01069 Assembly, Hub-Spindle (includes items 4-14) 1
4 EQE01070 —Spindle 1
5 EQE01071 —Seal 1
6 EQE01073 —Cone Bearing 1
7 EQE01072 —Cup Bearing 1
8 EQE01074 —Hub 1
9 EQE01014 —Stud 9
10 EQE01013 —Pipe Plug 2
11 EQE01008 —Cup Bearing 1
12 EQE01009 —Cone Bearing 1
13 EQE01011 —Spacer 1
14 EQE01012 —Retaining Ring 1
15 EQE01015 Internal Gear 1
16 E QE01055
. Assembly, Input Shaft (includes items 17-20) 1
17 EQE01075 —Input Shaft 1
19 EQE01032 —Spring 1
20 EQE01031 —Retaining Ring 1
21 EQE01036 Thrust Washer 2
22 EQE01057 Thrust Spacer 1
23 EQE01054 Input Gear 1
-24 EQE01016 Carrier Assembly (includes items 25-31) 1
25 EQE01017 —Carrier 1
26 EQE01021 —Planet Shaft 3
27 EQE01023 —Roll Pin 3
28 EQE01018 —Thrust Washer 6
29 EQE01022 —Cluster Gear 3
-30 EQE01019 —Roller, Needle 96
32 EQE01053 Thrust Spacer 1
33 EQE02300 0-Ring 2
34 EQE01024 Ring Gear 1
-35 EQE01025 Cover Assembly (includes items 36-46) 1
36 EQE01590 —Bolt, Hex 12
37 EQE02310 —Bolt, Shoulder 4
38 EQE01038 —Washer, Flat 16
39 EQE02000 —Cover, Hub 1
40 EQE01632 —0-Ring 1
41 EQE01026 —Cap, Cover 1
42 EQE01628 —0-Ring 1
43 EQE01028 —Rod, Disconnect 1
44 EQE01027 —Cap, Disconnect 1
45 BOW39002 —Bolt, Hex .25" - 20UNC x .75" long (Grade 8) 4
46 EQE01595 —Pipe Plug 1

MANUAL 92323-003 21
SEPTEMBER 1994

FIGURE 2.3B—Drive Motor Assembly
Ref. 38085 Hydraulic Motor, 5.4 cu in. displacement 2 (2WD)

1 (see item 28) Seal, Dust 1
2 (see item 28) Ring, Wire 1
3 (see item 28) Shim, Back-Up 1
4 (see item 28) Seal, High-Pressure 1
5 (see item 28) Shim, Back-Up 1
6 (see item 28) Seal, Teflon 1
7 (see item 28) Seal, Shaft 1
8 (see item 28) Seal, Body 4
9 (see item 28) Seal, Commutator 1
10 (see item 28) Seal, 0-Ring 1
11 (see item 28) Seal, Teflon 1
12 38085-001 Carrier, Seal 1
13 38085-002 Washer, Thrust 2
14 38085-003 Bearing, Thrust 2
15 38085-004 Bearing, Shaft 2
16 38085-005 Plate, Wear 1
17 38085-006 Manifold 1
18 38085-007 Commutator Assembly 1
19 38085-008 Piston, Endcover 1
20 38085-009 Spring, Piston 1
21 38085-010 Endcover, 875"-14 Rear Ports 1
22 Nameplate, HB-05565070 Identification 1
23 B0W36065 Bolt, Hex .375" - 24UNF x 3.75" long 4
24 38085-011 Housing, SAE 'A'-Style, 2-Bolt Flange 1
25 38085-012 Link, Drive 1
26 38085-013 Rotor Assembly 1
27 38085-014 Shaft, 13-Tooth Spline 1
28 38085-015 Seal Kit, #38085 Hydraulic Motor (includes items 1-11) 1

MANUAL 92323-003
22 SEPTEMBER 1994

FIGURE 2.3C—Brake Assembly

-1 34460 Brake 2 (2WD)

2 LHB01002 Bearing 1
3 LHB01003 Bolt, Flat Head 2
4 LHB01004 Cover Plate
5 LHB01005 Shaft 1
6 LHB01006 Outer Spline 1
7 LHB01007 Bolt, Socket Head Shoulder 4
8 LHB01008 Disc, Primary 1
9 LHB01009 Disc, Rotor 2
10 LHB01010 Disc, Stator 1
11 LHB01011 Bolt, Socket Head 2
12 LHB01012 Plate, Spring 1
13 LHB01013 Spring, Red 2
14 LHB01014 Spring, Blue 4
15 LHB01015 Piston 1
16 LHB01016 Plate, Pressure 1
17 LHB01017 Screw, Bleeder 1
-18 93156 Seal Kit (includes items 19-26) 1
1
19 —Retaining Ring
1
20 —Snap Ring
1
21 —Seal, Oil
2
22 —Gasket, Case
1
23 —Ring, Back-Up
1
24 —0-Ring
1
25 —Ring, Back-Up
1
26 —0-Ring
MANUAL 92323-003
SEPTEMBER 1994
23
FIGURE 2.4—Wheels Installation

-1 34217 Wheels Installation (2WD) 1

2 34536 Tire & Wheel Assembly, Drive 2
includes qty two (2) item 7 tire, qty two (2) item 5 rim
3 34545 Tire & Wheel Assembly, Steer 2
Includes qty two (2) item 7 tire, qty two (2) item 6 wheel
4 a ^ t -104,4 Nut, Wheel •50" - 20UNF (6/steer hub, 9/drive hub) 30
5 34332 Drive Wheel 2
6 34015 Steer Wheel 2
7 34531 Tire, 7.50 R16-60 PSI 4
8 34017 Steer Hub (each includes shown qty of items 11-17) 2
9 34749 Washer, Keyed 2
10 345 1 ....: .::‘,..
- Nut, Castle alb
2
11 91114 Grease Seal 1
12 91113 Inner Cone Bearing 1
13 91112 Inner Cup Bearing 1
14 BVQ01005 Hub 1
15 91024 Outer Bearing Cup 1
16 91023 Outer Bearing Cone 1
17 BVQ01004 Dust Cap 1
24 MANUAL 92323-003
SEPTEMBER 1994

FIGURE 2.5—Fuel Tank & Battery Installation
14

Ref. 34388 Fuel Tank Installation 1

1 51306 Fuel Tank, 12 GAL 1
51306-001 Cap Replacement 1
51306-002 Gauge, Replacement 1
2 51307 Bracket Set, Fuel Tank Mounting 1
3 BOW9749 Hose, Fuel Line .25" ID (from tank to fuel tube) 8L.F.
4 BOW24110 Hose Clamp 1
5 67624 Hose End 1
7 Counterweight, Carriage (Right-Hand) NSS*
8 Counterweight, Carriage (Left-Hand) NSS*
-11 38205 Tube, Fuel Line (from fuel hose to engine compartment) 1
12 BOW31201 Nut, Hex .25" - 20UNC 2
14 37722 Bracket, Battery Hold-Down 8.25" 1
15 BOW32488 Threaded Rod, .25" - 20UNC x 12.00" (cut to 9") 2
17 121-96822-00 Battery, 12V DC 1
*NSS — Not Sold Separately

MANUAL 92323-003
SEPTEMBER 1994
25
FIGURE 2.6 — Carriage Hydraulic Installation
32
17 28
31
29
10
30
13
AUX. LOWERING 5
POWER UNIT (OPTION) 14 (x2)
SEE FIG. 7.2
MANUAL 92323-003
26 SEPTEMBER 1994

FIGURE 2.6— Carriage Hydraulic Installation
Ref. 38081 Carriage Hydraulic Installation 1

1 36768 Lift/Steer Manifold Assembly (see fig. 2.8) 1
2 36707 Drive Valve Assembly, Series/Parallel (see Fig. 2.9) 1
-3 34219 Hydraulic Tank Assembly (see Fig. 2.7) 1
-4 38202 Tube Assembly 2
5 38203 Spacer Plate, Pilot-Operated Check Valve (item 14) 1
-6 00388 Straight, FJO8 MJ06 4
7 [Not Used]
8 37171 Valve, Solenoid 1
9 36922 Valve, Check/Choke (see Fig. 2 11) 1
10 38148 Drive Valve Assembly, Proportional (see Fig. 2.10) 1
-1 1 37757 Elbow, 90° Modified .375" NPT 1
-12 00218 Straight, MJ12 M010 1
13 58079 Valve, 2-Position/3-Way (see Fig. 2 11) 1
14 38186 Valve, Pilot-Operated Check 2
-15 02473 Straight, MJ06 M008 1
-16 02319 Elbow, 45° MJ06 FJO6 1
17 35052 Assembly, Wire Harness Connector 6
-18 02671 Elbow, 90° MJ06 M008 2
-19 02857 Elbow, 90° MJ04 M006 2
-20 00326 Tee, MJ08 FJO8 MJ08 4
-21 00348 Straight, FJO8 MJ04 2
-22 02219 Elbow, 90° MJ04 FJO4 1
-23 BOW30037 Bolt, Hex .3125" - 18UNC x 3.00" long 2
-25 BOW30010 Bolt, Hex 25" - 20UNC x 2.50" long 2
-27 67295-019 Cable, 2 Conductor/16AWG Type SO 8L.F.
28 37422 Accumulator 1
29 37421 Relief Valve 1
30 36841 Shuttle Valve 1
31 67169-005 Clamp, 2.25u 1
32 33430 Filter, Return (Replacement element #67408) 1
-33 02674 Elbow, 90° MJ10 MP12 1
-34 02675 Elbow, 90° MJ12 MP12 1

MANUAL 92323-003 27
SEPTEMBER 1994

FIGURE 2.7—Hydraulic Tank Assembly

Ref. 34219 Hydraulic Tank Assembly 1

1 37808 Filler Breather 1
2 52049 Gauge, Fluid Level 1
3 34209 Strainer, Tank 1
4 BOW13402 Nipple, 1.00" NPT 1
5 34212 Ball Valve, Low Pressure 1
6 02400 Tee, MJ16 MP16 MJ16 1
7 04019 Straight, FJ16 MJ06 1
8 BOW13372 Plug, 50" NPT 1
9 BOW13400 Nipple, 50" NPT 1
10 67051 Coupling, Quick Disconnect Male .50" 1
11 67053 Dust Cover, Quick Disconnect 1
MANUAL 92323-003
28 SEPTEMBER 1994
FIGURE 2.8—Lift/Steer Manifold Assembly
-1 36768 Assembly, Manifold and Fittings 1

2 36720 Lift/Steer Manifold Assembly (includes items 3-10) 1
3 51616 —Cartridge, Relief Valve 1
4 C0001007 --Seal Kit 1
5 34784 —Valve, 3-Position/4-Way DO1 2
6 BOW33596 —Capscrew, Socket Head #10 - 24UNF x 2.00' long 8
7 36721 —Manifold, Lift/Steer 1
8 BOW33627-1 —Capscrew, Socket Head .3125" - 18UNC x 3.00" long 2
9 35052 —Connector, Wire Harness 4
10 [Not Used]
11 02473 Straight, MJ06 M008 5
12 04012 Nut, Cap #8 1
13 00480 Plug, M008 1
14 04134 Straight, MJ04 M008 2
15 00353 Tee, MJ06 MJ06 FJO6 2
16 02298 Elbow, 90° MJ06 FJO6 1
17 04148 Straight, FJO6 MJ04 1
MANUAL 92323-003
- Indicates Items Not Shown SEPTEMBER 1994
29
FIGURE 2.9—Series/Parallel Drive Valve Assembly
ITEM PART NUMBER DESCRIPTION CITY

-1 Assembly, Series/Parallel Drive Manifold 1
2 00456 Straight, MJ04 M006 (P1) 1
3 02447 Plug, M006 2
4 02664 Elbow, 90° MJ08 M012 (Al A2, B1, B2) 4
5 00303 Straight, MJ08 M012 (A3, B3) 2
6 36707 Drive Manifold (includes items 7-14) 1
7 34967 —Body, Manifold 1
8 36287 —Cartridge, Logic Element NC 52 2
9 36285 —Cartridge, Logic Element NO 52 2
10 RTM01009 --Seal, Logic Element 4
11 36286 —Cartridge, Counterbalance Valve 2
12 RTM01011 --Seal, Counterbalance Valve 2
13 67401 —Cartridge, Flow Divider Combiner 1
14 COQ01001 --Seal, Flow Divider Combiner 1
15 00326 Tee, MJ08 FJO8 MJ08 ........ .............................. ............. 6
16 00388 Straight, FJO8 MJ06 6
MANUAL 92323-003
30 SEPTEMBER 1994

FIGURE 2.10—Proportional Drive Valve Assembly
Ref. 38148 Assembly, Proportional Drive Valve 1

1 38132 Drive Valve, 18 GPM 1
2 00353 Tee, MJ06 MJ06 FJO6 1
3 04017 Straight, FJ10 MJ06 2
4 00560 Straight, MJ08 M010 2
5 00327 Tee, MJ10 FJ10 MJ10 2
6 00222 Straight, MJ10 M010 2
7 00417 Plug, M004 1
8 02393 ........ ............. Plug, M010 1
Indicates Items Not Shown
MANUAL 92323-003
SEPTEMBER 1994
31
FIGURE 2.11 —Speed Control (2-Position/3-Way) Valve Assembly
32 MANUAL 92323-003
SEPTEMBER 1994
FIGURE 2.11—Speed Control (2-Position/3-Way) Valve Assembly
-1 Assembly, Speed Control Valve (2-Position/3-Way) 1

3 02458 Tee, MPO4 FP04 FP04 1
4 04537 Straight, MPO4 FJO4 1
5 36922 Valve, Check/Choke 1
6 58079 Valve, Control 1
7 35031 —Cartridge, 2-Position/3-Way 1
8 34374 —Coil, 12V DC 1
9 —Valve Body NSS*
*NSS — Not Sold Separately
MANUAL 92323-003
SEPTEMBER 1994
33
FIGURE 2.12—Kawasaki Gasoline Engine Installation
MANUAL 92323-003
34 SEPTEMBER 1994

FIGURE 2.12—Kawasaki Gasoline Engine Installation
Ref. 38079 Kawasaki Gasoline Engine Installation 1

-1 38082 Engine Assembly 1
2 38169 — Kawasaki Gasoline Engine Modified (with heatshield) 1
2A 38099 --Engine, Kawasaki FD620D 1
3 38033 —Plate, Engine Mounting 1
4 38224 —Adapter, Pump Mounting (Modified) 1
-5 BOW36056 —Bolt, Hex 375" - 16UNC x 1 50" long 4
-6 BOW31327 —Washer, Split Lock 375" ID 4
7 38084 —Pump Triplex 1
8 38118 —Coupling Assembly 1
-9 BOW46055 —Bolt Hex 375" - 16UNC x 1 25" long 2
-10 BOW31327 —Washer, Split Lock 375" ID 2
-11 38102 —Tailpipe 1
-12 67169-001 —Clamp, Muffler 1 25" 1
-13 38100 —Choke Assembly Remote-Mount 1
14 32111 —Solenoid Throttle 12V DC 1
15 38103 —Support Bracket Throttle Solenoid 4 00" 1
-16 38104 —Throttle Link Bellcrank-Throttle 1
17 38105 —Throttle Link Bellcrank-Solenoid 1
-18 38106 —Bellcrank 1
-19 BOW2120 —Clevis Pin, 25" x 75" long 1
-20 BOW2023 —Clevis Steel for 25" diameter rod 1
-21 BOW38217 —Cotter Pin 09375" x 1 00" long 1
-22 BOW30000 —Bolt Hex 25" - 20UNC x 50" long 2
-23 BOW31201 —Nut Hex 25" - 20UNC 2
-24 BOW31325 ......•• ...... —Washer, Split Lock .25" ID 2
-25 BOW31430 —Washer Flat #10 ID 3
-26 BOW32281 —Nut Hex Jam 25" - 28UNF 2
-27 BOW31 146 —Screw, Slotted Round Head #10 - 32UNF x 1.00" long •••• 2
-28 BOW31829 —Screw, Self-Tapping 2
-29 BOW31233 —Nut Hex Keps #10 - 32UNF 1
-30 37987 Engine Mount 4
-31 BOW39058 Bolt Hex 375" - 16UNC x 2 00" long (Grade 8) 4
-32 BOW31327 Washer, Split Lock 375" ID 4
-33 BOW31413 Washer, Flat 375" ID x 1 00" OD 4
34 67157-003 Oil Pressure Switch 4 PSI 1
MANUAL 92323-003
SEPTEMBER 1994
35
FIGURE 3.1 —Turret Installation
MANUAL 92323-003
36 SEPTEMBER 1994

FIGURE 3.1—Turret Installation

Ref. 38230 Turret Installation 1

1 37289 —Turret Weidment 1
2 38220 —Rotation Installation (see Fig. 3.2) 1
3 34812 —Turret Hydraulic Installation (see Fig. 3.5) 1
4 38080 —Turret Electrical Installation (see Fig. 3.6) 1
5 34521 —Pad, Arm Rest 1
6 37783 —Boom Rest, 38A 1
-7 BOW36836 —Bolt, Socket Flathead 375" - 16UNC x 1 50" long 2
MANUAL 92323-003
SEPTEMBER 1994
. 37
FIGURE 3.2 Rotation Installation
MANUAL 92323-003
38 SEPTEMBER 1994

FIGURE 3.2 Rotation Installation
Ref. 38220 Rotation Installation, 38AG 1

1 34033 Ring Gear 1
2 34034 Rotation Gearbox (see Fig. 3.3 for assembly) 1
3 32762 Hydraulic Motor, Turret Rotation (see Fig. 3.4) 1
4 32763 Assembly Cross-Port Relief Valve (id. items 5, 6) 1
5 RTM01004 —Valve Body 1
6 67486 —Cartridge Relief Valve 1100 PSI 2
9 BOW36717 Washer, Flat .625" ID x 1 31" OD 4
10 BOW36717-HD Washer, Flat .625" ID (Hardened) 46
15 BOW32277 Nut, Jam .625" - 11UNC 1
16 BOW36185 Bolt, Square Head .625" - 11UNC x 2.75' long 1
17 BOW7588 Lube Fitting, 90° .125" NPT 2
18 02298 Elbow, 90° MJ06 FJO6 2
19 34966-401 Orifice Fitting Assembly 2
MANUAL 92323-003
SEPTEMBER 1994
39
FIGURE 3.3—Rotation Gearbox Assembly
15
-1 34034 Rotation Gearbox 1

2 93098 —Retainer, Motor Shaft 1
3 BOW36081 —Bolt 4
4 93097 —Bearing Cup 2
5 93096 —Bearing Cone 2
6 93095 —Worm Shaft 1
7 93094 —Housing, Cast 1
8 93099 —Retainer, Hex End Shaft 1
9 BOW36080 —Bolt 4
10 93100 —Seal Kit (includes items 1 1-15) 1
11 --Seal, Bearing 2
12 --Seal, Shaft 1
13 --Shim, Bearing .003" 1
MANUAL 92323-003
40 SEPTEMBER 1994

FIGURE 3.4—Hydraulic Motor, Turret Rotation
11
17

-1 32762 Hydraulic Motor, Turret Rotation 1

3 —Dust Seal 1
4 —Wire Snap Ring 1
5 —Seal Spacer 1
6 —Shim, Back-Up 1
7 —Seal, Housing 1
8 —Seal, Body 3
9 VGH01002 Thrust Washer 1
10 93114 Thrust Bearing 1
11 93115 Housing, 2-Port Manifold 1
12 93113 Shaft 1
13 CLK00011-004 Key, Shaft 1

14 VGH01006 Plug, Cooling 1
15 93112 Link, Drive 1
16 93111 Plate, Wear 1
17 93109 Pin, Drive Link 1
18 VGH01014 Ball 1
19 93110 Rotor Set 1
20 93108 Endcover 1
21 93107 Bolt, Hex (torque to 50 ft -Ibs ) 1
MANUAL 92323-003
SEPTEMBER 1994
41
FIGURE 3.5—Turret Hydraulic Installation
42 MANUAL 92323-003
SEPTEMBER 1994
-1 34812 Turret Hydraulic Installation 1

2 [Not Used]
3 [Not Used]
4 [Not Used]
5 [Not Used]
6 [Not Used]
7 34221 Lower Control Valve Assembly (includes items 1 1-20) 1
8 BOW31201 Nut, Hex .25" - 20UNC 2
10 BOW31444 Washer, Flat .25" ID x .625" OD 2
11 ENR01020 —Banking Kit 1
12 ENR01008 —Inlet Section ("PRESS") 1
13 ENR01023 —Load Check Kit 1
14 ENR01016 --Ball, Load Check 2
15 ENR01017 --Retainer, Load Check 2
16 ENR01019 —Valve Section 4
17 ENR01009 —Outlet Section ("TANK") 1
18 34890 —Handle Kit, Lower Control Valve 1
19 ENR01002 --Handle 4
20 ENR01022 --Knob 4
21 00488 Tee, MJ06 FJO6 FJO6 2
22 04038 Straight 1
23 04012 Cap Nut 1
24 04563 Straight, MJ06 M006 (long) 4
25 02298 Elbow, 90° MJ06 FJO6 8
27 02662 Elbow, 90° MJ06 M006 5
28 36841 Shuttle Valve, .375" NPT 4
29 02448 Straight, MJ06 M006 7
30 52661 Flow Control Valve 1
31 04151 Elbow, 90° M006 MPO4 1
32 04141 Elbow, 90° 1
33 02447 Plug, M006 1
MANUAL 92323-003
SEPTEMBER 1994
43
FIGURE 3.5 — Turret Hydraulic Installation
23
31
INLET
(PRESS)
22
21
25
25
BOOM LIFT/
BOOM EXTENSION
TURRET
ROTATION
MANUAL 92323-003
44 SEPTEMBER 1994
25
22
33
-1 34812 Turret Hydraulic Installation 1

2 [Not Used]
3 [Not Used]
4 [Not Used]
5 [Not Used]
6 [Not Used]
7 34221 Lower Control Valve Assembly (includes items 1 1-20) 1
8 BOW31201 Nut, Hex .25" - 20UNC 2
10 BOW31444 Washer, Flat 25" ID x .625" OD 2
12 ENR01008 —Inlet Section ("PRESS") 1
13 ENR01023 —Load Check Kit 1
14 ENR01016 —Ball, Load Check 2
17 ENR01009 —Outlet Section ("TANK") 1
18 34890 —Handle Kit, Lower Control Valve 1
20 ENR01022 --Knob 4
21 00488 Tee, MJ06 FJO6 FJO6 2
22 04038 Straight 1
23 04012 Cap Nut 1
24 04563 Straight, MJ06 M006 (long) 4
25 02298 Elbow, 90° MJ06 FJO6 8
27 02662 Elbow, 90° MJ06 M006 5
28 36841 Shuttle Valve, .375" NPT 4
29 02448 Straight, MJ06 M006 7
31 04151 Elbow, 90° M006 MPO4 1
32 04141 Elbow, 90° 1
33 02447 Plug, M006 1
MANUAL 92323-003
SEPTEMBER 1994
45
FIGURE 3.6 —Turret Electrical Installation
6
(7-14)
MANUAL 92323-003
46 SEPTEMBER 1994

FIGURE 3.6—Turret Electrical Installation

Ref. 38080 Turret Electrical Installation 1

1 32002 Slope Sensor, 2-Axis 1
2 38071 Lower Control Box Assembly 1
-3 BOW31444 Washer, Flat .25" ID x .625" OD 4

-4 BOW36725 ......... Washer, Split Lock .25" ID 2

-5 BOW31201 Nut, Hex .25" - 20UNC 4
6 34509 Limit Switch Assembly (includes items 7-14) 1
7 51036 Body, Limit Switch 1
8 BOW31145 Screw, Round Head 2
9 BOW31323 Washer, Split Lock 2
10 BOW31233 Nut, Hex Keps 2
11 51037 Offset Head, Limit Switch 1
12 51039 Adjustable Arm, Limit Switch 1
13 67114-002 Strain Relief 1
14 34982 Harness, Limit Switch 1
-15 67123-001 Seal, Electrical Connector 50" 1
-16 BOW17351 Nut, Conduit Connector .50" 1
17 38075 Electrical Box Assembly, Kawasaki Engine (see Fig. 3.8) 1
18 37553 Bracket, Electrical Box 2

MANUAL 92323-003 47
SEPTEMBER 1994

FIGURE 3.7 - Lower Control Box Assembly
0•
SEE NOTE 3
SEE NOTE 2 0 CO e 00 0 4 PL
0 < (,)
CID ,r) co 0
ct. 5
411
11111kk
k
IL
IS
i
tairmailasaaaIN=
ma wa
•
iminu.... 1112
Or g+)
141 •
gA NI rs±)
itig+) g
llair
oo 11;+5 E3
JOIDICIIIL AMINO-
C+211 rg+) Cfr Op
L311 • 115.3 531'
parlim c+
7iionfir -moor / SEE NOTE 1
00 00 G O
NOTES:
1. CIRCUITS 5A, 5C AND 22/23 (INSIDE BOX) ARE TO BE 12 GAUGE (ITEM 16).
2. CABLE SHOWN IS FOR REFERENCE ONLY. •
3. CONNECTORS AND DECALS ARE NOT ILLUSTRATED.
4. SEE ELECTRICAL SCHEMATIC #38069.
48 MANUAL 92323-003
SEPTEMBER 1994

FIGURE 3.7—Lower Control Box Assembly
Ref. 38071 Lower Control Box Assembly 1

1 38001 Control Box 1
2 52671 Key Switch, 3-Position 1
3 52983 Operator, Push-Twist (Emergency Stop) 1
4 52669 Operator, Pushbutton—Black 1
5 69145 Operator, Pushbutton—Yellow 1
6 69146 Operator, Pushbutton—Green 1
7 52672 Contact Block, 1 NO w/Base 3
8 52029 Contact Block, 2 NO w/Base 2
9 34383 Contact Block, 1 NO 4
10 34552-012 Terminal Strip 1
11 BOW31234 Screw, Round Head #10 - 24UNC x 375" long 2
12 BOW31134 Nut, #10 - 24UNC 2
13 67114-009 Strain Relief 1
14 67124-002 Nut, Conduit Connector 1
15 67123-002 Seal, Electrical Connector 1
16 58251 Wire, 12 GA 4
17 58292 Wire, 16 GA 10
18 34836 Operator, Pushbutton—White 1
19 51914 Contact Block, 1 NC w/Base 1
20 38073 Decal Lower Control Box Electrical Tags 1
21 37969 Decal Upper/Lower Selector Switch 1
22 38072 Decal, Lower Controls 1
MANUAL 92323-003
SEPTEMBER 1994
49
FIGURE 3.8—Electrical Box Assembly, Kawasaki Engine
0 CIO • 0 00 0 0
4 PL MB 2 P 2 PL 0 fre 003 PL Oe 2 PL
0
0 0
TO
UGH TS
n ON
SEE NOTE 3
Firlo 41116
lc, TS
WOBBULATOR
11 S REGULATOR (ID •

START
Avi LOCKOUT
NEC (-) DELAY
LOCKOU T
111,14
4 SPK5 (ERN
5 5.. TOW
.05 (Oa)
IWG a)
4) 12 M.
X/27
000
VOLT METER
HOUR METER OPTION 2 PL
St
26/27
E5 12 AWG
*12M1
12 H. :LA
0 0 0 3 PL 0 2 pt. 0 0
00 6 PL
NOTES: (Revision 'C' Shown Above)
1. REFER TO WIRING DIAGRAM #38076 AND TO ELECTRICAL SCHEMATIC

#38069.
2. USE 12 GAUGE WIRE WHERE SHOWN. ALL OTHER WIRE TO BE 16 GAUGE.
3. WIRE BETWEEN WOBBULATOR AND SPEAKER IS SUPPLIED WITH SPEAKER.
4. ITEMS 16, 17, 52, 53, 54, 62, 63, 64, 72, 73, AND 74 NOT ILLUSTRATED.
5. ITEMS 31 AND FOLLOWING ARE LISTED FOR REFERENCE ONLY.
.
ITEM 41 IS A COMPONENT OF THE 110-VOLT LINE TO PLATFORM OPTION.

ITEMS 51-57 ARE COMPONENTS OF THE TRAVEL/MOTION ALARM OPTIONS.
(TRAVEL ALARM IS POWERED BY CIRCUIT 62; MOTION ALARM IS POWERED
BY CIRCUIT 8A)
ITEMS 61-67 ARE COMPONENTS OF THE SIGNAL HORN OPTION.
ITEMS 71-74 ARE COMPONENTS OF THE HEAD & TAIL LIGHTS OPTION.
ITEM 81 IS A COMPONENT OF THE VOLTMETER OPTION.
6. VOLTAGE REGULATOR (ITEM 31) IS SUPPLIED WITH KAWASAKI ENGINE.
7. WIRES SHOWN OUT OF PLACE FOR CLARITY.
MANUAL 92323-003
50 SEPTEMBER 1994

FIGURE 3.8—Electrical Box Assembly, Kawasaki Engine
Ref. 38075 Electrical Box Assembly, Kawasaki Engine 1

1 38087 Relay Box, 47AG-Kawasaki 1
2 29163 Circuit Breaker, 15 AMP 2
3 67280 Relay, 12V DC 2
4 [Not Used]
5 21342 Solenoid, Starter 12V DC 1
6 80045 Relay, 12V DC 1
7 34552-016 Terminal Strip 3
8 BOW31 124 Screw, Slotted Round Head #6 - 32UNF x 50" long 8
9 BOW31231 Nut, Keps #6 - 32UNF 8
10 BOW33886 Screw, Slotted Pan Head .25" - 2OUNC x 50" long 4
1 1 BOW33888 Screw, Slotted Pan Head .25" - 2OUNC x 1 00" long 2
12 BOW31288 Nut, Keps .25" - 2OUNC 6
13 34542 Jumper 6
14 58251 Wire, 12 GA—White 4L.F.
15 58292 Wire, 16 GA—White 20L.F.
16 38092 Decal, Circuit Breaker 1
17 38093 Decals, J-Box 1
18 80024 Relay 1
19 80049 Socket, 8-Pin Octal 1
20 BOW31127 Screw, Slotted Round Head #6 - 32UNF x 1 00" long 2
21 BOW31231 Nut, Keps #6 - 32UNF 2
22 80027 Hour Meter 1
23-30 [Not Used]
31 Voltage Regulator (see NOTE 6, left) NSS*
32-40 [Not Used]
41 29163 Circuit Breaker, 15 AMP (see Note 5, left) 2
42-50 [Not Used]
51 80188 Wobbulator and Speaker (see Note 5, left) 1
52 67114-001 Strain Relief, 50" NPT .1251.25" 1
53 67123-001 Seal, Electrical Connector .50" 1
54 BOW17350 Nut, Conduit Connector .50" 1
55 BOW31148 Screw, Slotted Pan Head #10 - 32UNF x 1 75" long 4
56 BOW31144 Screw, Slotted Pan Head #10 - 32UNF x .50" long 3
57 BOW31233 Nut, Keps #10 - 32UNF 7
58-60 [Not Used]

61 80335 Horn, Auto-Type 1
62 67114-001 Strain Relief, .50" NPT .125"/.25" 1
65 BOW31144 Screw, Slotted Pan Head #10 - 32UNF x 1 75" long 1
66 BOW31233 Nut, Keps #10 - 32UNF 1
67 67295-035 Cable, 2 Conductor/16 GA (bulk) 2L.F.
68-70 [Not Used]
71 67280 Relay 1
72 67114-001 Strain Relief, .50" NPT .1251.25" 1

75-80 [Not Used]

81 67830 Voltmeter 1
*NSS—Not Sold Separately

MANUAL 92323-003
SEPTEMBER 1994
51

FIGURE 4.1—Lift Installation
_5
Ref. 37314 Lift Installation 1

1 37561 Lift Hydraulic Installation (includes items 2-5) 1
2 37002 —Arm Lift Cylinder Assembly (see Fig. 4.2) 1
3 36870 — —Lift Cylinder (Texas Hydraulics; Seal Kit #36870-100) ... 1
4 37485 — —Manifold Assembly (see Fig. 4.2) 1
5 38131 —Arm Hose Kit (see Fig. 5.9) 1
6 37274 • Boom Pivot Weldment 1
7 37284 Lift Arm Weldment 1
9 37318 Leveling Arm Weldment 2
11 36930 Pin Weldment 1
12 BOW36724 Washer, Flat 1.50" ID x 3.00" OD 2
13 36924 Washer, Flat 1
14 36847-073 Pin, Grooved .25" x 2.50" long 1
16 BOW36052 Bolt, Hex .375" - 16UNC x 75" long 2
MANUAL 92323-003
52 SEPTEMBER 1994

FIGURE 4.2—Arm Lift Cylinder Assembly

Ref. 37002 Arm Lift Cylinder Assembly (does not include 6, 7, 8) 1

1 36870 Lift Cylinder (Texas Hydraulics; Seal Kit #36870-100) 1
2 37485 Manifold Assembly 1
3 37484 —Manifold 1
4 35033 —Cartridge, Counterbalance 1
5 54623 —Needle Valve 1
6 BOW9977 0-Ring, .375" ID x .50" OD 2
9 34145 Bushing, Self-Lube (included with cylinder) 4
MANUAL 92323-003
SEPTEMBER 1994
53
NOTES
54 MANUAL 92323-003
SEPTEMBER 1994

FIGURE 5.1—Boom Installation
Ref. 37316 Boom Installation, 38A 1

1 37335 Aluminum Boom Assembly, 38AG 1
2 37385 Track Assembly, 38A 1
3 51325 Cable, 24 Conductor/16GA 50L.F.
-4 37398-001 Hose Wrap, Skirt/Boom 1
-5 37398-002 Hose Wrap, Track/Boom 1
-6 37398-003 Hose Wrap, Boom/Pivot 1
MANUAL 92323-003
SEPTEMBER 1994
55
FIGURE 5.2—Aluminum Boom Assembly
MANUAL 92323-003
56 SEPTEMBER 1994

FIGURE 5.2—Aluminum Boom Assembly
23
Ref. 37335 Aluminum Boom Assembly 1

1 37678-002 Retaining Ring, 1 50" shaft diameter 2
2 37334 Outer Boom Weldment 1
3 37758 Inner Boom Weldment, Aluminum 1
4 02236 Elbow, 90° MJ04 M004 2
5 34025 Master Leveling Cylinder (see Fig. 5.5) 1
8 BOW36834 Bolt, Socket Flathead .375" - 16UNC x 1 00" long 4
10 37674 Nylon Screw, .375" x .75" long 8
11 37390 Boom Extension Cylinder Assembly (see Fig. 5.3) 1
12 37679 Pin, Extension Cylinder 1
13 37680 Pin, Slave Cylinder 1
14 37678-001 Retaining Ring, 1.25" shaft diameter 2
15 SQK00111 Trim, Black A/R
17 34441 Slave Leveling Cylinder Assembly (see Fig. 5.6) 1
18 37654 Shim, Small (only if needed) 16
19 37264 Shim (only if needed) 8
20 37502-001 Bearing Pad, Top 2
21 37502-002 Bearing Pad, Bottom 2
22 37653 Bearing Pad, Small 8
23 37503 Nylon Screw, .375" x 625" long 24
24 [Not Used]
25 BOW36603 Nut, Hex .375" - 16UNC 16
26 02317 Elbow, 90° MJ04 MB04 2
27 00334 Nut, Bulkhead #4 2
-28 37040-002 Bearing Pad 2
A/R = As required
MANUAL 92323-003
SEPTEMBER 1994
57
FIGURE 5.3—Boom Extension Cylinder Assembly
Ir -----14 STARTING WITH S/N 1349
MANUAL 92323-003
58 SEPTEMBER 1994
FIGURE 5.3—Boom Extension Cylinder Assembly
-1 37390 Boom Extension Cylinder Assembly 1

2 34814 Assembly, Regenerative Manifold (includes items 5-8) 1
5 34369 —Cartridge, Logic Element NO 2
6 35033 —Cartridge, Counterbalance 2
7 38167 —Plug 1
8 34799 —Manifold, Regenerative 1
9 02448 Straight MJ06 M006 2
10 02298 Elbow, 90° MJ06 FJO6 2
11 BOW9977 0-Ring, 375" ID x 50" OD 2
12 34884 Cylinder, Boom Extension (see Fig. 5.4 for breakdown) 1
13 34411 Wear Pad 1
14 BOW36815 Bolt, Socket Flathead .25" - 20UNC x 1.00" long 2
15 37292 Wear Pad 1
16 BOW36817 Bolt, Socket Flathead .25" - 20UNC x 1.50" long 2
MANUAL 92323-003
SEPTEMBER 1994
59
FIGURE 5.4—Boom Extension Cylinder Parts Breakdown
MANUAL 92323-003
60 SEPTEMBER 1994
FIGURE 5.4—Boom Extension Cylinder Parts Breakdown
-1 34884 Boom Extension Cylinder (Texas Hydraulics) 1

2 Plug, Test Port 2
3 Tube Weldment 1
4 Locknut 1
5 Piston 1
6 Spacer 1
7 Head 1
8 Rod Weldment 1
-9 SBW01030 Seal Kit (includes items 10-18) 1
10 —Wear Ring 2
11 —Seal, AQ 1
12 —0-Ring, Rod-Piston 1
13 —0-Ring, Head 1
14 —Ring, Back-Up 1
15 —Wear Ring 2
16 —0-Ring 1
17 —U-Cup, Polypak 1
18 —Wiper 1
MANUAL 92323-003
SEPTEMBER 1994
61
FIGURE 5.5—Master Leveling Cylinder Parts Breakdown
15
14
13
17
12
10
11
62 MANUAL 92323-003
SEPTEMBER 1994
FIGURE 5.5—Master Leveling Cylinder Parts Breakdown

-1 34025 Master Leveling Cylinder (Texas Hydraulics) 1

3 Tube Weldment 1
4 Piston 1
5 Head 1
6 End Cap 1
7 Rod Weldment 1
9 —Locknut 1
10 —Wear Ring 1
11 —Seal, AQ 1
12 —0-Ring, Piston-Rod 1
14 —Back-Up Ring, Head 1
16 —Wiper, Rod 1
17 —Set Screw 1
18 —Nylon Plug 1
MANUAL 92323-003
SEPTEMBER 1994
63
FIGURE 5.6—Slave Leveling Cylinder Assembly
MANUAL 92323-003
64 SEPTEMBER 1994
FIGURE 5.6—Slave Leveling Cylinder Assembly
-1 34441 Slave Leveling Cylinder Assembly 1

2 34026 Slave Leveling Cylinder (Texas Hydraulics; see Fig. 5.7) 1
3 34443 Tube Assembly (left-hand) 1
4 34442 Tube Assembly (right-hand) 1
6 30322 Holding Valve (see Fig. 5.8) 1
10 02202 Clamp 1
11 21479 Needle Valve 1
12 02683 Straight, MJ04 MJ04 1
MANUAL 92323-003
SEPTEMBER 1994
65 .
FIGURE 5.7—Slave Leveling Cylinder Parts Breakdown
MANUAL 92323-003
66 SEPTEMBER 1994
FIGURE 5.7—Slave Leveling Cylinder Parts Breakdown
-1 34026 Slave Leveling Cylinder (Texas Hydraulics) 1

2 Tube Weldment 1
3 Piston 1
4 Head 1
5 End Cap 1
6 Rod Weldment 1
9 —Locknut 1
10 —Wear Ring 1
11 —Seal, AQ 1
12 —0-Ring, Rod-Piston 1
14 —Back-Up Ring 1
16 —Wiper 1
17 —Nylon Plug 1
18 —Set Screw 1
MANUAL 92323-003
SEPTEMBER 1994
67
FIGURE 5.8—Holding Valve Assembly
4
5
6
7
8
10
MANUAL 92323-003
68 SEPTEMBER 1994
FIGURE 5.8—Holding Valve Assembly
-1 30322 Holding Valve, Slave Leveling Cylinder 1

2 QZB01013 Body 1
3 QZB01015 Piston 1
4 QZB01016 Poppet 2
5 QZB01017 Ball 2
6 QZB01018 Spring 2
7 QZB01019 Spring 2
8 QZB01020 Plug 2
9 QZB01014 Seal Kit (includes items 10-12) 1
10 —0-Ring, Plug 2
11 —0-Ring, Piston 1
12 —0-Ring, Body 2
MANUAL 92323-003
SEPTEMBER 1994
69
FIGURE 5.9—Boom Hydraulic Installation
12° 191
18
8
1 12 13 1
14
MANUAL 92323-003
70 SEPTEMBER 1994

FIGURE 5.9—Boom Hydraulic Installation

-1 37563 Boom Hydraulic Installation 1

2 36841 Shuttle Valve 4
4 00498 Elbow, 90° MJ06 MPO6 7
7 04597 Elbow, 90° 1
8 34062 Valve, Dual Counterbalance 1
11 BOW30181 Bolt, Hex .25" - 28UNF x 1 50" long 2
12 RTM01005 Body, Counterbalance Valve 1
13 35033 Cartridge, Counterbalance Valve 2
14 02219 Elbow, 90° MJ04 FJO4 3
15 02857 Elbow, 90° MJ04 M006 3
16 00456 Straight, MJ04 M006 1
17 00344 Tee, MJ04 FJO4 MJ04 2
18 37002 Boom Lift Cylinder Assembly 1
19 36870 —Lift Cylinder (Texas Hydraulics; Seal Kit #36870-100) 1
20 37485 —Manifold Assembly (see Fig. 4.2, Lift section) 1
-21 34145 Bushing, Self-Lube (included with cylinder) 4
MANUAL 92323-003
SEPTEMBER 1994
71

FIGURE 5.10—Hose Installation Diagram
BOOM
UFT
CYL
A. 11
BU
ON INNER VALVE 34041
ON PLATFORM 1P 2P
BOOM
(BOTTOM vc-vo r"- 1

2P 9P 3P 7P 1P P e/X. C)313 C)11P ek5\P\®Se
18 ac
®
5C
q2'®6
28 €405P TO LIFT 6p 4P
ei 11P VALVE IN BOOM TURRET PLIFIN BOOM EXT ARM UFTe4
CARRIAGE LET ROT 11.T IN/OUT UP /DN
1 Gs 12F
:
41 •
ir
8C
I 4a1 0 BB
10P 4P BP
,o
38 7A
3A
E 989A
REF
COUPUNG. 6 PL
TO TMKN,4,
28 2A CARRIME
7A
vi 34062 v2,12B
Cf VALE 34040 ON TURRET

12C 11C
108
2A •
1 DA BOOM •11R. BOOM ARM 1GC
11A
UFT ROT. EX1D UFT
UP/ON LFT/R t•I /OUT UP /DN
TO LIFT
ti VALVE IN
. CARR!AGE
I10A
•
4,4 'Ll3fr , :::
2763 J .3„
=A
L-4R SSF bL14
RELE
ARM UFT C•L

E
FLOW DC
R
CONTROL
EMIL
1. BUBEtE LEGEND:
0 -HOSE KIT, PLTFRM (SEE 8/14
38128 IN COMPUTER)
al -HOSEKIT, BOOM (SEE 8,44
A 38129 IN COMPUTER)
bx -HOSEKIT. ARM (SEE 8,44
38131 IN COMPUTER)
cp -HOSE 10T CYLNOERS (SEE
RIM 38130 IN COMPUTER)
2. NUMBERS NEXT TO HOSES ARE
IN DINAOUAL HOSE LABELS.
MANUAL 92323-003
72 SEPTEMBER 1994

FIGURE 5.10 - Hose Installation Diagram


NOTE: Descriptions indicate the inner diameter, length, and fittings for hose assemblies.
The description 'ST-ST indicates straight fittings at both hose ends.
The description 'ST-90' indicates one straight fitting and one 90° fitting.
Ref. 38129 Hose Kit, Boom 1

1 66045-289 Hose Assembly, #5 289.00" long ST-ST 1
3 66043-281 Hose Assembly, #3 281 00" long ST-ST 1
9 66045-274 Hose Assembly, #5 274.00' long ST-ST 1
1 1 66043-252 Hose Assembly, #5 252.00" long ST-ST 1
Ref. 38130 Hose Kit, Cylinders 1

1 66035-023 Hose Assembly, #4 23.00" long 4/6 ST-ST 1
2 66035-022 Hose Assembly, #4 22.00 long 4/6 ST-ST 1
10 66001-026 Hose Assembly, #4 26.00" long ST-90 2
Ref. 38128 Hose Kit, Platform 1

Ref. 38131 Hose Kit, Arm 1

MANUAL 92323-003
-Indicates Items Not Shown SEPTEMBER 1994
73
FIGURE 5.1 1 —Track Assembly
2
5
6
MANUAL 92323-003
74 SEPTEMBER 1994

FIGURE 5.11—Track Assembly
Ref. 37385 Track Assembly 1

1 38289 Hose Support 1
2 38295 Channel, Track 1
3 37810 Link, Chain (Repair Link #67865) 20
4 37809 Mounting Bracket (set of two) 2 SETS
5 34373 Plate, Track 8.375" 1
6 34392 Plate, Track 2
7 38294 Retainer, Hose 1
-9 BOW34273 Nut, Hex Lock .3125" - 18UNC 15
-10 BOW30007 Bolt, Hex .25" - 20UNC x 1 75" long 3
-11 BOW34272 Nut, Hex Lock .25" - 20UNC 6
-13 BOW30200 Bolt, Hex .3125" - 24UNF x .50" long 5
-15 BOW31412 Washer, Flat 3125" ID 8

MANUAL 92323-003 75
SEPTEMBER 1994

FIGURE 6.1 —Platform Installation
lit, 1171111011 °
0 , ioll!lio 0
.....:.
,d di, •
, , ,,...* V *---
ik• , • '.-- • - ...,.... • • • .
.r.4*.••• ,... . ......•-• a i
d.
, * 41■•• 0 • ' . . ' -
ill ., 4 ,. *tow ■dr ..- .4 4 4, • 41, Ill 4 . .
'• a
• .. • • . • # #• • • • *••' ..
.• - a•#••
• * • • s". , • 0

• • 11
••'. ••••• ji
„.•
• #.. - . • •-# t.'..II.' '
' 4....ar:44
a•—
;0'.*;
4
;
MANUAL 92323-003
76 SEPTEMBER 1994
FIGURE 6.1—Platform Installation
C NO NC
FOOTSWITCH CABLE I-
cc ca
3 CONDUCTOR 16 AWG

-1 Ref. Platform Installation Ref.

2 34112 Platform Weldment 1
3 34046 Platform Assembly (see Fig. 6.2) 1
4 34609 Plate, Upper Control Box 1
5 Ref. Platform Wiring (see Fig. 6.3) Ref.
6 BOW36004 Bolt, Hex 25" - 20UNC x 1.00" long 6
8 BOW36725 Washer, Split Lock .25" ID ........ ........ ..... ............. . ...... ..... 6
9 BOW31201 Nut, Hex 25" - 20UNC 6
10 34226 Platform Hydraulic Installation (see Fig. 6.4) Ref.
11 [Not Used]
13 BOW31445 Washer, Flat 3125" ID x .6875" OD 4
16 34667 Retainer, Footswitch 1
17 36083 Footswitch 1
36083-100 Kit, Footswitch (microswitch, hardware) 1
18 36084 Guard, Footswitch 1
19 BOW36005 Bolt, Hex .25" - 20UNC x 1.00" long (USS) 2
20 BOW36701 Washer, Flat 25" ID 2
21 BOW36601 Nut, Hex .25" - 20UNC 2
22 37193 Cover, Switch 1
MANUAL 92323-003
SEPTEMBER 1994
77
FIGURE 6.2—Platform Assembly
REF. PLATFORM
WELDMENT
34
23
24
26
78 MANUAL 92323-003
SEPTEMBER 1994
FIGURE 6.2—Platform Assembly
14
13
7
9
12
10
16

-1 34046 Platform Assembly 1

2 34274 Platform Rotation Gearbox Assembly (id. items 5-16) 1
5 34409 —Handle, Modified 1
6 36847-034 —Pin, Grooved Type A 3125" dia. x 1 50" long 1
7 34819 —Washer, Modified 2
8 34244 .......... ........... —Worm Shaft 1
9 34238 —Bushing, Flanged 2
10 34798 —Worm, Modified 1
11 36847-024 —Pin, Grooved Type A 3125" dia. x 1 25" long 1
12 34239 —Weldment, Gearbox 1
13 BOW31208 —Nut, Hex .75" - 10UNC 1
14 BOW32278 —Nut, Hex Jam .75" - 10UNC 1
15 [Not Used]
16 36986 —Platform Rotation Gear 1
17 BOW32585-1 Clamp, Wire Loom 1.00" 2
18 BOW31201 Nut, Hex 25" - 20UNC 4
21 38284 Thrust Washer, 1 26" ID x 2.50' OD 1
24 BOW36705 Washer, Flat .50" ID x 1 06" OD 4
25 BOW361 14 Bolt, Hex 50" - 16UNC x 3.50" long 2
27 37839 Skirt Weldment 1
28 [Not Used]
31 36934 Washer 3
32 BOW35058 Pin, Spring Rolled .25" diameter x 1 75" long 3
33 B0W40541 Set Screw, Socket Head .375" - 16UNC x .50" long .... ..... 4
34 BOW36004 Bolt, Hex .25" - 20UNC x 1 00" long 1
35 37822 Hose Guard 1
36 BOW36817 Bolt, Socket Flathead .25" - 20UNC x 1 50" long 2
MANUAL 92323-003
- Indicates Items Not Shown SEPTEMBER 1994
79
NOTES
MANUAL 92323-003
80 SEPTEMBER 1994
• °
= •1
FIGURE 6.3-Platform Wiring
EMERGENCY /
STOP
21
22
21A
4-0
-110 r-A
LP
CHOKE
GAS
21A OH 25
21A
zO
-k0 r,
START SEE NOTE 3
22
HORN
19
59
I 28 BOW31231 4.00 _I EA NUT, KEPS f3-32UNF

27 BOW31124 4.00 1 EA SCR„ SLT RD #6 -32UNF X.50
I 26 34767 1.00 1 EA DECAL EMERGENCY PUMP
25 38144 1.00 I EA DECAL PLATFORM CONTROL BOX
cD ' 24 67124-002 ' 1.00 I EA I CONNECTOR, LOCKNUT 3 /4

0112.),A, ; . EA SEAL CONNECTOR ELECT 3/4
67114-009 1.00 lEA STRAIN REUEF. 3/4 NPT .6254750
J
22
55 21 67124-001 1.00 I EA CONNECTOR, LOCKNUT 1/2
20 67123-001 1.00 I EA SEAL, CONNECTOR ELECT 1/2
18 59 19 67114-003 1.00 I EA STRAIN RELIEF. 1/2 NPT .375/.500
•9 160 18 58251 6.00 I LF WIRE, 12GA-WHITE
17 58292 20.00 I IF WIRE, 16GA-WHITE
20 62 16 67295-022 8.00 IF CABLE. 3 CONDUCTOR 120A. SJO
15 34552-012 2.00 I EA TERMINAL STRIP
21 63 14 34644 1.00 l EA ALARM
13 EA OEM DRIVE CONTROLLER
64 12
37165
38032
1.00
4.00 EA WASHER, SEAL
22 11 40880 4.00 EA GUARD, TOGGLE SWITCH MICRO
10 50077 2.00 EA SWUTCH, TOGGLE, 2-POS. MAINTAINED
23 BLANK 9 80305 2.00 EA SWITCH, TOGGtE, 2-POS, MOMENTARY
o 0 e **s
52029
REF EA
1.00 EA CONTACT BLOM 2 NO
6 51914 1.00 EA CONTACT BLOCK, 1 NC
I 5 52672 1.00 EA CONTACT BLOCK, 1 NO
4 34836 1.00 EA OPERATOR. WHITE PUSH-BUTTON
69145 EA 1.00 OPERATOR, YELLOW PUSH-BUTTON
51913 EA I 1.00 OPERATOR, RED PUSH-PULL
38095 EA 1.00 CNIRL BOX, PLTFRM KAWASAKI
NOTES:
ITEM PART NUMBER Q TY UM DESCRIPTION
1. ITEMS 11, 12 AND 19 THRU 26 ARE NOT ILLUSTRATED. PROPRIETARY INFORIAATION
2. REFER TO SCHEMATIC 38069.

is WOMB RIO Min IMPSWIL 10111WWWW
MUSK WIPSIMI. WINWAS Wb Saint AVIPart
W MAWR OWPWW3W. /WM It UMW, AMMO •
wAco, TEXAS
ara s Wain at MAW 11 IX MIK NOW VI*01
3. REFER TO DRAWING 38076 FOR CIRCUIT DESCRIPTION. mos
1g MR MEM arsor W CALAIS 1111111141110111. MIMS TIRE
-17-3-7W
67 UMMIWCYMMINIEWWCWEDI WIRING, 47AG KAWASAKI PLTFRI
OWADMCPSAWLMOKIMEW
6221 11/24/94 IRAK
WUMMKOVOlt mlioW mmmom
5990 I 11/10/23 RAK
r/7/-
a r 3 DRAWS
38097
2.c.A. NO. DATE IAPPR. DRAM J.CARMICAL
4100 i 11/21/93 RAX C
ER.N. NO. I DATE *PPM serows RAK 11/21/.3 =Au 3/4 1 OF 1

FIGURE 6.4—Platform Hydraulic Installation
1, 5
11
8, 9, 10
2
7
REF. 6
11

Ref. 34226 Platform Hydraulic Installation 1

1 34817 Upper Control Valve Assembly 1
2 02337 Elbow, 90° 10
3 00425 Straight 2
4 34966-402 Orifice Fitting Assembly 2
5 34041 Upper Control Valve (includes items 6 715) 1
7 ENR01008 —Inlet Section ('PRESS') 1
8 ENR01023 —Kit, Load Check (includes items 9 and 10) 1
9 ENR01016 --Ball, Load Check 2
12 ENR01009 —Outlet Section ('TANK') 1
13 34818 —Handle Kit (includes items 14 and 15) 1
14 ENR01022 --Knob 5
-16 BOW31201 Nut, Hex .25" - 20UNC 2
-17 BOW36725 Washer, Split Lock 25" ID 2
- Indicates Items Not Shown MANUAL 92323-003

SEPTEMBER 1994
83
FIGURE 7.1 —Kubota Diesel Engine Installation (Option)
21
23 19
24 18
/ 25
84 MANUAL 92323-003
SEPTEMBER 1994
FIGURE 7.1 —Kubota Diesel Engine Installation (Option)
-1 37371 Diesel Engine Installation 1

-2 Ref. Engine Electrical Installation (see Fig. 7.1A) 1
-3 37297 Engine/Pump Assembly 1
4 37299 —Kubota D850-B2 Diesel Engine (see Fig. 7.1B) 1
5 37360 --Bracket, Solenoid Mounting 1
6 40808 --Solenoid, Throttle 12V DC 1
7 BOW36701 --Washer, Flat .25" ID 1
8 BOW36004 --Bolt, Hex .25" - 20UNC x 1.00" long 4
9 BOW36000 --Bolt, Hex .25" - 20UNC x .50" long 2
10 BOW36725 --Washer, Split Lock .25" ID 6
11 BOW34272 --Nut, Hex Lock .25" - 20UNC 4
12 BOW32281 --Nut, Hex Jam .25" - 28UNF 1
13 NNV01008 --Rod End 1
14 67858 --Coupling 1
15 BOW40531 --Set Screw, Allen Head .3125" - 18UNC 2
16 67897 --Plate, Pump Mounting 1
17 37339 --Gear Pump, Tandem 1
18 BOW36727 --Washer, Split Lock .375" ID 6
19 BOW36054 --Bolt, Hex .375" - 16UNC x 1.00" long 6
20 02216 --Elbow, 90° MJ16 M016 2
21 02214 --Elbow, 90° MJ10 M010 1
22 01397 --Elbow, 90° MJ06 M010 1
23 37273/37273-001 .... —Rear Motor Mount (right-hand/left-hand) 2
24 BOW36705 —Washer, Flat .50" ID x 1.0625" OD 8
25 BOW36729 —Washer, Split Lock .50" ID 8
26 BOW36105 —Bolt, Hex .50" - 13UNC x 1 25" long 8
27 37272-001 —Front Motor Mount, left-hand 1
28 37272-002 —Front Motor Mount, right-hand 1
29 BOW42465 —Washer, Flat 10mm ID 8
30 BOW42455 —Washer, Split Lock 10mm ID 8
31 BOW42331 —Bolt, Hex 10mm - 1 25mm x 25mm long 8
32 80303 —Rubber Mount 4
33 BOW36769 —Washer, Flat .50" ID x 1.375" OD 4
34 BOW36784 —Nut, Hex Lock .50" - 13UNC 4
-35 34999 Module, 3-Wire Solenoid Control 1
-36 37299-200 Operator's Manual, Kubota D850 (Replacement part #) ....Ref.
-37 37299-201 Workshop Manual, Kubota D850 (Replacement part #) Ref.
MANUAL 92323-003
SEPTEMBER 1994
85
FIGURE 7.1A—Diesel Engine Electrical Installation
9 15----10
8 4)

-1 Ref. Diesel Engine Electrical Installation ...... . ............ ..... . 1

2 Ref. —Plate, Wood 1
3 121-96822-00 —Battery, 12V 1
4 67351-008 —Battery Cable 2
5 37722 —Bracket, Battery Hold-Down 8.25" 1
6 BOW32488 —Threaded Rod, .25" - 20UNC x 12.00" long 2
7 37940 —Electrical Box Assembly, Diesel Engine (see Fig. 7 1D) 1
8 BOW31444 —Washer, Flat 25" ID x 625" OD 6
9 BOW36725 —Washer, Split Lock 25" ID 6
10 BOW31201 —Nut, Hex 25" - 2OUNC 6
MANUAL 92323-003
86 SEPTEMBER 1994

FIGURE 7.1B—Kubota D850-B2 Diesel Engine

-1 37299 Kubota D850-B2 Diesel Engine 1

2 JVA01001 —Element, Oil Filter 1
3 JVA01002 —Fan Belt 1
4 37394 —Fuel Filter Kit 1
5 JVA01003 --Element, Fuel Filter 1
6 37397 —Kit, 90° Thermostat 1
7 JVA01004 --Cover, 90° 1
8 JVA01005 --Gasket 1
9 JVA01006 —Thermostat 1
10 37395 —Solenoid, Shut-Down 1
11 JVA01007 —Glowplug 3
12 37396 —Gauge, Coolant Temperature 1
13 37392 —Kit, Air Cleaner 1
14 JVA01008 —-Element, Air Filter 1
15 BOW36725 —Washer, Split Lock .25" ID 2
16 BOW36002 —Bolt, Hex .25" - 20UNC x .75" long 2
17 BOW24116 —Hose Clamp, 2.00" 2
18 67099-003 —Air Hose, Inline 1
19 37393 —Muffler Kit 1
20 67169-017 —Clamp, Muffler 1
21 37480 —Tip Muffler 1
22 37399 —Alternator Kit, 25 AMP 1
-23 67157-003 —Oil Pressure Switch, 4 PSI 1
- Indicates Items Not Shown MANUAL 92323-003

87
SEPTEMBER 1994
FIGURE 7.1C—Radiator Installation, Diesel Engine
10

-1 37469 Radiator Installation, Diesel Engine 1

2 80175 —Tank, Coolant Recovery 1
3 BOW31431 —Washer, Flat 25" ID x 625" OD 4
5 BOW36001 —Bolt, Hex 25" - 2OUNC x 625" long 2
6 37510 —Radiator, Modified 1
7 37306 —Electric Fan 1
8 37476 —Radiator Hose (34 00") 5.67
9 BOW24113 —Hose Clamp, 625" - 75" - 1 25" 4
10 37350 —Bracket, Radiator Mounting 1
12 BOVV36054 —Bolt, Hex 375" - 16UNC x 1 00" long 2
MANUAL 92323-003
88 SEPTEMBER 1994
. ..... • • •
• •••• 1 • • • • • • • • • • • • • •. * : ".-
•
FIGURE 7.1D-Electrical Box Assembly, Diesel Engine
CABLE TO ENGINE (R)

51 BU< ! ENGINE MODULE + AUX
58 RED I ENGINE MODULE + HOT
8A WHT ! ENGINE - THROTTLE SOLENOID 1
t
CABLE TO ENGINE (L)
t
BLK ENGINE STARTER
25B
RED • SOLENOID
55 WHT 1 4-PSI OIL PRESSURE SWITCHi
31 WHT/BLK I OIL PRESSURE SWITCH
E GRN •
F ORN ALTERNATOR
N BLU I
RED/BLK 'SPARE
CABLE TO MURPHY ELECTRICAL BOX - 37598 1

I MURPHY SWITCH -
5HT BU< ;HI TEMP SHUTOFF
31 WHT FAN RELAY COIL
I.
TO ENGINE (R) TO TURRET
4!) CONTROL BOX I 'CABLE TO TURRET CONTROL BOX
1 25t 1 GRN GROUND
(.
25/1 -
8A BLK '
31 25 5A KEYSWITCH
RED .
8
25A 25C 8 WHT 1 KEYSWITCH
1T, LOCKOUT STARTER
24 ORN GLOWPLUGS _SWITCH
HIGH TEMPI i I DELAY LOCKOUT 25 BLU I ENGINE START SWITCH
CUTOFF RELAY 55 WHT/BLK I KEY SWITCH
TO MURPHY
25A BOX
TO ENGINE (L) i RED/BLK I SPARE
- -- 10 GAGE WIRE 2.1 314'Sq
4 PL
19 14
TO GLOWPLUGS
ON ENGINE
0
-J
25B
1.0" E'A VOLTAGE REGLL LA-TO Q.
I 20 167295-019 8.00 IS CABLE MULT1CONDUCTOR 2C/16GA SO

19 67114-001 1.00 IEA CONNECTOR, STRAIN RELIEF
18 67124-002 2.00 LOCKNUT CONNECTOR .75
2 PL 17 67123-002 2.00 I EA SEAL CONNECTOR ELECT 3/4
10 GAGE WIRE 8 GAGE CABLE 16 67114-008 2.00 lEA CONNECTOR. STRAIN RELIEF
15 BOW17351 4.00 EA NUT 1/2 CONDUIT CONNECTOR
14 67123-001 4.00 1 EA SEAL CONNECTOR ELECT 1/2
13 67114-002 3.00 I EA STRAIN RELIEF 1/2 NPT .25/.38
12 BOW31431 1.00 EA WASHER FLAT .25 ID X .63 OD
11 B OW36725 1.00 EA WASHER SPLIT LOCK .2510
10 BOW36002 1.00 EA BOLT HEX .25-20UNC X .75
9 BOW31126 1.00 EA SCREW, RND HD #6-32 X 3/41.
8 BOW31429 1.00 lEA WASHER #8
7 21342 2.00 EA SOLENOID STARTER 12VDC
6 67295-005 8.00 LF CABLE MULT1CONDUCTOR 3C/160A SO
NOTES: 5 67947-015 2.00 EA CIRCUIT BKR AUTO RESET 15 AMPS
1. ALL WIRING TO BE 16 GAGE EXCEPT WHERE NOTED. 4 67295-024 22.00 lIF CABLE MULTICONDUCTOR 8C/16GA SO
3 34552-016 1.00 EA TERMINAL STRIP
2 67280 4.00 EA RELAY BOSCH
37586 1.00 EA BOX, MODIFICATION
ITEM PART NUMBER QTY UN DESCRIPTION
PRDIPRIETARY INFORMATION
ToRs soma MI MIK WO& 1102.02111.
',A/ACO, TEXAS
VMS IS IMAM 1 I I 1 Mgt Wit MK MINK
- 4 TIE MR IWIIM UMW WOW,*
MSS.
171tE
UNLE. OINEAMIL 1P11.1ROM
CARMOOMS ME Al NOW. DIAGRAM, ELEC BOX A524-47AG-K
TOLERANOLS Mt mom Amu. omm.Ames.
Ayr iirtri.
• -• 6636

1.7X. C.C.* 140- K ALBERTS 4/204 AQ HO.
37940
• r-11"
3864 C
Lilt. e..R.N. NO. 1 Or 1

FIGURE 7.2—Auxiliary Lowering Power Unit (Option)
PUMP/MOTOR
LOCATION IN
CARRIAGE

Ref. Ref . Auxiliary Lowering Power Unit 1

1 35659 Assembly, Auxiliary Pump/Motor 1
2 35244 —Motor, Auxiliary Lowering 1
3 AZP01005 —Solenoid 1
4 35245 —Pump, Auxiliary Lowering 1
5 50148 Inline Filter, 375" NPT 1
6 51634 —Element, Inline Filter 1
7 00368 Elbow, 90° MJ08 MPO6 1
8 04155 Elbow, 90° M008 MPO6 1
9 00458 Straight, MJ08 M008 1
11 BOW36701 Washer, Flat .25" ID 2
-12 34767 Decal, Auxiliary Lowering .......... ..... ........ 2
-13 52029 Contact Block, 2 NO 2
-14 34836 Operator, Pushbutton 2
NOTE: Items 12 14 located at platform control console.

-
MANUAL 92323-003
SEPTEMBER 1994
91

FIGURE 7.3—Strobe Light Assembly (Option)
1I
8 BRACKET
STROBE
-,_
Ref. Ref. Strobe Light Assembly (Option) 1

1 58395 Light, Amber Strobe 12-72V DC 1
2 37751 Mounting Bracket 1
MANUAL 92323-003
92 SEPTEMBER 1994
FIGURE 7.4—Dual Fuel Carburetor Assembly, Liquid (Option)
REGULATOR LOCATION
(REF - CHASSIS WELDMEN T)
CARBURETOR
- r— r
GASOLINE LINE
LP VAPOR LINE SOLENOID
CARBURETOR
•-■-■111110.
C ADAPTER VALVE
INTAKE
MANIFOLD
APORI ZER 6 4=GAS

CIRCUIT
----\
63=LP
FILTER CIRCUIT
REGULATOR LOCK
LIQUID LP LINE
FROM LP TANK
ENGINE
COOLANT
LINES
3
WA TER JACKET
WATER PUMP
ENGINE BLOCK
REFERENCE
Ref. Dual Fuel Carburetor Assembly, Liquid (Option) 1

1 38180 Adapter Kit, Gas/LP (Kawasaki Engine) 1
2 66238 Vaporizer Regulator, Liquid 1
3 51630 Filterlock, FL-218 LP Gas 1
4 68097 Valve, Fuel Shut-Off 1
- indicates Items Not Shown
MANUAL 92323-003
SEPTEMBER 1994
93
FIGURE 7.5—Dual Fuel Tank Assembly, Liquid (Option)
2
3
4
5
6
7
-1 Ref Dual Fuel Tank Assembly, Liquid (Option) 1

2 67104 Bracket, Horizontal LP Tank Mounting 2
3 BOW36603 Nut, Hex .375" - 16UNC 4
5 BOW36713-HD Washer, Flat 375" ID (SAE) 4
6 BOW21654 Spring 2
7 BOW34142 Washer, Flat 4
8 67856-002 Tank; LP Gas (Liquid) 43.5 lb 1
9 67075-002 Coupling, Quick Disconnect 1
10 02458 Tee, MPO4 FP04 FP04 1
11 36428 Relief Valve, Liquid LP 1
13 ZPN01026 ...... ....... ... Hose Assembly, LP Gas 1
94 MANUAL 92323-003
SEPTEMBER 1994
FIGURE 7.6—Dual Fuel Carburetor Assembly, Vapor (Option)
REGULATOR LOCATION
(REF - CHASSIS WELDMEN T)
REF CALAVAR 68097

REF CALAVAR 38180
CARBURETOR KIT
GASOLINE LINE
LP VAPOR LINE SOLENOID
CARBURETOR
ADAPTER VALVE
TAKE
MANIFOLD
64=GAS
CIRCUIT
63=LP
CIRCUI T
LIQUID LP LINE
FROM LP TANK
REF CALAVAR 51630

FILTER -LOCK
REF CALAVAR 66095
REGULATOR

Ref. Dual Fuel Carburetor Assembly, Liquid (Option) 1

1 38180 Adapter Kit, Gas/LP (Kawasaki Engine) 1
2 66238 Vaporizer Regulator, Liquid 1
3 51630 Filterlock, FL-218 LP Gas 1
4 68097 Valve, Fuel Shut-Off 1
MANUAL 92323-003
SEPTEMBER 1994
95
FIGURE 7.7—Dual Fuel Tank Assembly, Vapor (Option)
11

-1 Ref. Dual Fuel Tank Assembly, Vapor (Option) 1

2 67104 Bracket, Horizontal LP Tank Mounting 2
3 BOW36603 Nut, Hex 375" - 16UNC 4
5 BOW36713-HD Washer, Flat .375" ID (SAE) 4
6 BOW21654 Spring 2
7 BOW34142 Washer, Flat 4
8 67103-001 Tank, LP Gas (Vapor) 33.5 lb. 1
9 67075-002 Coupling, Quick Disconnect 1
11 ZPN01026 Hose Assembly, LP Gas 1
MANUAL 92323-003
96 SEPTEMBER 1994

FIGURE 7.8—Travel Alarm Assembly (Option)
REF.
4
3
2
7 7
pi
41 It
witiqUUtini
0
11111•111111111
AO 17
18
20
8A 21
_J.Q_. c 222 23,
2/
13 ,
14 : 24
, 15 , 25
16 25B
c 26/1:7 7
. 26/27 D
26/27
Ref. Ref. Travel Alarm Assembly (Option) 1

1 80188 Wobbulator and Speaker, 12V 1
2 67114-001 Connector, Strain Relief 1
3 67123-001 Seal, Electrical Connector 50" 1
4 67124-001 Locknut, 50" Strain Relief 1
5 BOW31148 Screw, Round Head #10 - 32UNF x 2.00" long 4
6 BOW31 144 Screw, Slotted Round Head #10 - 32UNF x .50" long 3
7 BOW31233 _Nut, Hex Keps #10 - 32UNF 7
MANUAL 92323-003
SEPTEMBER 1994
97

FIGURE 7.9—Motion Alarm Assembly (Option)
REF.
4
3
4,1
17
5 18
5A
20
8A 21
22/23
22/23
13
14 24
15 25
16 25B
26/27 26/27
26/27 26/27
,c)
Ref. Ref. Travel Alarm Assembly (Option) 1

1 80188 Wobbulator and Speaker, 12V 1
2 67114-001 Connector, Strain Relief 1
4 67124-001 Locknut, 50" Strain Relief 1
5 BOW31 148 Screw, Round Head #10 - 32UNF x 2.00" long 4
6 BOW31 144 Screw, Slotted Round Head #10 - 32UNF x .50" long 3
7 BOW31233 Nut, Hex Keps #10 - 32UNF 7
MANUAL 92323-003
98 SEPTEMBER 1994
FIGURE 7.10—Air Line to Platform Assembly (Option)
2
3
4
5
7
Ref. Ref. Air Line to Platform Assembly (Option) 1

1 81389 Bulk Hose, #8 60L.F.
2 67993-105 Hose End Fitting, Straight J08 H08 2
3 37176 Bracket, Coupling 2
4 02800 Straight, MJ08 M008 2
5 67051 Coupling, Quick Disconnect Male .50" ._ _ 1
6 • 67052 Coupling, Quick Disconnect Female 1
7 67053 Dust Cover, Quick Disconnect (for male) 1
8 67054 Cap, Quick Disconnect (for female) 1
MANUAL 92323-003
SEPTEMBER 1994
99

FIGURE 7.11-110-Volt Line to Platform Assembly (Option)
1
2
(3)
4
00
5
6
7
8
9
10
13
(3)
11
12
14
Ref. Ref. 110-Volt Line to Platform Assembly (Option) 1

1 40956 Box, Rain-Tight Single Gang 1
2 67295-017 Cable, 3-Conductor/12 GA 60L.F.
3 80361 Receptacle, 15 AMP/125V 1
4 29161 Cover, Weatherproof Duplex 1
5 67114-003 Strain Relief, 50" NPT 1
6 67123-001 Seal, Electrical Connector 50" 1
7 29163 Circuit Breaker, 15 AMP 1
8 BOW31 146 Screw, Slotted Round Head #10 - 32UNF x 1 00" long 8
9 BOW31430 Washer, Flat #10 ID 8
10 BOW31362 Washer, Split Lock #10 ID 8
11 52710 Plug, 110V 1
12 BOW23075 Butt Connector, 12-10 GA Wire 2
13 52735 Decal, 110 Volts (located on box @ platform) 1
14 15376-024 Decal, 110 Volts Power to Platform (located on turret) 1
MANUAL 92323-003
100 SEPTEMBER 1994

FIGURE 7.12—Foam-Filled Tires Assembly (Option)
ITEM PART NUMBER • DESCRIPTION QTY
Ref. Ref. Foam-Filled Tires Assembly (Option) 1

-1 34523 Decal, Tire Pressure 60 PSI (see Fig. 1 2) 4
-2 58398 Decal, Tire Replacement (located on chassis side plates) 4
3 37817 Tire & Wheel Assembly, Steer (Foam) 2
4 37818 Tire & Wheel Assembly, Drive (Foam) 2

MANUAL 92323-003
SEPTEMBER 1994
101

FIGURE 7.13—Self-Closing Platform Gate Assembly (Option)
c L_ L
Ref. Ref. Self-Closing Platform Gate Assembly (Option) 1

1 36147 Gate Weldment 1
2 CLA00310-001 Angle, 3.00" x 3.00" x .25" w x 1.50" long 1
3 33415 Hinge Mounting Bracket 2
4 CLK00719-001 Flat Bar, 1 5" x 3.0" x 3.0" long 1
5 67170 Hinge, Self-Closing 1PAIR
6 BOW36908-5 Bolt, Socket Flathead #10 - 32UNF x .25" long 12
7 67171 Latch, Gate 1
MANUAL 92323-003
102 SEPTEMBER 1994

FIGURE 7.14—Five-Foot-Wide Platform Assembly (Option)
Ref. Ref. Five-Foot-Wide Platform Assembly (Option) 1

1 34548 Platform Weldment, 60" x 30" x 43.5" 1
NOTE: Replaces standard platform weldment (48" x 30" x 43.5") #34112
MANUAL 92323-003
SEPTEMBER 1994
103

FIGURE 7.15—Platform-Mounted Work Light Assembly (Option)
REF
CONTROL BOX ON
PLATFORM
2 PL.
6 PL
PLATFORM CONTROL
6 PL CONSOLE GUARD
REF
i 0
:SEE
9.TE.
1 i
REF CONTROL BOX REF
PLATFORM
NOTES:
1. REFER TO ELECTRICAL SCHEMATIC FOR NUMBER OF
CIRCUIT THAT FEEDS THE PLATFORM WORK LIGHT.

Ref. Ref. Platform-Mounted Work Light Assembly (Option) 1

1 67260-027 Work Light Assembly 1
2 58252 Cable, 1 Conductor/12 GA 3L.F.
3 67114-001 Strain Relief, .50" NPT 1
6 69338 Plate, Work Light Mounting 1
7 69339 Clamp, Work Light 1
8 BOW31201 Nut, Hex 25" - 20UNC 2
9 BOW36701 Washer, Flat .25" ID 6
MANUAL 92323-003
104 SEPTEMBER 1994
FIGURE 8.1 —List of Schematics & Diagrams
U.S. Standard Schematics/Diagrams:
• 38083 (REV. E) Hydraulic Schematic, Kawasaki Engine Models, June 1994

• 38069 (REV. C) Electrical Schematic, Kawasaki Engine Models, July 1994
• 38076 (REV. B) Turret Wiring, Kawasaki Engine Models, July 1994
• 37941 (REV. A) Electrical Schematic, Kubota Diesel Engine Models, July 1994
MANUAL 92323-003
SEPTEMBER 1994
105

so,
37171
• Li__ :.:',E .-ijBS 5.4 CPR
yI -.... -_-.. -, —-: ,:\IE MOTORS
......---- „,,,
.E..2.5 ,;. 7 ---",,,, ::-_- D85
4--• SAHR
..›,_..../ ' VALVE ASSY. DUAL 03AL
/ ;_1-1 : :2:RAKES 34041 IN 34-062 — 1=0 PSI
. < ; 34460 PLATFORM
, 33186 `. —1 t-4-1
.029
i
, it. • • ) •
•,)'p•
•‘,._/'
• x ! PO CHECK I _ NEEDLE I
VALVE
-
r
°•-.1..-te ' 2479I
174—"t .329 4-1 i EL
3032.2 _
0-4 •
.04-0 4. /
5 21 A2 A3, DR i• C.AOKE
;404),C
VALVE
3692.2
• SA ,E CY1.. 34026 ,J.AST ER 01. 34.025
T
r r —1 3000 f RA
R I PSI
4 4 i BOOM EXT.
; 2500 CYL.
PSI : -
34884/34815
: t t. I400EL 38A MOOT 47A
I H! /LOW 0 • • ts;
SPEED E
DRIVE _11 L'
MANIFOLD VALVE
ASSY. 58079
36707 REGENERATIVE MANIFOLD
34-814
40--■••••••-•• 0 •
51 Al ; — 3000 I
BOOM CYL.
,
36871(5)
150
04
'os • 36870(T)
7 0--1
ACCUMULATOR FLOW
CONTROL MANIFOLD I
;AGE 52661 ASSY. — 2 PL I
Et-
PORT I (2 PLC S) 37485
RE EF
4--
I •
VALVE •
SHUTTLE
37421 , 3300
ARM CYL.
36841 : PSI sHuTTLE 36844(5) SAME AS
v36AL8V4E1
B ! A I 36843(T) BOOM CYL
. P (8 PL) XIiI MDL47A
73000 *
0-18 1 PSI X
GPM STEER CYL.
51170 r TURRET ROTATE
3 DIA .047 HYD. MOTOR
IraVI ■ i 1.4 ti 5 STROKE L..1— I Ti t, AT&T
; 1 ; ,._._ 32762
4- --1 . -t4 ''—i
,--\ I ! -1 i rt Pti—i
1000 PSI
I 1 x
; I I , 1.1 ....., I .047
I ,
1 --, CROSS PORT RELIEF VALVE
• 14
. ..___, I 32763
T VALVE ASSY.
P3 34040 ON
: . DRIVE TURRET
• : 7" VALVE
i i • II 38132 VALVE ASSY
i! 36720
• N
I\Av
NOTE:
PUMP 1. (5) MEANS SIERRA
CI-JECKVALVE
38084
CKS01301
POWER UNIT (T) MEANS TEXAS
• • 35659 FOR
1000
PSI 1 AUXIUARY
LOWERING
(OPIION)
FD620D ■ 1
! KAWASAKI
.3800 I
RP141 I •
PROPRIE2Ry INFORM AlION

BALL VALVE V S's cowstio ITS DESICA ;YET AL Daemon. Toinwas AC
CaalnoMEan
34212 E 6651 !VF/94I ti '
COMMIE NE THE COMM WORIIMION AND COMM PRCFERTY
7 CALAVAR CORPCRATION. AND Aell MOT BE TRACED. REACCUCED CR
j...PaltATio4 WACO, TEXAS
‘s.
I 5/19/94 RAK
07ED IM WAR kW [ZOOM 10 AO OUTSIDE MT( WTHUJT
RETURN
D 6579 TFE MICR NIMBI =SEM OF CALAYAR CORPoRATION. Au. RIGHTS
'TITLE
SUCTION 101358,.
\ LINE 6237 1 /26/94 I R AK
FILTER
STRAINER
34209
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES
SCHEMATIC, 47AG—KAWASAKI HYD
33430 B 5990 01/20/94 I R AK
TOLERANCES ON: ANC1Z DIECIMALS FRAc-noNAL
HYDRAUUC TANK * 1 /2. ±1/16
A 5841 I 10/12/93 1 RAK o
SIZE I DRAWING NO. REV.
LTR. E.C.N. NO. DATE I APPR. DRAWN COLEMAN 17/30/93
4045 8/25/93 RAK CHECKED C 3 8 0 8 3 E
LTR. E.R.N. NO. DATE 1 APPR. APPROVED RAK 8/25/93 SCALE NONE I sHEET 1 OF 1
•••
22/23 cit.!, 65
5 65A
• HEAD/TAIL LIGHTS OPTION
20 AUXILIARY LOWERING OPTION

!
5
EMERGENCY _ _
STOP 15A
5C NEG
oto --arta° —1 • 12VDC BA I IERY
P05 111111111111
• YOTION ALARM OPTION
PLUG ON 15A
5B 8A
TURRET 3—POS ROTARY • 0+ • THROTTLE SOLENOID
KEYSWITCH — 3 PL
I.- I • THROTTLE RELAY
10 -t- —
17
>> • OPTIONAL CHARGE LAMP
• VOLTAGE REGULATOR
2A eLK
,/ ALTERNATOR
AUX THROTTLE 31 , BLK
• OPTIONAL OIL LAMP
i 10 10
20
31 I 11:07 STARTER MOTOR
zi 5B 25B RED I
• STARTER SOLENOID
a1 START 25A
T
q
i19 P))
25 25T 25A1
• START RELAY
LOWER 31 I 25C
• WI CHOKE I START LOCKOUT RELAY
a- I •
a_ I
c5'4''9' • . 25A
-0 I • LOCKOUT DELAY RELAY
; 24
, 11 —41
91 c/
55 551 31 /
\‹ YEL/WHT
IGNITION COIL
0 < 0 N 21
31 ED 0 K
R BL
F- • FUEL PUMP
LU 0
4 PSI
> w Ct 31
▪ Z • HOUR METER
64
31 • GAS I
-°°‘.? 63 DUAL FUEL OPTION
0 —04 • LP
EMERGENCY 55 5515
STOP • HIGH TEMP SHUTOFF

<< YU-
11 0 VEX TEN SI ON
22/23 21 55 232'
0 • BEACON/STROBE OPTION
55
0
E
17 0
et, VOLT METER OPTION
"UPPER" SEE NOTE 1
0
0 CHOKE 10
04 • "LOWER" SEE NOTE 1
21A • 24
04 • CHOKE SOLENOID
B 15
• LEFT
STEERING
21A: START 25 A
16
0- 4 -0— • RIGHT
,
.... / 27
• GROUND
IN PLATFORM
AUX' 0 14
• FORWARD
20
ol
f
211 21A
• I ® 13 • REVERSE
DRIVE
—L __
17 E2 0 60 62 DRIVE SPEED RANGE
IN CONTROI I FR
17 FOOTSWITCH 62 SEE NOTE 2
U.11 0 • TRAVEL ALARM OPTION
0 C.)
18
1 SERIES/PARAI FL DRIVE
62 o
SPEED PILOT VALVE
18
0+-0 • LOCKUP RELEASE VALVE
22/23 RED BLK
• • SLOPE SENSOR
22/23 1 T
34644 SLOPE ALARM
22/23 HORN 59 -I 803 1. 5. j
o o SIGNAL HORN OPTION
NOTES:
1. "UPPER" AND "LOWER" DESIGNATE COILS OF 3—POS, 4—WAY VALVE
Mtmmmytymnftwyw
THAT DIRECTS HYDRAUUC FLUID TO UPPER OR LOWER CONTROL VALVE. ,,, Ma.la OW. Raw mirems Maras itai
MUM ME 1C COND. IIMEIMMIE ND OMMMT MIME
V MAW Carat:Mk NV Ma VW weft mimeo
/It •
WACO, TEXAS
Ora V VW Mat MS MUM NM WWII MY tarn
2. LIFT LIMIT SWITCH IS SHOWN WITH ARMS ALL THE WAY DOWN IV Ma 011101.1 P.M allnalaft .11/11111 r1i
AND WITH BOOM LEVEL OR LOWER.

6741 ilimirt, Ewa
UNLESS 01HIERMAit SPOCIFIEDt
.1.421,010 MIL 04 MCKIM
SCHEMATIC, 47A KAWASAKI EL
B 6221 I 1/26/B4 RA
IIXERANCE3 Mal wow. mranemora.
3. >> DESIGNATE CONNECTORS AT ENGINE. 5990 11/10/93 [RAF< *vx 411111, "1"
DRAM 06A41040/40.
.TR. E.C.A. N0.1 DAZE AFF CARUICAL 17/20,13
4. GROUND IS DESIGNATED AS 26/27 OR 1 OR
4045 i 9/23/99 RAK CHECKED C 38069
' LT& NO I DARE APPR. APPROV0) RAK isets/s3 scALE NONE zi 1 OF 1

r CABLE TO PLATFORM - EF ONLY CABLE TO VALVES

NO. FUNCTION NO. i COOR iNCTION
-
: 13 DRIVE REVERS 10 GRN "L.C/rtiER" VALVE

14 DRIVE FORWARD 13 I RED 2- ,RIVE REVERSE
15 STEER LEFT 14 REO/BLK 'DRIVE FORWARD
161 STEER RIGHT 15 STEER LEFT
17 POWER FROM FOOTS'f,ITCH 16 . .e.111./BLK STEER RIGHT
I la DRIVE SPEED. VALVE • 17 BUJ "UPPER" VALVE
19 . SLOPE ALARM 18 I 7.1_,K RIVE SPEED PILOT
20 AUXIUARY LOWERING 18 GRN/BLK _CCKL:P RELEASE
2 "RUN" FROM PLATFORM 20 • CFFI .,.:JX1UARY LOWERING
22/231 POWER TO PLATFORM GRN/BLK SPARE
24 I CHOKE
25 START . ENG:NE
26/271 GROUND
31 "RUN" FROM ENGINE
55 SPARE ,IOTES:
59 SIGNAL HORN OPTION • 1. REFER TO ELECTRICAL SCHEMATIC 38069.
60 DRIVE SPEED RANGE 2. ITEMS 21, 22, 23, ARE COMPONENTS OF 110V UNE TO PLATFORM OPTION.
62 I ON ?MEN DRIVING 3. ITEMS 31, 32, 33 ARE COMPONENTS OF BEACON/STROBE OPTION.
63 LP FUEL OPTION
64. I GAS DUAL FJEL
65 HEAD/TAIL ,..IGHTS OPTION
BLANK I SPARE,
33 BOW17350 1.00 REF I CONNECTOR, LOCKNUT 1/2

32 67123-001 1.00 I REF I SEAL, CONNECTOR ELECT 1/2
31 67114-002 1.00 I REF I STRAIN RELIEF, 1/2 NPT .250/.375
23 I BOW17350 2.00 REF CONNECTOR, LOCKNUT 1/2
21 i 67114-003 2.00 REF I STRAIN RELIEF, 1/2 NPT .375/.500

CABLE TO Ei:IG:NE
10. I COLOR FUNCTION/RENARKS
16 I 67124-002 2.00 I EA CONNECTOR, LOCKNUT 3/4
2A I RED/WHT F ALTERNATOR ? S' PLUG AT BLK
15 I 67123-002 2.00 EA I SEAL, CONNECTOR ELECT 3/4
28 BLU/WHT CHARGING ; ENGINE BLK
14 67124-003 2.001 EA I SEAL, CONNECTOR ELECT 1
5 RED ?S:+12\10C CONNECT TO
?S 13 I 67114-008 2.00 EA STRAIN RELIEF, 3/4 NPT .500/.625
RED/BLK 4
POWER (STARTER
12 I BOW17350 3.00 I EA I CONNECTOR, LOCKNUT 1/2
8A i EL:J/BLK I THROTTLE. S..',1.2101D
11 67123-001 3.00 I EA i SEAL, CONNECTOR ELECT 1/2
24 2U</Wt-IT I CHOKE
10 I 67114-003 1.00 I EA I STRAIN REUEF, 1/2 NPT .375/.500
25B BLU STARTER SOLENOID-PLUG AT ENGINE - RED
9 67114-002 2.00 I EA I STRAIN RELIEF, 1/2 NPT .250/.375
26/27 GRN ?C. GROUND-CONNECT
3 i 67114-014 2.00 EA I STRAIN RELIEF, 1 NPT .750/.875
26/271 GRN/BLK TO CHASSIS WLDMNT
7 I 67123-003 2.00 I EA i SEAL CONNECTOR ELECT 1
31 51-11 IGNITION COL-PLUG AT ENGINE - YFL
_ /WHT
67295-035 '0.00 LE • CABLE, 2 CONDUCTOR 16 GA
31 . PSI SWITCH CR OPTIONAL VACUUM SWITCH
= 67295-036 8.00 LF CABLE, 3 CONDUCTOR 16 GA
55T •ELK 4- PSI SWITCH
4 67295-035 10.00 I LF i CABLE, 2 CONDUCTOR 16 GA
5515 BLK/RED I 232* F SWITCH-PLUG AT ENGINE - '(EL
3 I 67295-023 12.00 I LF I CABLE, 10 CONDUCTOR 16 GA
63 I ORN ? DUAL ?flP
2 I 67295-004 12.00 a IF CABLE, 12 CONDUCTOR 16 GA
64 ORN/BLK FUEL ;) (GAS
67295-003 10.00 LF CABLE, 16 CONDUCTOR 16 GA
GRN/WHT SPARE
ITEM I PART NUMBER OTY UM I DESCRIPTION
...
inciMEMEILIMMAtnaki
342.
:ACO, TEXAS
M. OMMMI MI MOW WM. IMMIMEMIL ittekven No
•
mamt At se comm. maw= AM MUM POMMY
au*. earamoi. is Hu. 01 II *MR MPMMOM Mt ,. '--- ,,'
01111 .11MIIM IM MOM 11 MN CAME WM IMMIM
at_
IME MS MIMMI UMW, 4:1LONt COMM . MSS mitt
ItIMS.
04.1M1011.10MIVEMMU
....... A. .4 WM
WIRING, 47AG—KAWASAKI TURRET
B I 6823 11/alyy_i ,
-,- TOURAMS OW M. arm. swallow.
. lir at=
A 6221 I 1/Z6/94 IRAK W.
38076 :
LTR. E.C.N. N0. I DATE I APPR. main J. CARMICAL -TIDRAw." "9'
6/1/0 s
Th REY.
IQ
- 4100 1 8/23/S3 I RAK 0..0 C 1
- -
E.R.H.
ER Hat DATE I NVROMM
.. . ____. RAK I S/23,13 SCALE NONE I slim I OP 7
j:
-.

?A
W
1a
1 , 5A!ei
0 •,:11 '/HT
0 VOLT
5A 55T EXTENSION
55TS OPTION
GRN
BLANK
8A 59
10 22/231 60
72/231 62
13 1
14
64
258 65 22/23 BLK RED
26/27 26/27 26/27 •
26/27 26/27E 26/27 ' WHT WHT SLOPE
SENSOR
26/27 ORN BLK
'7 6;27 BLK

-) BEACON
0;-BLE _OVVER COTRCS STROBE
SEE D',I;G 38071 O
OPTION
55 WHT
CABLE 77) HYDRAULIC VALVES

SEE CHART ON SHEET 1
CABLE IO ENGINE
r
SEE CHART ON PAGE 1 LIMIT
SIM TCH
2 PL
26/27 BLK BLK
FUEL
2 PL 31 'NHT RED PUMP
2 PL
MMWMILAMMIna
es maw na ram Kix. Norm
MUSK AK X COMM DOAK MOW
If W. MORM1011. /OVAL ow wawa 111.11.110
WACO, TEXAS
COM I NW WOO Mt MUM 11 *Of ORM NWT MON
se MN, giro mow cMAINt UNNIPAINI. ow 1TTLE
MOS
..111 3PEZIFIEDt
7,11.11110411 ARE IN INCHES
WIRING, 47AG—KAWASAKI TURRET
TOLERANCES ONt masa maws meow..
siir m)
CARMIC.A.L I 8/1/93 DRAG

E.C.H. NO. I DATE I APPN. DRAM
38076
LTh j.
4100 s/25/$3 RAK CHEOCED

LT1 LILN. NO. I DATE LAMM OffitCMED RAK 6/251,3 9CALE 3/4 Isiar 2 OF 2

•••
58 65A HEAD/TAIL L;SHTS OPTION 17-LUG 0;1

—— JRRET
20
5 I AU XILJARY LOWERING OPTION

EMERGENCY
50 LTC? A NEG
• 12`/DC BA11ERY
8A
51813 I • MOTION ALARM OPTION
15A1 5B
3—POS ROTARY 8A
04-0 • THROTT-E SOLENOID
KEYSWITCH — 3 PL
+ •• e • 11-1 R 0 TT_E RELAY
10 — + - I5 24A
17 I I 9 9
GLOWPLUGS
24 g 0
25A ORN BLK
FAN
31 2107 ON - 185F RESET
• MURPHY SWITCH
VOLTAGE REGULATOR COLOR CODE A VOLTAGE REGULAISE.

31 B = WHT F = WHT/GRN
L Ct
E = BLK L = WHT/RED
AUX 7.-17: OTME = BLK/WHT
N = 611T/BLK
0 10
1
o o '5
''. B ALTERNATOR
20
0 e 3994
V1/0 JUMPER
.3U 0 RUN
PULLtN4 HOLD
>>
*HT 0 i SOLENOID
>>
REP 0
4-W 0
5B
-44101 0
NI) Of
_105HT
51 220.1:
>> 1
1
10
I -65
• HIGHTEMP SHUTOFF MURPHY SWITCH • H-
31 0 ><
5
kt E
a.
U
STARTER MOTOR O o
5B 25B RED
STAR
I ER SOLENOID
25A
START
vc!, 25 25 I 25A
START RELAY
cc LOWER 31
CHOKE 25C START LOCKOUT RELAY
a. 6 RECEPTACLE
a. 25A e°
24 LOCKOUT DELAY RELAY IN PLATFORM
55
21 ?
• 4 PSI
31
--0 f HOUR METER
55 ...■■•■■■■■■■■•■■•■■■■■■■■■•■s); BEACON /STROBE OPTION

i 55 • VOLT METER OPTIONS
EMERGENCY
STOP 17
04-o "UPPER" SEE NOTE 1
22/23 21 GLOWPLUGS I 10
0
0-4%-o "LOWER" SEE NOTE 1
21Aj 24
15
c«-t-o LEFT
STEERING
16 NOTES:
o4-0 RIGHT.)
i 21A START 25 I 17 26/27 1 I . "UPPER" AND "LOWER" DESIGNATE COILS CF 3—POS, 4—WAY VALVE
GROUND
c) I 14 THAT DIRECTS HYDRAUUC FLUID TO UPPER OR LOWER CONTROL VALVE.
o÷o FORWARD
AUX DRIVE 2. LIFT LIMIT SWITCH IS SHOWN WITH ARMS ALL THE WAY DOWN
QC 13
oo REVERSE j AND WITH BOOM LEVEL OR LOWER.
20 21 21A > 0
0 t 8 pm 60 62 DRIVE SPEED RANGE 3. >>. DESIGNATE CONNECTORS AT ENGINE.
o
• -1
z 62 SEE NOTE 2 IN CONTROLLER 4. GROUND IS DESIGNATED AS 26/27 OR 1 OR
W O 80188 1 TRAVEL ALARM OPTION
117 FOOTSV:ITCH 0 0 5. DRAWING 37941 SUPERCEDES DRAWING 37723.
18 SERIES/PARALLEL DRIVE
62 o-+-o
SPEED PILOT VALVE
oo LOCKUP RELEASE VALVE
22/23 RED BLK
• SLOPE SENSOR
mopprTANY NFORIIATIaR
22/23 11,9
0000 OS MM. MIL 00000 1010000 110
MUM al VC =POCK 00110.110 NO DOME MOM
• 01. 1 • II 110
'."/ACO, TEXAS
34644 WHT SLOPE ALARM • GUM WW2* MO W.
UPS • 01 MON 0000
010. 11•11001
iff WOK POW IMOR
VC OUR WM 10110f 'QUM 01,00110.. 01118
0100
22/23 HORN L114/33 01140t010 0.031F12.
01 OSWW1
SCHEMATIC, A524-47AG—K EL
80335 SIGNAL HORN OPTION
.4,0101 ME
'3 0 TOLER.= OP& maul mums mown.
at.
6636 11/d 94 /144
4/24A3 DItA11010 •
CM. ECANal DATE !WM. K AU3ERTS
379 41
DRA101
3.564 1 4/2f/s3 RAK 000003 1.4C8

CM EJULNa DATE APP00`40 RAK 4 scam NONE 1 OF 1

Condor 38AG OMP No. 92323

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Condor 38AG OMP No. 92323

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BOOM-SUPPORTED

ELEVATING WORK PLATFORM

OPERATION, PARTS & MAINTENANCE MANUAL

THIS MANUAL APPLIES ONLY TO CONDOR® MODEL 38AG

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

It is YOUR RESPONIBILITY to follow safe procedures while operating the CONDOR®.

It is also YOUR RESPONSIBILITY to understand and obey all federal, ai id local

DO NOT ALTER OR MODIFY THIS UNIT WITHOUT PRIOR WRITTEN APPROVAL

SERVICE & MAINTENANCE

Condor® Self-Propelled Aerial Work Platforms

No agent, employee, distributor, dealer, or other representative of Calavar is authorized to

8300 Imperial Drive, P.O. Box 21447, Waco, Texas 76702-1447

MODELS 38AG, 47AG, AND 47AE

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

It is YOUR RESPONIBILITY to follow safe procedures while operating the CONDOR®.

DO NOT ALTER OR MODIFY THIS UNIT WITHOUT PRIOR WRITTEN APPROVAL

SERVICE & MAINTENANCE

I. PREPARATION, INSPECTION, AND MAINTENANCE 1

A. Overall Machine Condition 1

II. MACHINE OPERATION 2

A. Rated Work Load 2

III. OPTIONAL EQUIPMENT 7

IV. AUXILIARY LOWERING 7

V. MOVING FROM JOB SITE TO JOB SITE 8

VI. EMERGENCY STOPPING 8

APPENDIX: DECALS ILLUSTRATION 9

ANSI/SIA 92.5-1992 MANUAL OF RESPONSIBILITIES

I. PREPARATION, INSPECTION, STEERING:

MISSING, BROKEN, OR DAMAGED B. LOWER CONTROL STATION

Check for damaged or cracked

Check electrical installations for

Check to see that slide bar is in

LII Check the red EMERGENCY STOP

El Check the operation of the auxil-

LI Check for hydraulic oil leaks at all

LI Ensure that hydraulic lines are

AUX. LOWERING ARM LIFT

using the two bolts.

The CONDOR® Model 47A weighs ap-

APPENDIX: DECALS ILLUSTRATION

47AG 47AD 47A 38AG 38AD

1 34271 Decal, 47A 2 2 2 N/A N/A

- Indicates Items Not Shown

Condor® Self-Propelled Aerial Work Platforms

No agent, employee, distributor, dealer, or other representative of Calavar is authorized to

8300 Imperial Drive, P.O. Box 21447, Waco, Texas 76702-1447

THIS MANUAL APPLIES ONLY TO CONDOR® MODEL 38AG

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

It is YOUR RESPONIBILITY to follow safe procedures while operating the CONDOR®.

DO NOT ALTER OR MODIFY THIS UNIT WITHOUT PRIOR WRITTEN APPROVAL

SERVICE & MAINTENANCE

CONDOR® SERVICE INFORMATION

B. PRE-DELIVERY INSPECTION SHEET (P.D.I.) 6

C. ITEMS NOT COVERED 6

SERIAL NUMBER LOCATION 9

CONDOR® SERVICE INFORMATION

(817) 666-4545 Telephone

2. IMPORTANT: Check tire pressure. Tires must be properly inflated before

4. Fill fuel tank using unleaded gasoline or diesel fuel.

5. Check battery with an hydrometer. Battery must have a full charge.

7. Turn on the key switch at the lower control station; IF D1ESEL-POWERED,

10. A series/parallel drive valve is located in the front carriage compartment

1 1 . The wheel drive has the following features:

A. There is a FAST/SLOW speed selector (toggle switch) on the upper