Anyone here wrenched on boom lifts?

Here is the deal, we are is serious need of one, and actually have an older Condor sitting here but it has a hydro leak on the boom extension cylinder. I took one look at that and said "nah, this will suck big ones", but our options are thinning.

Curious if anyone has been here? Surely someone thought of this day and made this easier? It looks like we would have to separate all boom sections? Appears everything is on cables and shivs. I cannot even see it all to know how it might come apart.

Other main issue is it has main swing drive play. About 12" at full retraction. It might seem like nothing until being in the air and slamming into something. Is there any take up, backlash adjustment, etc? I'd settle for half of that for the moment. Just trying to reduce the fix list so we can move!

Not real familiar with the Condor set up, but most aerials, up to the 80 ft range with two telescoping sections, the telescope cylinder attaches to the main (base) boom section and the intermediate (mid) boom section and uses chains or cables to operate the tip section. Yes, it's a project, and yes it typically requires pulling the telescoping sections, no way around that. And typically requires removal of platform to make it easier to handle removal of sections, also so you don't have to disconnect all the wires going to the platform. That is if it has external wires and hoses in a power trak chain. If that stuff is inside the telescoping sections, life just got way more interesting. Yes, it's a big job, I've done a number of other brands. As for the swing, you just need to check the mounting. If there's a bull gear mesh adjustment you should see it, but not all aerials have an adjustment, swing gearbox is mounted solid to the turntable base. If it's mounted solid, you better check the bearings in the bull gear shaft, that lower bearing may be worn slap out.

Yeah, that all sounds consistent so far. As far as internal boom hoses/wires, yeah, that is what it has, but I don't recall seeing them any other way??

As for the swing drive, it says "Braden Winch" on it. That is all I know at the moment. I think everything else would be reasonable to repair but that boom is not cool! I'm sure they put the best seals in those that money can buy, but just timed out. I am hoping for a hose but I can't even see in there to know what is leaking! I am desperate just to see in illustration of how they are built! This one has cables, I can see that. I can also see where the rear of the cylinder mounts inside the boom. the rest is a guess so I assume the other end of the cylinder mounts to the intermediate section?

If I remember right the end of the extension cylinder had a skid plated double sheave assembly. There was an extension/retraction cable set up that anchored at the skid, wound through the sheave system, and both cable ends anchored at the back of the main boom. You do have to remove the boom to do most all service. It’s more likely that your extension cylinder seals are leaking......it’s a common problem.

Here is where I am at guys. I don't need any boom extension right now so I intend to plug off the lines for the extension circuit. I will just do a little mod somewhere to ensure the boom cannot try to slide out a bit but that is pretty unlikely and we are only working 8ft off the ground.

What I found on the swing is someone has been in this before! I see evidence on some bolts but they never even tightened the turret reduction drive! There is an adjuster bolt to push the bull gear into the ring. The issue is you cannot see a thing! Likely totally enclosed, even from below I cannot see one tooth of that ring gear. So when I ran the adjuster in, I realize it can stress the bull gear bearing if there is excessive pressure, so I ran it in until it it seemed to bottom out, then backed it up about 1/2 turn or so and tightened the bolts on the turret drive. This was more of a test to see how much backlash I could get out. I have not tried to run it yet because I don't have the actual procedure for this and I don't want to risk bull gear damage.

So.....would anyone happen to have a procedure on a similar tele lift? I would assume Genie or someone probably have very similar components. What I have is the owners manual, parts manuals, and some other stuff like engine, hubs, etc. Nothing about setting this gear. I also don't want to be leaving anything on the table in terms of backlash.